Hind Energy & Coal Beneficiation (India) Pvt....

PRE-FEASIBILITY REPORT

for

Change in technology from DRY to WET type of coal washery

Hind Energy & Coal Beneficiation (India) Pvt. Ltd. at

Hindadih Village, Masturi Tehsil

Bilaspur District, Chhattisgarh

Hind Energy & Coal Beneficiation (India) Pvt. Ltd.

Prefeasibility Report

Table of Contents

Chapter – 1 : EXECUTIVE SUMMARY ........................................................................................ 1

1.1SALIENT FEATURES OF THE PROJECT .................................................................................. 1

1.1ABOUT PROJECT PROPONENT ............................................................................................ 2

Chapter – 2 : INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION ..................... 3

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT ................................................. 3

2.2BRIEF DESCRIPTION OF NATURE OF PRODUCT ................................................................... 3

2.3 NEED FOR THE PROJECT AND IMPORTANCE TO THE REGION............................................. 4

2.4 DEMAND – SUPPLY GAP .................................................................................................... 5

2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT) ............................................................ 6

Chapter – 3 : PROJECT DESCRIPTION ....................................................................................... 7

3.1 TYPE OF THE PROJECT ....................................................................................................... 7

3.2 LOCATION OF THE PROJECT ............................................................................................... 8

3.3 DETAILS OF THE ALTERNATE SITES ............................................................................... 9

3.4 SIZE OR MAGNITUDE OF OPERATION .............................................................................. 10

3.5 MANUFACTURING PROCESS ............................................................................................ 10

3.5.1 COAL WASHERY ......................................................................................................... 10

3.5.2 JUSTIFICATION OF CHANGE IN TECHNOLOGY FROM DRY TYPE TO WET TYPE ............ 14

3.6RAW MATERIAL REQUIREMENT ....................................................................................... 15

3.7MODE OF TRANSPORT FOR RAW MATERIALS AND FINISHED PRODUCTS ......................... 15

3.8WATER REQUIREMENT AND ITS SOURCE .......................................................................... 15

3.9QUANTITY OF WASTE GENERATED ................................................................................... 16

3.10 SOLID WASTE GENERATION AND ITS DISPOSAL ......................................................... 17

Chapter – 4 : SITE ANALYSIS .................................................................................................. 18

4.1 CONNECTIVITY ................................................................................................................ 18

4.2 Land use .......................................................................................................................... 18

4.3 Topography ..................................................................................................................... 18

4.4 Existing land use pattern ................................................................................................. 19

4.4 Existing infrastructure ..................................................................................................... 19



4.5Soil Classification .............................................................................................................. 19

4.6Climatic data from secondary sources .............................................................................. 19

Chapter – 5 : PLANNING BRIEF .............................................................................................. 20

5.1 Planning Concept ............................................................................................................ 20

5.2 Population Projection ...................................................................................................... 20

5.3 Land use Planning ............................................................................................................ 20

5.4 Amenities / Facilities ....................................................................................................... 21

Chapter – 6 PROPOSED INFRASTRUCTURE ............................................................................ 22

6.1INDUSTRIAL AREA (PROCESSING AREA) ............................................................................ 22

6.2RESIDENTIAL AREA (NON PROCESSING AREA) .................................................................. 23

6.3 GREEN BELT ..................................................................................................................... 23

6.4 SOCIAL INFRASTRUCTURE ................................................................................................ 23

6.5 CONNECTIVITY ................................................................................................................ 23

6.6 DRINKING WATER MANAGEMENT ................................................................................... 24

6.7 SEWERAGE SYSTEM ......................................................................................................... 24

6.8 INDUSTRIAL WASTE MANAGEMENT ................................................................................ 24

6.9SOLID WASTE MANAGEMENT .......................................................................................... 24

6.10 POWER REQUIREMENT & ITS SOURCE ....................................................................... 24

Chapter – 7 REHABILITATION & RESETTLEMENT (R & R) PLAN ............................................... 26

Chapter – 8 PROJECT SCHEDULE & COST ESTIMATES ............................................................. 27

8.1PROJECT SCHEDULE .......................................................................................................... 27

8.2PROJECT COST .................................................................................................................. 27

Chapter – 9 ANALYSIS OF PROPOSAL ..................................................................................... 29

9.1FINANCIAL AND SOCIAL BENEFITS .................................................................................... 29

9.2SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES ............................................................. 29

