Pre-Feasibility Report
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PRE-FEASIBILITY REPORT Proposed 4.0 MTPA Coal Washery at Kistaram Village, Sathupalli Mandal, Khammam District, Telangana State Submitted to: Ministry of Environment, Forest and Climate Change New Delhi Submitted by: Global Coal & Mining Pvt. Ltd Hyderabad January, 2018 1. EXECUTIVE SUMMARY Sr. No. Description Details 1. Name of the Project Global Coal & Mining Pvt. Ltd. proposed to install a coal washery with a capacity of 4.0 MTPA at Kistaram village, Sattupalli mandal, Khammam district, Telangana state. 2. Location Kistaram village, Khammam district, Telangana state. Geographical Co-ordinates: Latitude: 17°12‟12.95”-17°12‟38.84”N Longitude:80°47‟19.31”-80°47‟39.22”E 3. Coal Washery Capacity (raw coal) 4.0 MTPA 4. Project area 13.03 ha 5. Process Technology Batac Jig & drum washer 6. Water requirement & Source Source: SCCL will supply raw water on chargeable basis to GCMPL from time to time. Requirement: Water consumption 100 litres/ton of raw coal is required for feeding to the plant taking into all types of consumption into consideration. The water as given above shall be utilized by GCMPL for the works connected to washery plant including Dust Suppression arrangements only. 7. Power requirement & Source The power requirement will be around 3.8 units per tonne of raw coal. The HT power supply source at the required capacity & rate of supply shall be made available by SCCL at the firm‟s sub-station point of the washery. The required energy meter shall be provided by SCCL in the premises of substation. 8. Working hours The plant will operate in three shifts each of 8 hours for 300 days in a year and approximately 5400 effective annual working hours i.e. effective of 18 hours in a day. 9. Rehabilitation and Resettlement No R & R issue involved 10. Manpower for construction& Approximately 250 persons during Operation phases construction period and 200 persons during operation. 11. Estimated Cost of the Project Rs.70 Crores 1 2.0 INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION 2.1 Introduction World proved coal reserves are currently sufficient to meet 153 years of global production, roughly three times the reserves to production (R/P) ratio for oil and gas By region, Asia Pacific holds the most proved reserves (46.5% of total), with China accounting for 21.4%. The US remains the largest reserve holder with (22.1%) of the total. North America has the highest regional reserves to production (R/P) ratio (356 years). R/P ratios are available by country and feature in the table of coal reserves. R/P ratios for the region and the world are depicted in the chart above and the Energy charting tool. Coal reserve data is in million tons. In India, GSI has estimated a total of 306.60 billion tons of coal reserves as on 01.04.15 of which Prime coking coal is 5.313 billion tons, medium & semi coking coal are 29.09 billion tons, Non- Coking Coal is 270.70 billion tons & Tertiary coal (High Sulphur) is 1.49 billon tons. 2 The Singareni Collieries Company Limited (SCCL) is a Government coal mining company jointly owned by the Government of Telangana and Government of India on a 51:49 equity basis. The Singareni coal reserves stretch across 350 Km of the Pranahita – Godavari Valley of Telangana with a proven geological reserves aggregating to whopping 8791 million tones. While historically technology has been a critical factor in SCCL's ability to reduce environmental impacts and occupational hazards, the need to constantly increase productivity and cut costs has demanded that the company goes in for phased mechanization and adapts state-of-the-art technologies. The coal production is concentrated in four districts of the State and around 40 % of the coal mineral production extracted only from Khammam district, followed by Karimnagar with 31% and Adilabad with 24% and Warangal with 5%. SCCL produces non-coking coal for supply to core sector industries including power houses, captive power plants, cement plants, defense etc. 2.2 Beneficiation Background Coal is the main source of commercial energy in India. India is the third largest coal producer in the world. With the projected growth of GDP at 8%, the requirement of coal for power generation will increase exponentially. Coal reserves in India for thermal generation of power are in abundance and are amenable for opencast mining economically. The raw coal for power generation in the major coalfields of India contains 35% to 45% ash. Coal of this quality is used by most of the thermal power stations, since 60s with the development of PFF and improvements in boiler design. As we have no significant open cast reserves of coal with less than 30% ash, this