[1]
PRE-FEASIBILITY REPORT
EXPANSION OF COAL WASHERY FROM 0.70 MTPA TO 5.70 MTPA
AT VILLAGE-BOMALOI, TEHSIL-RENGALI,
DISTRICT SAMBALPUR, ODISHA
Aryan Ispat & Power Private Limited
APRIL 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
28
5 PLANNING BRIEF
31
6 PROPOSED INFRASTRUCTURE
33
7 REHABILITATION AND RESETTLEMENT (R & R) PLAN
35
8 PROJECT SCHEDULE & COST ESTIMATES
36
9 ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS)
39
Annexure – I : Process Flow Sheet
Annexure - II : Water Balance
Annexure - III : ETP flow Diagram
Annexure - IV : Plant Layout
[3]
1. EXECUTIVE SUMMARY
S .No Description Details
1. Name of the Project Expansion of coal washery from 0.70 MTPA to 5.70 MTPA within the Integrated Steel Plant at village-Bomaloi, Tehsil-Rengali, District Sambalpur, Odisha by M/s Aryan Ispat & Power Private Limited [AIPPL].
2. Location of the Plant Village Bomaloi, Tehsil -Rengali, District Sambalpur, Odisha
3. Coal Washery Capacity (Total) 5.70 MTPA [Throughput]
4. Total project area
Expansion proposed within the existing project area of 204.65 acres. No additional land is needed.
5. Washing Technology Heavy Media Cyclone
6. Additional Water requirement & Source Process Plantation, dust suppression etc. Domestic
55 m3/hr 4.41 cusecs water from Hirkud Reservoir approved for the entire plant is adequate to meet the additional demand for the proposed washery addition. 44 m3 / hr 8 m3 / hr 3 m3 / hr Existing washery water consumption is 8 m3/hr
7. Power requirement [Total] & Source 5 MVA – Own Power Plant connected with the Grid Corporation of Odisha.
8. Working hours 3 shifts daily of 8 hr each 330 days a year [Effective working 18 hrs a day]
9. Rehabilitation and Resettlement No R & R issue involved
10. Manpower [Operation] 70 persons
11. Estimated Cost of the Project Rs. 60.07 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 significantly increase.
M/S Aryan Ispat & Power Private Limited (AIPPL) intends to expand its
coal washery capacity from 0.7 MTPA to 5.70 MTPA. The expansion is
envisaged based on Heavy Media Cyclone process. The washery will
produce washed coal of an average ash around 34% (GCV 4350 Kcal /
kg.), middling (ash content about 58%) of GCV around 2350 Kcal per Kg
useable as fuel in FBC boilers. In the washing process, waste in the form
of rejects (ash content about 86.5%) with no useful heat value (3-4%
Carbon) will also be generated.
The proposed expansion will be the State-of-the-art with close circuit
water system, classifying cyclone, high frequency screens, thickener and
multi roll belt press filters.
Brief description of nature of the project
Need for the Project
The coal India Limited and its subsidiaries are the major domestic
producers and suppliers of coal in India. The annual requirement of non-
coking coal for various industrial sectors like power, steel and cement is
increasing day by day. The reserves of low ash good coal are depleting.
To meet demand, huge reserves of inferior grade coal are being mined.
The average ash in coal now being supplied is around 45 to 50%.
AIPPL’s decision to expand its washery capacity 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
[6]
points of view.
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.
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.
At present, 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. Besides, action to
finalize to more washeries is in the advance stage. Further, 12 more
washeries have been identified by CIL to be taken up during the XIIth Five
Year Plan.
The wide gap assessed between the projected requirement of beneficiated
non-coking coal and the existing total capacity, clearly indicates that there
is enough scope for building up of capacity to beneficiate non-coking coal
in the private sector. Further, it may not be consistently feasible to
[7]
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, AIPPL proposal
for expansion of Bomaloi washery by 5 MTPA is justified. Supply of sized
quality coal from the washery to the client is important for AIPPL.