9.3COMPARATIVE EVALUATION OF DRY & WET PROCESS ..................................................... 30



1

Chapter –1 :EXECUTIVE SUMMARY

1.1 SALIENT FEATURES OF THE PROJECT

S.No. Particulars Description

1. Name of the Project Hind Energy & Coal Beneficiation (India) Pvt. Ltd.

2. Location of the Plant Hindadih Village, Masturi Tehsil

Bilaspur District, Chhattisgarh

3. Capacity of the Plant(Existing) 3.6 MTPA comprising

2.4 MTPA Dry type Coal Washery

&

1.2 MTPA Wet type Coal Washery

4. Proposed Project Change in Technology from 2.4 MTPA Dry type to

2.4 Wet type Coal Washery

5. Capacity of the plant after

proposed change in technology

3.6 MTPA Wet type (no change in plant capacity)

6. Total Land 27.42 acress (in possession)

7. Cost of the project for the

present proposal

Rs. 12 Crores

(for conversion of DRY to WET type of coal

washery2.4 MTPA)



1.1 ABOUT PROJECT PROPONENT

Hind Energy & Coal Beneficiation (India) Pvt. Ltd. (here in after referred as HECBIPL) is

Flagship Company of Hind Energy group of Chhattisgarh having wide interest in coal

handling, washing & trading, thermal power generation, logistics and real estate

development. Today HECBIPLis one of dominant player in coal operating in mineral rich

states of Orissa and Chhattisgarh. It provides all coal services at a single window from

securing linkage of coal (from Ministry of Coal and Coal India Limited) up to delivery of coal

i.e. allotment of coal, long term fuel supply agreement, procurement of coal directly from

mines, quality and quantity control, transportation, washing, logistics and delivery at the

plant of the consumer.

HECBIPL is incorporated with Registrar of Companies, Gwalior as Private Limited Company

with objective of coal and other mineral Beneficiation. The company is promoted by Shri

Pawan Agrawal engaged in various businesses and having good reputation in the market,

which was gained with good business experience.



3

Chapter –2 :INTRODUCTION OF THE PROJECT / BACKGROUND INFORMATION

2.1 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT

Hind Energy & Coal Beneficiation (India) Pvt. Ltd. (here in after referred as HECBIPL) is

Flagship Company of Hind Energy group of Chhattisgarh having wide interest in coal

handling, washing & trading, thermal power generation, logistics and real estate

development. Today HECBIPLis one of dominant player in coal operating in mineral rich

states of Orissa and Chhattisgarh. It provides all coal services at a single window from

securing linkage of coal (from Ministry of Coal and Coal India Limited) up to delivery of

coal i.e. allotment of coal, long term fuel supply agreement, procurement of coal directly

from mines, quality and quantity control, transportation, washing, logistics and delivery at

the plant of the consumer.

HECBIPL is incorporated with Registrar of Companies, Gwalior as Private Limited Company

with objective of coal and other mineral Beneficiation. The company is promoted by Shri

Pawan Agrawal engaged in various businesses and having good reputation in the market,

which was gained with good business experience.

2.2 BRIEF DESCRIPTION OF NATURE OF PRODUCT

HECBIPLis an existing coal washeryat Village Hindadih, Tehsil Masturi, District Bilaspur,

Chhattisgarh.

The following Chronology of permissions pertaining to the plant:

• Consent to Establish issued by CECB for 1.2 MTPA Dry type coal washery in 1264 /

RO / RS / CECB / 2005 dated 5th August 2005. Subsequently production has been

commenced.



4

• A proposal has been submitted to MoEF for expanding the plant from 1.2 MTPA

(Dry type) to 2.4 MTPA (Dry type) and obtained Environmental Clearance vide no.

J-11015/190/2007-IA-II (M) Dated 24th June 2008.

• Subsequently, another proposal has been submitted to MoEF for expansion of

existing plant from 2.4 MTPA (Dry type) to 3.6 MTPAby addition of1x1.2 MTPA Wet

type washeryand obtained Environmental Clearance vide no. J-11015/364/2009-

IA-II(M) dated 21st May 2014.

• This EC issued on 21st May 2014 has superseded the earlier EC obtained vide no. J-

11015/190/2007-IA-II(M) Dated 24th June 2008.

• As on date both 2.4 MTPA dry type washeryand 1.2 MTPA coal washery (wet type)

are in operation.

Now it has been proposed to convert the existing 2.4 MTPA - DRY TYPE coal washery to

2.4 MTPA- WET TYPE coal washery to meet the customer requirement.With this

modification, the total washing capacity shall be 3.6 MTPA (Wet Type).