is the raw coal quantity that will be available for power generation. Govt. of India in order to enforce strict environmental standards, after considering all the aspects of coal mining, transportation of coal over long distances for power generation, ash generated at the power houses and consequent atmospheric pollution, has laid down the following guideline as per MoEF – Gazette notification dated 30.06.1998 and on 14.09.1999:- “On and from the 1st day of June 2001, the following coal based thermal power plants shall use raw or blended or beneficiated coal with an ash content not exceeding 34% on an annual average basis namely:- Any thermal power plant located beyond 1000 km from the pit head. Any thermal power plant located in urban areas or sensitive areas or critically polluted area irrespective of their distance from pit head except any pit head power plant, provided that any thermal power plant using FBC or circulating FBC or atmospheric FBC or Pressurized FBC or Integrated Gasification, Combined Cycle Technologies or any other clean technologies as may be notified by Central Govt. in the official gazette shall be exempted from clauses (a) & (b)”. Use of fly ash, pond ash or bottom ash – All Thermal Power Stations will phase out dumping of fly and bottom ash in ash ponds and will utilize 100% of ash generated within a certain time frame. Coal beneficiation is a process of segregating good quality coal from inferior coal/rejects. It is mainly done by using physical property of coal. Poor quality coal is heavier than the good quality coal. However, depending upon raw coal quality 3 and consumer specifications for clean coal, different washing technologies can be used. Presently Global Coal & Mining Pvt. Ltd. (GCMPL) is having four (04) functional coal beneficiation plants at Talcher & IB-Valley in Odisha and Ramagundem & Manugur in Telangana. Manuguru (1.5 MTPA) on BOO concept with Singareni Collieries Company Limited (SCCL), which happens to be India‟s first project on BOO basis. 3.0 BRIEF DESCRIPTION OF NATURE OF THE PROJECT The Singareni Collieries Company Limited (SCCL) is a Government coal mining company jointly owned by the Government of Telangana and Government of India on a 51:49 equity basis. SCCL produces non-coking coal for supply to core sector industries including power houses, captive power plants, cement plants, Defense etc. Total coal requirement and source of coal: Jalagam Vengala Rao Opencast - II Mine (JVROC-II) project operations were commenced from 01.09.2017 and the coal extraction has been commenced from 31.10.2017. The total extractable coal reserves considering mining losses in JVR OC-II Block are 239.16 MT and OB removal is 1033.25 mcum with a stripping ratio of 4.32 cum/t in 25 year project life period. The project was designed with a target of 10MT of coal per annum as per RCE-2016 from 4th year onwards. Out of which it is proposed to produce and transport two grades of coal i.e. G-12 (3891 K Cal/kg) (60.55%) and G-9 (4814 k.cal/kg) (39.45%). As per the stipulation of MoEF&CC for transportation >34% of ash coal to not to transport for 500 Km and above (MoEF&CC circular No. G.S.R. 2(E), dtd. 02.01.2014. As such it is proposed to wash the coal at pit head for the average G-12 grade coal with a yield of 55.29% to G-9 grade washed. Hence the total G- 12 coal produced from JVR OC-II Project is planned to wash after installation of Washery plant. So, SCCL desires to set up the coal washery on Build-Own- Operate (BOO) basis. Accordingly, SCCL float the NIT for setting up of coal washery for washing of 4.0 MTPA of raw coal for a period of 15 years under Build-Own-Operate (BOO) concept at JVROCP, Sathupalli, Khammam Dist., Telangana state. Global Coal & Mining Pvt. Ltd. (GCMPL) participate in the tender and awarded the BOO operator to setting up coal washery for washing of 4.0 MTPA of raw coal for a period of 15 years under Build-Own-Operate (BOO) concept. Under the „BOO‟ scheme, the washery will be planned, designed, constructed, installed, commissioned (including procurement, manufacturing, fabrication & erection of P&M equipment & civil works and all associated works etc.) operated & maintained by BOO operator at their own cost adhering to the statutory and regulatory norms applicable. The BOO operator is responsible to select the technology in order to produce the clean coal with the qualitative & quantitative requirements laid down by the SCCL. Establishing a coal washery with proven internationally accepted „state of the art technology‟ of continuous operation and with zero effluent discharge system at the site mentioned above. Used / old material, used / old plant & machinery etc., shall not be used in the construction of the plant.