At AIPPL’s washery, raw coal of around 45 - 50% ash will be washed to
produce washed coal having around 34% ash. The primary discards will
be subjected to secondary washing to produce middling at around 58%
ash and rejects at around 86.5% ash. The use of washed coal has the
following advantages:
1. Supply of consistent quality coal can be ensured thereby avoiding
frequent adjustments in input to boiler and minimizing operators’
error
2. Higher thermal efficiency of boiler and higher steam rate
3. Less wear and tear of the coal grinding mills
4. Lower capital and operating cost for installing smaller ESP
5. Higher productivity and campaign life of DRI kiln
The total capacity of the coal washery after expansion will become 5.70
Million TPA of raw coal throughput. The existing plant capacity is 0.70
MTPA. Additional 5 MTPA capacity will have the following parameters:
Capacity : 1000 TPH
No. of operating days in a year : 330 days
No. of effective operating hours in a day: 18 hours, three shifts
operation
[8]
Plant utilization : 85%
Annual throughput : 100 X 18 X 330 X 0.85
= 5049000 tonnes
Say 5 million tonnes
The project will have the following outputs:
Raw Coal - Ash - 45 - 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 - 4350 K cal / Kg.
Middling - Ash - 58%, Moist – 8.5%, FC 22%, VM 20%,
Yield 47% , GCV - 2350 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.
(ii) Demand-Supply Gap
The demand for washed non-coking coal has significantly increased in
view of the Ministry of Environment and Forests Notification on use of coal
with ash content not more than 34% in power plants located beyond 1000
km from the pithead and in urban area or sensitive area or critically
polluted area. The demand for use of washed coal for power generation
would further increase as the distance threshold limit has been reduced to
500 km. The Government has also laid thrust on adoption of Clean Coal
Technologies (CCTs) to mitigate adverse impact of coal usage on the
environment.
[9]
Total established non-coking coal washing capacity [November 2011] of
CIL & others is 95.96 MTY. The coal requirement for power generation in
2016-17 has been estimated by CEA as 842 MT. The requirement of
washed coal will be 361 MTPA. This does not include demand from the
other sectors like sponge iron and cement.
By the end of XII Plan, low grade coal production, other than pithead
linked coal, has been estimated as 360 MT and total capacity of
beneficiation of non-coking coal as 199 MTY. Thus there is a huge gap of
161 MT for washery capacity addition in the XII Plan.
(iii) Imports vs Indigenous production
Raw coal will be obtained from the Mahanadi Coalfields Ltd. 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
Coal washeries established in India are not able to meet the domestic
requirement of washed coal at present.
(vi) Employment Generation (Direct &Indirect) due to the
Project
During construction period, the 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.
[10]
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.
1. PROJECT DESCRIPTION
(i) Type of project including interlinked and interdependent
projects, if any.
[11]
It is envisaged to create additional 5 Million TPA capacity to wash coal using
Heavy Media Cyclone technology.
(ii) Location
The proposed expansion is within the existing integrated steel plant site at
Bomaloi Village, Tehsil Rengali, Distt. Sambalpur, Odisha. Total project area
is 204.65 acres. The project span between Latitude: 22°08’02.39”-
22°08’19.41” North and Longitude: 83°14’ 30.21”-83°14’ 50.01” East. The
entire project area falls in Survey of India Toposheet No. 73C/2, (1A
Quadrant).
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.
[12]
FIGURE-1 INDEX MAP SHOWING THE PROJECT SITE
[13]
FIGURE-2 MAP OF THE AREA 10 KM AROUND THE PROJECT SITE
[14]
(iii) Details of alternate sites considered and the basis of selecting
the proposed site, particularly the environmental considerations
gone into should be highlighted.
Alternate sites have not been considered as the proposal is for expansion
of the coal washery within the project premises. The requisite logistic
support is available at the existing plant.
(iii) Size or magnitude of operation.
5.70 MTPA (Total Throughput) capacity
(v) Project description with process details
The entire raw coal for beneficiation will be brought from the mines of MCL
by rail. The own railway siding is about 700m from the project site.
Modular concept of designing the washery is envisaged. Two identical
additional modules of 2.50 MTPA each will beneficiate 1000 TPH coal.