2.3 NEED FOR THE PROJECT AND IMPORTANCE TO THE REGION

Coal is the most abundant fossil fuel. India is blessed with huge coal reserve, nearly 7% of

total coal in the world, 85% of this reserve is non-coking coal, which caters to the need of

power, cement and sponge iron plants, however most of these reserve are of very low

grade coal and the reserve of good quality coal is fast depleting.

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 oflow

ash good coal are depleting and hence in order to fulfill industry’s demand, hugereserves

of inferior grade coal are being mined. Due to higher demand, selectiveminingis not



5

possible. The average ash in coal, now being supplied is around37%.Inordertomaintain a

consistent quality of coal as per the requirements of variouscustomersofcoal, it is

necessary to set up coal washing plants in the country.

Based on the above facts, it is felt that washing of coal in the present scenario shall helpus

in achieving the operational efficiency and better plant performance. Hence, washingof

coal is in the national as well as regional interest.

The use of washed coal has the following advantages:

Increased generation efficiency, mainly due to the reduction in energy loss as inert

material passes through the combustion process.

Increased plant availability.

Reduced investment costs.

Reduced operation and maintenance (O&M) costs due to less wear and reduced

costs for fuel and ash handling.

Energy conservation in the transportation sector and lower transportation costs.

Less impurities and improved coal quality.

Reduced load on the air pollution control system; and

Reduction in the amount of solid waste that has to be disposed off.

Present proposal of Coal Washery unit will generate revenues for the State Government

byway of taxes on coal and benefit the local people by way of direct and

indirectemployment.

2.4 DEMAND – SUPPLY GAP

Ministry of coal identified coal washing as an important area aiming at value addition. To

reap the benefits of economics as well as environment, Coal India limited is planning to

expand the capacity of thermal coal.



6

Starting from 1774, India has a long history of commercial coal mining. Gross coal

resources ~ 286 BT of which 114 BT in proven category. Ash content very high,

from 20 to 55% but low in sulphur content.

20 major coalfields located in east and south eastern quadrant of the country,

involving long distance rail haulages for major consumers.

The coal production is projected to reach 795 MTY in 2016-17 and further to 1500

MTY in 2031-32.

Current coal demand ~ 770 MT and growing @ 6-7% per year to 980 MT in 2016-

17and further to 1800 MT in 2031-32.

2.6 EMPLOYMENT GENERATION (DIRECT & INDIRECT)

The present proposal will create employment to 80 people during construction and 40

people during operation of the Coal washery.

SKILLED

Total skilled employment in the proposed plant will be around 15.

SEMI-SKILLED

Total Semi-skilled employment in the proposed project will be around 10. Priority will be

given to local people for semi-skilled jobs.

UNSKILLED

Total Unskilled employment in the proposed project will be around 10. Top priority will be

given to local people for unskilled jobs.



7

Chapter –3 :PROJECT DESCRIPTION

3.1 TYPE OF THE PROJECT

HECPIPL is operating 2.4 MTPA Dry type of coal washery at Village Hindadih, Tehsil

Masturi, District Bilaspur, Chhattisgarh.

Existing plant is present in total land of 27.42 acres and same is in possession of

management. No additional land shall be required for the proposed modification. Total

cost for the present proposal of change in technology from DRY to WET type of coal

washery will be Rs. 12 Crores.

The following Chronology of permissions pertaining to the plant:

• Consent to Establish issued by CECB for 1.2 MTPA Dry type coal washery in 1264 /

RO / RS / CECB / 2005 dated 5th August 2005. Subsequently production has been

commenced.

• A proposal has been submitted to MoEF for expanding the plant from 1.2 MTPA

(Dry type) to 2.4 MTPA (Dry type) and obtained Environmental Clearance vide no.

J-11015/190/2007-IA-II (M) Dated 24th June 2008.

• Subsequently, another proposal has been submitted to MoEF for expansion of

existing plant from 2.4 MTPA (Dry type) to 3.6 MTPAby addition of1x1.2 MTPA Wet

type washeryand obtained Environmental Clearance vide no. J-11015/364/2009-

IA-II(M) dated 21st May 2014.

• This EC issued on 21st May 2014 has superseded the earlier EC obtained vide no. J-

11015/190/2007-IA-II(M) Dated 24th June 2008.

• As on date both 2.4 MTPA dry type washery and 1.2 MTPA coal washery (wet type)

are in operation.



8

Now it has been proposed to convert the existing 2.4 MTPA - DRY TYPE coal washery to

2.4 MTPA- WET TYPE coal washery to meet the customer requirement.With this

modification, the total washing capacity shall be 3.6 MTPA (Wet Type).

