[1]

PRE-FEASIBILITY REPORT

COAL WASHERY PROJECT

AT

BHENGARI VILLAGE,

TEHSIL GHARGHORA, DISTRICT RAIGARD,

CHHATTISHGARH

MAHAVIR COAL WASHERIES PVT. LTD.

MARCH – 2015

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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

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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.

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FIGURE-1 INDEX MAP SHOWING THE PROJECT SITE

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FIGURE-2

MAP OF THE AREA 10 KM AROUND THE PROJECT SITE

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(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

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[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]