Washed coal, middling and rejects will be transported by rail-cum-road
mode.
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 MCL mines in the 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 enhance the capacity of the coal
beneficiation plant to 5.70 MTPA to produce sized and quality coal to suit
[15]
the captive requirement as well as that of the other clients.
Coal Washing Processes
There are several processes for coal washing which may be categorized
under two broad headings as follows:
Dry Process
Pneumatic tables or Jig Rotary Breaker
Wet Process
Natural media barrel Natural media cyclone Jig Chance cone separator Heavy media Bath Heavy media drum Heavy media cyclone Larcodem Triflow separators Dyna Whirlpool separator Vorsyl Separator Froth floatation Column floatation Spirals
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
[16]
up of the bed, and it is the extent to which this dilation may be controlled
which governs the effectiveness of the separation.
During the pulsion, or rising part of the cycle, the bed is elevated en
masse. But as the velocity decreases towards the end of the pulsion
stroke, the bed begins to dilate, with the bottom ceasing motion first and
the lowermost fragments commencing their descent. This produces an
element of freedom of movement for all fragments signalling the
commencement of the various principal effects leading to stratification.
The most influential effects occurring during jigging are, in order of
occurrence:
o Dilation;
o Differential acceleration;
o Hindered settling; and
o Consolidated tracking.
The Jig is divided into two compartments lengthwise, one completely
sealed from the atmosphere - called the air chamber - and one open
section, which receives the material to be separated and accommodates it
during the stratification process. The water valve allows admission of ‘
back water’ at a level below that of the bed plate. The longitudinal section
is further divided into several sections or compartments along the
direction of flow. The purpose of this is to provide control over the
separation as 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
[17]
conveyor which delivers it to the bucket elevators.
Efficient collection of the product is of paramount importance. Clean coal
overflows the end of the box together with the majority of the flowing
water.
Merits
Water is used in this process instead of magnetite.
This process gives fairly good efficiency if the coal is easy to wash (low
NGM like European coal) at cut point gravity above 1.7 (deshaling
application).
Large size coal up to ( - ) 100 mm can be fed to Jigs.
Demerits
Not a suitable process for washing Indian Coal which is “Exceedingly
Difficult” to wash due to high Near Gravity Material (NGM).
Mediocar efficiency.
Sensitive to variations in feed rate and / or characteristics.
Electronic adjustment system is complex and requires optimizing.
Efficiency becomes extremely low for gravities below 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.
[18]
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 utilizes the centrifugal
force (e.g., 100 X gravity) for the separation of fractions, it became
possible also to treat fine-grained coal (sized, e.g. 0.5 mm to 6 mm).
Because the force potential of cyclone separator is great, it is possible to
treat relatively large quantities of raw coal in a unit of small physical size
when compared to dense-medium baths. The corresponding relationship
to this form of separation is:
Settling Velocity, S = [S2/r X v(d – D) – R]
[19]
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.
[20]
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
[21]
The process misplacement which is depicted by the partition curve (Fig 8.3
attached) also shows minimum misplacement in case of HM Cyclone
process.
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
Coal [ROM] from MCL mines will be transported to the washing plant by rail.
Own railway siding is 700m away from the project site. Trucks will either
dump coal into the ground hopper or on to the nearby ground dump from
where the same will be fed in the ground hopper.
From the ground hopper the raw coal will be subjected to two stage close
circuit crushing and screening and finally sized to minus 50 mm. The sized
coal will be taken to a series of storage bunker
[22]
Washing Section
Sized raw coal, (-) 50 mm, from bunker will be transported to the washing
plant building through covered belt conveyors where the same will be fed
into coal wetting launder where water will be added with coal. Coal water
slurry then will flow through launder to a set of Desliming Sieve Bend and
Screen to remove (-) 1 mm coal fines from the slurryl. Coal slurry collected
from Desliming Sieve Bend and Screen under pan will gravitate through
pipes to a Fine Coal Sump.
De-slimed coal coarser fraction of (+) 1 mm will go from screen discharge
chute to the launder. Magnetite media of required specific gravity will be
added at the back of the launder to get mixed with the coal and
simultaneously to push the mixture of magnetite & coal slurry into the
central column provided in the centre of the Primary HM Cyclone tank.