3.2 LOCATION OF THE PROJECT

Project is located at Village Hindadih, Tehsil Masturi, District Bilaspur, Chhattisgarh.

Topographical location of project site is shown below:



9



10

3.3 DETAILS OF THE ALTERNATE SITES

No alternative site has been considered, as per present proposal will be taken up in the

existing plant premises itself, as it is only change in technology from DRY to WET type of

coal washery.

3.4 SIZE OR MAGNITUDE OF OPERATION

Change in Technology of 2.4 MTPA DRY type of coal washery to 2.4 MTPA WET type of

coal washery.With this modification, the total washing capacity shall be 3.6 MTPA (Wet

Type).

3.5 MANUFACTURING PROCESS

3.5.1 COAL WASHERY

• Sized Raw Coal [(-) 50 mm] from the existing dry circuit will be transported to an

intermediate storage bunker.

• From the intermediate storage bunker, sized raw coal will be fed to the Washing Plant

building through belt conveyor. The sized raw coal will be fed into a Banana Screen.

• The first part of Banana Screen will dry screen raw coal at 8 mm to separate (–)8 mm

fraction which will be taken to a ground dump and will be mixed with washed coal. The

second part of the banana screen will wet screen the raw coal at (–)1 mm for

desliming.

• The deslimed coal [coarser fraction of (-)50 (+)1mm] goes to the HM process. The

magnetite media of required specific gravity will be added in the heavy media process

to get mixed with the coal.

• The Bath / cyclone will have overflow and underflow. The washed coal along with

magnetite media will be received as overflow, from the Bath / cyclone and will be fed

to a set of washed coal sieve bend and Washed Coal Drain & Rinsing Screen.



11

• The Magnetite media separated through sieve bend and first part of the screen and

will be collected in the screen’s dense under pans. The same will be circulated back to

the system.

• The carried away magnetite with the coal particles are removed by water spraying in

the discharge part of the screens.

• The magnetite removed from coal by water spraying will be collected in the dilute

catch pan of screen as dilute media. The magnetite from dilute media will be recovered

through Wet Drum Magnetic Separator.

• The washed coal collected at discharge end of screen will then be transported to

storage bunker through belt conveyor.

• The reject from the HM Bath / cyclone will be fed to a drain and rinsing screen to take

out the media and then transported to the bunker through belt conveyor.

• The underflow from desliming screen collected in the fine coal sump will be pumped to

a back to classifying cyclone. The underflow of classifying cyclone will be dewatered in

High Frequency screen.

• The overflow of classifying cyclone will be taken to the Thickener. Effluent from High

Frequency Screen and Belt Press Filter will also be taken to the Thickener.

• The clarified water from the thickener overflow will be recycled as process water and

fed to the plant.



12

Process flow sheet

Advantages of Washed Coal

Below mentioned are the uses of Washed/Beneficiated Coal:

In the process of washing the coal the abrasive non-coal matter like stones and shale

will be removed from the ROM coal. As such use of washed coal in the Sponge Iron

plant will result in less wear and tear of the Machinery. The life of the Rotary Kiln will

be prolonged with the use of washed coal.

Due to the uniform size of the washed coal and the uniform quality (Ash content

being more or less uniform with a very little variation) as compared to much larger

variation in the quality of Raw Coal form the coal mines, the operating parameters of

manufacturing the sponge iron can be better regulated. Together with this and with



13

the increased heat value of washed coal the productivity of the Rotary Kiln will

increase by 15 to 20%

Use of cleaner coal will improve the environmental conditions.

Less production of char from the Kiln (which contains un-burnt coal & other

nonmagnetic material), gives some sort of rid from its disposal.

Characteristics of Raw Coal, Clean Coal & Reject Coal (WET type)

S.No. Particulars Raw Coal Clean Coal Reject Coal

1 GCV (Kcal / Kg) 3000-3200 4000 – 4200 1800 - 2000

2 Ash (%) 41-42 30 – 32 62-70

3 Volatile Matter (%) 23 27 18

4 Fixed Carbon (%) 24-26 34 16

5 Yield (%) --- 70 - 75 25-30

6 Sulphur (%) 0.5 0.5 0.5

Characteristics of Raw Coal, Clean Coal & Reject Coal (DRY Type)

S.No. Particulars Raw Coal Clean Coal Reject Coal

1 GCV (Kcal / Kg) 3500-3600 3800 – 4000 2000 - 2200

2 Ash (%) 37-38 30-32 65-70

3 Volatile Matter (%) 25 26 20

4 Fixed Carbon (%) 29 34 17

5 Yield (%) --- 75-80 20-25

6 Sulphur (%) 0.5 0.5 0.5



14

3.5.2 JUSTIFICATION OF CHANGE IN TECHNOLOGY FROM DRY TYPE TO WET TYPE

• The existing Dry process has limited scope for ash reduction.