Coal & magnetite mixture from the centre column will be pumped by
Primary Cyclone Feed Pump to feed to Primary Heavy Media Cyclones.
Cyclones are lined with high alumna ceramic tiles. Cyclone will have
overflow and underflow. Clean coal along with magnetite media will be
received as over flow from the cyclone and be fed to a set of Clean Coal
Sieve Bend and Clean Coal Draining & Rinsing Screen. Magnetite media will
be drained through Sieve Bend and first part of the Screen and be collected
in the screen’s dense catch pan. The same will be re-circulated back to the
primary washing system.
The carried away magnetite with the coal particles will be removed by water
spraying in the discharge part of the screen. Magnetite removed from coal
by water spraying will be collected in the dilute catch pan of screen as dilute
media, and be taken to dilute media tank
Underflow of primary cyclone treated as primary discard will be fed to a set
of double sieve bend. Magnetite media drained through sieve bend will be
[23]
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.
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
[24]
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.
Media Preparation & Regeneration Circuit
Dilute media as collected in the Dilute Media Tank will be pumped by a
Dilute Media Pump to a Magnetic Separator Feed box. From there, the dilute
media will be feed to a Wet Drum Magnetic Separator. The Separators will
separate out magnetite from water and the dense media gets dislodged
from the magnetic drum to the dense media launders and from there to the
Primary Heavy Media Tank and Secondary Heavy Media tank.
Effluent from the magnetic separator goes to fine coal tank through wetting
launder.
During the process of operation, some amount of magnetite gets lost which
will be made up by adding fresh magnetite to the system. For this purpose,
a magnetite addition RCC sump will be provided where ground magnetite
will be charged and diluted with water. The dilute magnetite media then will
be pumped through a vertical sump pump to the Dilute Media Tank.
Process Control Philosophy
There will be a control room with a centralized PLC based control system to
enable operator(s) to start-up, monitor, control and shut down all main
equipment and process functions like feed input to the plant, product
transfer to conveyors etc. A hot standby back-up will be provided to take
care of power tripping and fluctuations.
[25]
All major items of equipment will be interlocked in an automatic stopping
sequence within the PLC in such a manner that both material and liquid
flows will always be fail safe. Stop push buttons will be located adjacent to
each drive and will be operable at all times.
An emergency stop button will be located either in the control room or in the
operating computer to enable the whole plant to be stopped.
The density of the magnetite media will be controlled to ensure the required
quality of the washed products. The specific gravity control will be achieved
automatically by respective modulating splitter actuators. The density
measurement will be done by a nucleonic density gauge. Indication and
recording of the density levels will be done in the control room computer.
(vii) Raw material required along with estimated quantity likely
source, marketing area of final products, mode of transport of raw
material and finished product.
Additional 1000 MTPA raw coal will be brought to the washery site by rail
from the MCL mines which are linked to the rail network otherwise by road.
The washery will produce clean coal, middling, fines and rejects. After captive
consumption [100TPD], washed coal and middling including rejects will be
transported to the clients. Clean coal, middling mixed with fines and rejects
will be transported to the end users by rail-cum-road. The railway siding is
700m from the project site. Lapanga railway station is about 1 km from the
project site.
(vii) Resource optimization / recycling and reuse envisaged in the
project, if any, should be given.
Plant will have close circuit water circulation system so that no effluent is
discharged in the open outside the plant boundary. All the process effluent
will be collected in the thickener. Settled slurry of the thickener will be
[26]
dewatered in a multi roll belt press filter. The dewatered filter cake will be
mixed with the middling. The clarified water from the thickener overflow will
be re-circulated in the washing circuit as process water. Only make-up water
requirement will be added in the clarified water tank.
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 ponds will be
constructed within the plant boundary to take care of any unforeseen
situation like pipe line jamming or break down of thickener. The clarified
water from these emergency settling ponds will also be pumped back to the
plant for use as process water. These emergency settling ponds will also be
used for harvesting rain water, which can be used as process water.