• The misplacement of good quality coal as Rotary Discard is high since some good

quality coal is not broken inside Rotary Breaker and report to Rotary Discard. This in

turn leads to loss of yield.

• Smaller pieces of stones and shales report to the sized coal fraction leading to higher

ash in beneficiated coal and as a result the dry process is not able to maintain

consistent product quality.

• To overcome these problems enumerated above, it has been proposed to change the

beneficiation process from existing dry circuit (2.4 MTPA) to wet process (2.4 MTPA)

with Heavy Media process.

• In various tender pre-qualification technical requirement, it is clearly mentioned that

bidder should have its own coal beneficiation plant using wet technology i.e. Heavy

Media Cyclone / Heavy Media Bath.

• At present the quality of ROM coal is deteriorating day by day and in future we shall

not be able to fulfill the required ash quality to the customers.

The Heavy Media process will have the following advantages over the dry process:

• Maximum ash reduction can be achieved without any problem.

• Heavy Media process is ideally suited to treat high ash Indian Coal with high Near

Gravity Material (NGM).

• The process is capable of achieving low misplacement of good coal to rejects as well as

rejects to beneficiated product.



15

3.6 RAW MATERIAL REQUIREMENT

Run of mines [ROM] coal will be the raw material requirement for proposed washery.

3.7 MODE OF TRANSPORT FOR RAW MATERIALS AND FINISHED PRODUCTS

Desired quantum of ROM coal will be transported through covered trucks or rail

routesfrom coal mines. Washed coal and Rejects will be transported either through

covered trucks or rail routes.

MODE OF TRANSPORTATION OF WASHED COAL

Washed coal from the plant will be transported by road in covered trucks directly to the

customer (or) by rail. The mode of transport of washed coal will depend on the MoU with

the customers who may have either road transport or rail transport. All the trucks

required for transportation of coal will be covered and environmentally compliant. Pucca

road exist upto the site. The existing road is capable of absorbing this additional truck

movement. Hence there will not be any significant adverse impact on air environment due

to the transportation of raw coal & washed coal.

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.

3.8 WATER REQUIREMENT AND ITS SOURCE

• Total water requirement for 2.4 MTPA (Dry washery) & 1.2 MTPA (Wet process) for

which EC has been accorded is 610 cum/day.



16

• After conversion of 2.4 MTPA DRY type coal washery to 2.4 MTPA WET type coal

washery, an additional water of 500 cum/day will be required.

• The total water requirement after proposed amendment will be 1085 cum/day only.

Water permission has already been obtained from CGWA for drawl of 610 cum/day of

ground water.

• The source of additional water for the present proposal will be Hindadih Check Dam /

Lilagarh river.

• An application has been submitted to Water Resources Department, Govt. of

Chhattisgarh for additional allocation of water.

The following is the breakup of water requirement:

S.No. Particulars Water Requirement

(in KLD)

Consumption / System Loss

(in KLD)

Waste Generation

(in KLD)

Utilization / Disposal

1 Process Recycled Fresh Make-up Sub Total 1 :

11400

805 11830

805 (Evaporation Loss & Losses

through Products)

---

Recycle, Close Circuit Water System

2 Miscellaneous Road sprinkling Dust Suppression Plant Greenery / Gardening Sub Total 2 :

60 50 50

160

160

---

---

3 Domestic - Potable - Toilets

Sub Total 3 :

50 70

120

50 10 60

--- 60 60

Septic tanks

followed by soak pit

Total 1085 (Net

Requirement)

1025 60 Zero Discharge 1085

3.9 QUANTITY OF WASTE GENERATED

Closed circuit water system will be adopted in the proposed Coal washery. Hence there

will not be any wastewater generation from the process. However only wastewater



17

generated will be sanitary wastewater which will be treated through Septic Tanks followed

sub surface dispersion trench.

3.10 SOLID WASTE GENERATION AND ITS DISPOSAL

Washery reject will be generatedfrom the proposed coal washery. These rejects have

considerable amount of carbonaceous material hence the same will be utilized as blend

with coal to make fuel mix for generation of power and will be sold-out to nearby Power

Generating units.