Expensive imported equipment like centrifuge, belt press filter, high
frequency screen as well as thickener will be installed to ensure close circuit
water system; minimize loss of water through products; and evaporation
losses.
(vi) Availability of water its source, Energy / power
requirement and source should be given.
Water Supply & Sewerage
Water supply arrangement for the proposed expansion will basically cover
the industrial and potable water demand. Washery will operate on closed
water circuit, therefore, only make-up water is required. Requirement of
additional water for pollution control measures will be 8 m3/hr for dust
suppression, floor washing and plantation. In accordance with the
technology adopted, process and other features, the additional process
[27]
water [make-up] requirement of the washing circuit will be 44 m³/hr. An
additional RCC water reservoir of around 1500 m3 storage capacity will be
constructed.
Additional 55 m3/hr of water is required for the proposed washery.
4.41 cusecs water approved for the integrated steel plant from the
Hirakud Reservoir is adequate to meet the additional water demand.
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
Additional
Requirement
Consumption
/ loss
Waste
water
generation
Process [Make-up]
44 44 - Close Circuit System
Domestic & others 3 1 2 Septic tank & soak pit
Dust suppression & plantation
8 8 -
Total 55 53 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 2 units per tonne of raw coal
throughput.
Power for the proposed expansion will be met from the own the Power Plant
/ 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.
[28]
Proper illumination of the plant, conveyor gantries, and transfer points and
general illumination etc. is envisaged. Proper PLC based automation system
is envisaged for the automatic control of all the equipment including
instrumentation like level transmitters, flow meters, pressure gauges, fire
alarms system.
Two DG sets of 1250 KVA each are available at the project.
(vii) Quantity of wastes to be generated and scheme for their
Management/disposal.
The washery will generate additional 90 TPH rejects. Efforts will be made to
supply rejects to the brick kiln owners in the region.
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 additional 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
o Availability of water
o Permanent and reliable source of power
o Adequate land for the plant, storage of raw coal and products and
disposal of waste material
Coal from MCL mines, namely, Basundra, Samleswari, Belpahar,
Lakhanpur etc., located within about 100km, will be transported by rail.
Own railway siding is 700m from the project site. The nearest Railway
[29]
station is Lapanga about 1 km from the project site. Power supply can be
easily met from 33 KVA line connected with the Grid Corporation of
Odisha. Sufficient land for expansion of coal washing plant is available.
(i) Connectivity
District Headquarter Sambalpur, nearest township Jharsuguda and rail
head at Lapanga are about 24 km, 22 km and 1 km respectively from the
project site. The nearest Airport is at Raipur, 292 km by road from the
project site. The nearest State Highway is SH-10.
(ii) Land details
No additional land for the proposed expansion is required. The existing
204.65 acres land acquired through IDCO is adequate to meet the
functional needs, green belt development, essential staff accommodation
etc.
It is proposed to bring coal to the plant site by rail-cum-road mode.
Washed coal, middling and rejects will be dispatch from the existing
railway siding.
Sr. No. Particulars Area (in Acres) Existing Additional
1. Washery Plant 4.47 9.85
2. Raw Coal Stockyard 5.00 7.00
3. Clean coal, middling & Rejects 5.00 4.47
4. Plantation - 9.15
Total 14.47 30.47
** Includes bins (iii) Topography and drainage
The topography of the site is fairly flat and requires minimum filling. No
filling material from outside is envisaged for the plant construction.
[30]
The drainage pattern in the buffer zone is dendritic to sub-parallel. The
drainage density is medium to high.
(iv) Existing land use pattern, shortest distances from the periphery
of the project to periphery of the forests, water bodies.
The land use of the project site is industrial. There is no water body in the
project area. Information on forests and water bodies falling within 10 km
from the project site is given below:
Water bodies
10 km around the project site forms the part of Mahanadi river basin. The
river Mahanadi and its tributaries control the drainage of the area. The
main tributaries of Mahanadi, within 10 km, are Bheden river [6.6 km,
NW] and Ib river [10.5 km, WNW]. The minor tributaries are Matwali nadi
[2.6 km, S]. The river Mahanadi has been dammed at Hirakud. The
Hirakud Reservoir is about 1 km W of the project site.
Forests
Ghichaimura RF, Maulabhanja RF Patrapalli RF, Baighara RF and Katikela
RF are 4.3 km E, 5.2 km SW, 8.2 km NW, 8.6 km S and 8.6 km NNE
respectively from the project site.
There is no notified Sanctuary, National Park, Tiger reserve or Biosphere
reserve within 15 km around the project site. Elephant corridor is about
36.5 km SE from project site. Elephants movement starts from Badrama
Sanctuary located within the Sambalpur Elephant Reserve [SER] and
enters the adjoining Mahanadi Elephant Reserve [MER]. Nearest fringe of
SER is 0.1km E. MER is about 89.5 km SE from project site.
[31]
(v) Infrastructure facility The plant site is well connected through the State and National highways. The nearest railway station is at Lapanga about 1 km of the project site.
5. PLANNING BRIEF (i) Planning concept (type of industries, facilities transportation
etc). Town and country planning/development authority classification
The following large scale industries / PSUs [2010-11] are located in
Sambalpur and in its surroundings:
1. Maa Samaleshwari Sponoge Iron Ltd., Katrabag, Sambalpur
2. T.R Chemicals Pvt. Ltd., Belpada Bamra
3. M/s. Hindalco Industries Ltd., Hirakud
4. Samaleswari Ferro Metal Pvt. Ltd., Dishalkhinda, Dhankuda
5. Bhushan Steel & Power, Thelkuli, Rengali, Sambalpur
6. Aryan Ispat & Power Pvt. Ltd., Bomaloi, Rengali, Sambalpur
7. Rathi Steel & Power Projects Ltd., Sikridi, Pitapali, Rengali
8. R.B Sponge Iron Ltd. Kenghati, Jujumara,
9. Vedanata Smelter Plant & CPP
10. Jay Jagannath Steel & Power Ltd., Belpada, Bamra
11. Shyam DRI, Power Ltd., Rengali
12. Viraj Steel & Energy Ltd., Gurupali
13. Maa Samaleshwari Industries Pvt. Ltd., Lapanga
14. Aditya Aluminium Ltd., Lapanga
15. Mahanadi Coal Fields Ltd., Jagruti Vihar, Burla
16. Hindalco Talabira Coal Mine
Besides, there are 5990 micro and small enterprises and other units in the
Sambalpur District. The project area falls in the region which is well
connected by road and rail to the District Headquarters Sambalpur.
[32]
Due to setting up of increasing number of large and medium industries in
Sambalpur and nearby region, there is positive growth in the large and
medium enterprises in the area. The industrial growth and development in
the surroundings is being organized by the District Industrial Centre under
the Department of Industries, Govt. of Odisha.
(ii) Land use planning
Expansion is within the 204.65 acres of integrated steel plant. 30.47
acres of land is available for the washery plant expansion. Out of 204.65
acres, 73 acres area is under plantation.
(iii) Assessment of infrastructure demand (physical & social)
Amenities / Facilities.
Facilities available for the existing project will be upgraded 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
Existing office building, sub-station, other buildings areas such as first
aid centre, rest shelter, canteen etc. of appropriate size will be upgraded,
if needed.
Residential Buildings
The Bachelor’s accommodation and staff quarters will be located in the
project area.
[33]
Roads
No new approach road is required. 6. PROPOSED INFRASTRUCTURE
(i) Industrial area (processing area)
The entire 204.65 acres of project land is under industrial use.
(ii) Residential Area
Improvement of bachelor’s accommodation and staff quarters in the
project area.
(iii) Green belt
Approx. 73 acres of the project area is under plantation.
(iv) Social infrastructure
The existing canteen, rest shelter / room, recreation room will be upgraded,
if needed.
(v) Connectivity
The existing road and rail network is adequate and does not require any
up-gradation. Already coal from the MCL mines is being transported via
these routes.
vi) Drinking Water Management (Source & Supply of water) Domestic and other purposes water demand of the existing integrated
steel plant including the washery for is 35 m3/hr. The additional
[34]
requirement of 3 m3 / hour water for domestic purpose will be met from
ground water resource. The project area on ground water resource
considerations falls in “Safe Zone” category.