18

Chapter –4 :SITE ANALYSIS

4.1 CONNECTIVITY

The proposed site is well connected with Road network. The following table gives brief

regarding connectivity of the proposed site:

Component Description

Road : NH # 200 – 20.0Kms.

Rail : Nearest station – JairamnagarRS: 14.5 Kms.

Air : Raipur Air Port – 125 KM

Sea Port : Vishakapatanam – 550 Kms.

Below mentioned table gives brief regarding environmental setting of the project site

S.No Particulars Distance from the site

1. National Park = No national Park is situated within the 15 km radial distance periphery

2. Wild life sanctuaries = Nil

3. Eco Sensitive Areas = Nil

4. Forests = Dalha Protected Forest: 6.0 Kms Bitkuli Reserve Forest: 2.0Kms

5. Surface water bodies = Liligarh River – 3.3Kms. Kurg Left bank canal - 5.0 Kms.

6. Costal Regulation Zone [CRZ] = Nil

4.2 Land use

Present use of land is industrial land. No additional land is required for the present

proposal, as the present proposal is for change in technology i.e. DRY to WET. Total land is

in possession of the management.Hence there will not be any change in local land use

plan due to the proposed activity.

4.3 Topography

The topography of the land is more or less flat without undulations.



19

4.4 Existing land use pattern

Installation of proposed wet type of washery will be carried out within existing plant

premises only in 27.42 acres. The land is already in possession of the Management. Land is

already diverted for industrial purpose. No agriculture land is involved in the site.

Item Area (in Acres)

Plant area 10.97

Parking & Roads 2.18

Raw coal storage area 1.50

Washed Coal Storage 2.50

Storage area for rejects 1.10

Greenbelt 9.17

Total 27.42

4.4 Existing infrastructure

Present proposal is change in technology from DRY to WET type of coal washery, it will be

taken up in the existing plant premises.

4.5 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.

4.6 Climatic data from secondary sources

The climate is pleasant and mild in the winter (minimum temperature 10 °C, 50 °F). There

are medium rains in the monsoon season. The summers are very hot and dry, with

maximum temperature 45+ °C, 113 °F.



20

Chapter –5:PLANNING BRIEF

5.1 Planning Concept

Present proposal is change in technology from DRY to WET type of coal washery, it will be

taken up in the existing plant premises.

5.2 Population Projection

As of 2011 India census,Bilaspur had a population near 680,000. Final population data are

yet to come which is estimated at 700,000. Nearby or suburban areas will soon be

included in the city limits. Males constitute 51% of the population and females 49%.

Bilaspur has an average literacy rate of 87.29%, higher than the national average of 74%;

with male literacy of 92.94% and female literacy of 81.33%. 15% of the population is under

6 years of age.

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

Installation of proposed wet type of washery will be carried out within existing plant

premises only in 27.42 acres. The land is already in possession of the Management. Land is

already diverted for industrial purpose. No agriculture land is involved in the site.

Item Area (in Acres)

Plant area 10.97

Parking & Roads 2.18

Raw coal storage area 1.50

Washed Coal Storage 2.50



21

Storage area for rejects 1.10

Greenbelt 9.17

Total 27.42

5.4 Amenities / Facilities

Facilities like canteen, rest room and indoor games facilities will already been provided in

the existing plant as basic facilities to workers. No other additional facilities are proposed.



22

Chapter – 6PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA (PROCESSING AREA)

Sr. No.

Item Description Make Quantity

A. A.1

Know How Design and Engineering

--- L.S.

B. Building & Structural ---

B.1 Civil Work (RCC work in foundations, buildings, etc.)

--- 1000 Cu. M.

B.2 Structural Steel Work i) Structural Steel work in Buildings ii) Technological Structures like Tanks, Vessels, Chutes, etc.

--- 500 MT 75 MT

--- Sub Total B

C. Plant & Machinery

C.1 Unbalanced Motor Feeder IC / ELEKTROMAG 1 No.

C.2 Suspended Magnet ELEKTROMAG 1 No.

C.3 Heavy Media bath /Heavy Media Cyclone MMH 1 No.

C.4 Multi Slope Banana Screen IC / IMT 1 No.

C.5 Wet Screen IC 2 Nos.

C.6 Sieve MMH 2 Nos.

C.7 Slurry Pumps Weir Minerals / Metso

C.8 Water Pumps KSB / M&P / Kirloskar

C.9 Air Compressor Atlas Copco / ELGI / IR

2 Nos.

C.10 Belt Conveyor 200 Mtr.

C.11 Classifying Cyclone CUMI / Weir Minerals

2 Nos.

C.12 High Frequency Screen Parnaby / DVE 1 No.

C.13 High Rate Thickener 13 mtr IMT / Delkor 1 No.

C.14 Multi Roll Belt Press Filter Parnaby / 1 No.

C.14 Wet Drum Magnetic Separator IMT / Eriez 1 No.

C.15 Spray Header with Nozzles Spray Tech / Spraying System / Lechler

C.16 Belt Weigher Schenck 3 Nos.

C.17 Auto Sampler MMH 3 Nos.

C.18 Miscellaneous items such as Take-up, Scraper, etc.

--- ---

C.19 Erection & Commissioning --- LS

C.20 Taxes, duties, freight etc. --- LS



23

D. Miscellaneous Fixed Assets --- ---

D.1 Pipes & Pipe fittings --- ---

D.2 Valves --- ---

D.3 Electric Motor --- ---

D.4 Sheeting --- ---

D.5 Electricals including PLC, MCC, Cables, etc. --- ---

6.2 RESIDENTIAL AREA (NON PROCESSING AREA)

No colonization is proposed; however facilities like canteen, rest room facilities will be

provided in the proposed plant and one Admin building is also proposed.

6.3 GREEN BELT

More than 1/3rd of total land availability is reserved for plantation i.e. greenery.

Greenbelt development plan

Local DFO will be consulted in developing the green belt.

Greenbelt of 33% of the area will be developed in the plant premises as per CPCB

guidelines.

10 m wide greenbelt is being maintained all around the plant.

The tree species to be selected for the plantation are pollutant tolerant, fast

growing, wind firm, deep rooted. A three tier plantation is proposed comprising of

an outer most belt of taller trees which will act as barrier, middle core acting as air

cleaner and the innermost core which may be termed as absorptive layer

consisting of trees which are known to be particularly tolerant to pollutants.

6.4 SOCIAL INFRASTRUCTURE

Social infrastructure will be developed as per need based in the Villages of the close

vicinity of the project.

6.5 CONNECTIVITY

The proposed site is well connected with Road network. The following table gives brief

regarding connectivity of the proposed site:



24

Component Description

Road : NH # 200 – 20.0 Kms.

Rail : Nearest station – JairamnagarRS : 14.5 Kms.

Air : Raipur Air Port – 125 KM

Sea Port : Vishakapatanam – 550 Kms.

6.6 DRINKING WATER MANAGEMENT

The desired amount of water will be drawn from ground water sources.

6.7 SEWERAGE SYSTEM

Domestic effluent collected through toilet blocks and other areas will be collected through

well designed sewer network and send to Septic tanks followed by soak pits. No effluent

will be left-out after Soak pits.

6.8 INDUSTRIAL WASTE MANAGEMENT

It is proposed to install one effluent treatment plant which will be the part of process as

the effluent generated contains media solution; hence it is prime objective to recover the

media solution to maximum possible extent. This treatment plant comprising of settling

pond and thickener and clear water will be recycled back to process area as raw water.

6.9 SOLID WASTE MANAGEMENT

0.6 MTPA of Washery reject will be generatedfrom the proposed coal washery. These

rejects have considerable amount of carbonaceous material hence the same will be

utilized as blend with coal to make fuel mix for generation of power and will be sold-out to

nearby Power Generating units.

6.10 POWER REQUIREMENT & ITS SOURCE

It is estimated that about 1.0 – 1.5 MW of electricity will be required for operation of

proposed plant; which will CSPGCL grids.



25



26

Chapter – 7REHABILITATION & RESETTLEMENT (R & R) PLAN

No rehabilitation and resettlement is required as there are no habitations in the in the

Project site.



27

Chapter – 8PROJECT SCHEDULE & COST ESTIMATES

8.1 PROJECT SCHEDULE

The plant will be implemented in 18 months from the date of receipt of Environmental

Clearance from the SEIAA, Chhattisgarh& NOC from CECB.

8.2 PROJECT COST

Capital Cost Estimate for change of technology of 2.4 MTPA Coal Washery from Dry Circuit

to Wet Circuit)

S.No. Item Description Make Quantity Amount (Rs. in Lakhs)

Total

A. A.1

Know How Design and Engineering

L.S. 10.00

B. Building & Structural

B.1 Civil Work (RCC work in foundations, buildings, etc.)

1000 Cu. M.

150.00

B.2 Structural Steel Work i) Structural Steel work in Buildings ii) Technological Structures like Tanks, Vessels, Chutes, etc.