(vii) Sewerage System.
Domestic sewage will be treated and disposed of through Septic Tanks &
Soak Pits.
(ii) Industrial Waste Management.
a) Washery effluent:
Zero effluent discharge will be practiced. Waste water will be collected in
slime ponds and circulated back in the process.
b) Domestic effluent:
Septic Tanks & Soak Pits have been provided. Sludge after digestion is
used as manure.
(iii) Solid Waste Management. a. Rejects Additional 90 TPH rejects will be generated from the proposed expansion.
Efforts will be made to utilize this waste material in backfilling of de-
coaled pits in MCL opencast mines and supply to the brick kilns
manufacturers in the nearby region and / or other buyer(s).
b. Municipal waste
Additional 600kg per month municipal waste will be generated, which
after composting will be used as manure.
[35]
(iv) Power Requirement & Supply / source.
Power requirement of 5 MVA will be met from the own power plant
connected with the Grid Corporation of Odisha. A standby DG set of 125
KVA will be provided.
7. REHABILITATION AND RESETTLEMENT (R & R) PLAN
The entire 204.65 acres of project land is already under possession
through IDCO. There is no R & R issue involved.
PROJECT SCHEDULE & COST ESTIMATES (i) Likely date of start of construction and likely date of Completion It is planned to award EPC contract within 3 - 4 months of issuance of
“Environmental Clearance” and ‘Consent to Establish” and complete the
project in 24 months period.
(ii) Estimated project cost along with analysis in terms of economic viability of the project. Total project cost has been estimated as Rs. 60.07 crores. Broad break-up of investment is given below
1) Land : Rs.190.00 Lakhs 2) Land Development : Rs. 50.00 lakhs 3) Know How : Rs. 150.00 Lakhs TOTAL : Rs. 390.00 Lakhs
TABLE-8 : COST ESTIMATE FOR 800 TPH THROUGHPUT CAPACITY
[36]
COAL WASHING PLANT
Sr. No.
Item Description Make Quantity Amount (Rs. in Lakhs)
Total A. Know How
A.1
Design and Engineering
L.S. 55.00
B. Building & Structural B.1 Civil Work (RCC
work including) 3000 Cu
M3 230.00
B.2 Structural Steel work
3000 MT 1650.00
Sub Total B 1880.00 C. Plant & Machinery C.1 Unbalance Motor
Feeder IC /
ELECTROMAG/TRF
Lot 35.00
C.2 Over Band Magnetic Separator & Metal Detector
ELECTROMAG 2 Sets 25.00
C.3 Rotary Breaker L&T/TRF/MBE 1 No. 165.00 C.4 Crusher TRF/MBE/MECH
TECH 4 Nos. 175.00
C.5 Dry Screen MECHTECH / TRF / IC
4 Nos. 63.00
C.6 Wet Screens : Desliming D&R Screen
TRF/IC
12 Nos.
160.00
C.7 Sieve Bend MMH 16 Nos. 45.00 C.8 Pumps (Slurry) Metso/Warman /
MBE Lot. 90.00
C.9 H M Cyclone 710 Carborundum 12 Nos.
55.00
C10 Classifying Cyclone Carborundum 12 Nos.
20.00
C.11 Hi Rate Thickener HDO/MBE/Delkor 2 Nos. 65.00 C.12 Horizontal Basket
Centrifuge Don Valley, UK
6 Nos. 330.00
C.13 Wet Drum Magnetic Separator
Eriez/Ing. Mineral
4 Nos. 66.00
C.14 High Frequency Screen
Linatex, S.A / Parnaby, UK
3 No. 66.00
C.15 Multi Roll Belt Press Filter
Parnaby 2 Nos. 245.00
[37]
Sr. No.
Item Description Make Quantity Amount (Rs. in Lakhs)
C.16 Air Compressor with drier
IR/Atlas
2 Sets. 34.00
C.17 Dust Suppression system
TPS / Kaveri Lot 55.00
C.18 Belt Conveyor MMH/TRF / Masyc
900 Mtr. 245.00
C.19 Travelling Tripper MMH 2 Nos. 27.00 C.20 EOT Crane with grab
bucket WMI / Federal / Asian / Jaypee
3 Nos. 84.00
C.21 Rock Breaker 1 No. 28.00 C.22 Miscellaneous Items
like gate etc. MMH Lot 28.00
C.23 Erection & Commissioning
LS 210.00
C.24 Taxes & duties 355.00 Sub Total C 2671.00
D. Misc. Fixed Assets D1 Pipes & Pipe fitting Steel Tube /
Vasuki Lot 50.00
D.2 Valves Vaas/ Audco/ Steam & Mining /
Vasuki
Lot 50.00
D.3 Tiles & tiling work VS Enterprise/ CUMI
Lot 66.00
D.4 Electricals Lot 220.00 D.5 Instrument & cable Lot 110.00 D.6 Plant Lighting etc. Lot 30.00 D.7 Public Address system Lot 30.00 D.8 Laboratory Eqpt.. Lot 55.00
Sub Total D 611.00 E. Substation and
125 KVA DG Set 125.00
F. Total A+B+C+D+E 5342.00 G. Contingency 5% 275.00
Grand Total 5617.00** ** 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. 80.00, which does not include interest and
depreciation components. Its break-up is given below:
[38]
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.
9. ANALYSIS OF PROPOSAL (FINAL RECOMMENDATIONS) POLLUTION CONTROL
Design of washing plant expansion will include measures to ensure
effective compliance with environmental regulations. The following
measures are proposed:
Online Continuous Ambient Air Quality Monitoring system
(CAAQMS) and Continuous Stack Monitoring system CSMS have
been installed at the plant and real time data for PM, SO2, CO, NOX,
PM2.5 & PM10 is being transmitted to the State Pollution Control
Board server.
Dust extraction / dry fog type dust suppression system to control
dust from the material transfer points.
Regular Water Sprinkling on Roads Plant with close circuit water circulation system so that no effluent
is discharged in the open outside the plant boundary. All the
process effluent will be collected in the thickener. Settled slurry of
the thickener will be dewatered in a multi roll belt press filter. The
dewatered filter cake will be mixed with the middling. The clarified
[39]
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.
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.
[40]
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
additional initiatives to be planned by AIPPL 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 AIPPL will also
take up various community health care programs 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
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
further improve, which in-turn will improve the socio-economic
conditions of the area.
[41]
ANNEXURE-I PROCESS FLOW SHEET
HEAVY MEDIA CYCLONES
DIVERTER
CLEAN COAL CONVEYOR
MAGNETITE SUMP CHARGING
TANK & PUMP FINE COAL
HEAVY MEDIA TANK & PUMP
TANK & PUMPDILUTE MEDIA
BOX
DESLIME SCREEN
SIEVE SCREEN
DIVERTER
BOX
SIEVE SCREEN
CLEAN COAL D & R SCREEN with
MAG. SEP.FEED BOX
PLANT FEED BELT
MAGNETIC SEPARATORSINGLE DRUM
MIDDLING CONVEYOR
TANK & PUMP SECONDARY WASHING
SUMP & PUMP
CLEAN UP
TOPUMP
PROCESS WASH DOWN
HI-RATE THICKENER
PUMPU'FLOW
MAKE-UPWATER
O'FLOWPUMP
D & R SCREEN with
CLEAN
COAL CENTRIFUGE
PRIMARY DISCARD
BOX
DIVERTER SIEVE SCREEN
WASHING CYCLONE
BELT PRESS FINE COAL
HI-FREQUENCY SCREENCLASSIFYING
CYCLONES
REJECT CONVEYOR
FINES DUMP
MIDDLING CENTRIFUGE
WAANNE
ATER BALA
[42]
EXURE-II ANCE DIA
AGRAM
[43]
ANNEXURE-III EFFLUENT TREATMENT PLANT DIAGRAM
[44]
ANNEXURE-IV PLANT LAYOUT