500 MT 75 MT

300.00 60.00

C. Plant & Machinery

C.1 Unbalanced Motor Feeder IC / ELEKTROMAG 1 No. 2.50

C.2 Suspended Magnet ELEKTROMAG 1 No. 6.00

C.3 Heavy Media bath /Heavy Media Cyclone

MMH 1 No. 40.00

C.4 Multi Slope Banana Screen IC / IMT 1 No. 34.00

C.5 Wet Screen IC 2 Nos. 25.00

C.6 Sieve MMH 2 Nos. 5.00

C.7 Slurry Pumps Weir Minerals / Metso

25.00

C.8 Water Pumps KSB / M&P / Kirloskar

3.00

C.9 Air Compressor Atlas Copco / ELGI / IR

2 Nos. 14.00

C.10 Belt Conveyor 200 Mtr. 40.00

C.11 Classifying Cyclone CUMI / Weir Minerals

2 Nos. 4.00

C.12 High Frequency Screen Parnaby / DVE 1 No. 20.00

C.13 High Rate Thickener 13 mtr IMT / Delkor 1 No. 18.00

C.14 Multi Roll Belt Press Filter Parnaby / 1 No. 140.00



28

C.14 Wet Drum Magnetic Separator IMT / Eriez 1 No. 14.00

C.15 Spray Header with Nozzles Spray Tech / Spraying System /

Lechler

3.00

C.16 Belt Weigher Schenck 3 Nos. 6.00

C.17 Auto Sampler MMH 3 Nos. 6.00

C.18 Miscellaneous items such as Take-up, Scraper, etc.

10.00

C.19 Erection & Commissioning LS 25.00

C.20 Taxes, duties, freight etc. LS 62.50

D. Miscellaneous Fixed Assets

D.1 Pipes & Pipe fittings 12.00

D.2 Valves 12.00

D.3 Electric Motor 12.00

D.4 Sheeting 9.00

D.5 Electricals including PLC, MCC, Cables, etc.

75.00

Contingency 5% 57.00

GRAND TOTAL 1200.00



29

Chapter – 9ANALYSIS OF PROPOSAL

9.1 FINANCIAL AND SOCIAL BENEFITS

With the implementation of the proposed project, the socio-economic status of the local

people will improve substantially. The land rates in the area will improve in the nearby

areas due to the proposed activity. This will help in upliftment of the social status of the

people in the area. Educational institutions will also come-up and will lead to

improvement of educational status of the people in the area. Primary health centre will

also be developed by us and the medical facilities will certainly improve due to the

proposed project.

9.2 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

The management is committed to uplift the standards of living of the villagers by

undertaking following activities / responsibilities as the part of Corporate Social

Responsibility.

Health & hygiene

Drinking water

Education for poor

Village roads

Lighting

HEALTH & HYGINE

Personal and domestic hygiene,

Maintaining clean neighborhood,

Weekly health camps offering free-check up& medicines

Ambulance services

Education & drug de-addiction, aids.



30

DRINKING WATER

Making drinking water available at centralized locations in the village,

SUPPORTING EDUCATION

Providing books to all poor children,

Conducting annual sports festival in the village schools,

Providing amenities like fans, lavatories,

Maintain play ground etc.

9.3 COMPARATIVE EVALUATION OF DRY & WET PROCESS

S.No Parameter EXISTING

2.4 MTPA Coal Washery (Dry Process) & 1.2

MTPA Coal Washery (wet process for which Consent to Operate has

been accorded and is operational)

PROPOSED

2.4 MTPA Coal Washery (wet type)

&

1.2 MTPA Coal washery (Wet

process)

Remarks

1 Land 27.42 acres 27.42 acres No change in land due to conversion of 2.4 MTPA Dry type to wet type washery.

2 Quality of washed coal

Dry process has limited scope for ash reduction

Wet process:Maximum reduction in ash content is possible

Wet process gives better ash reduction to suit to the customer requirement

3 Consistent product quality

Not possible Possible Wet process is suited for customers with requirement for consistent product quality

4 Yield Lesser yield as good quality coal may report as Rotary Breaker Discard.

Better yield, as no such loss of good quality coal

Better yield with Wet Process

5 Particulate emission

More Less Wet process will have lesser PM.

6 Total water requirement

610 KLD

(water drawl permission obtained from water resources Department, Govt. of Chhattisgarh

Additional 475 KLD due to conversion from DRY to WET type.

Total water requirement after proposed request for amendment will be 1085 cum/day.

Date post:	09-Aug-2020
Category:	Documents
Upload:	others
View:	1 times
Download:	0 times

Hind Energy & Coal Beneficiation (India) Pvt....

Documents