Bharat Coking Coal Limited Bhojudih Coal Washery
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BHARAT COKING COAL LIMITED (A Subsidiary of Coal India Limited) FEASIBILITY REPORT OF BHOJUDIH COAL WASHERY CAPACITY : 1.7 MTY Eastern Washery Zone Oct - 2018 CMPDI CONTENTS SL. PAGE PARTICULARS NO. NO. 1. INTRODUCTION 2 2. LINKAGE OF COAL 4 3. WASHABILITY DATA 5 4. MASS BALANCE OF PRODUCTS 6 5. ENVIRONMENTAL MEASURES 7 6. BREAK UP OF CAPITAL ESTIMATE 8 7. ECONOMICS 9 LIST OF PLATES SL. PLATE PARTICULARS NO. NO. 1. PROCESS FLOWSHEET 1 2. PLANT LAYOUT 2 Job No. 200313003 1 CMPDI INTRODUCTION Bhojudih Coal Washery is a beneficiation plant where raw coal received from different underground mines and open cast mines is processed for decreasing ash contents of raw coal. During processing of raw coal, washed coal / clean coal and middling coal / washed coal (Power) and slurry are produced. Washed coal dispatched to different Steel plant by rail and middling / washed coal (Power) dispatched to different Power plant by rail. Slurry is liquidated by e auction. Bhojudih Coal Washery is constructed by THE COPPE Company (Great Britain) Ltd. and commissioned in the year 1962 by the agency. Brief History of Mahuda Coal Washery Name of the plant & address : Bhojudih Coal Washery Eastern Washery Zone, Santaldih P.O. - Santaldih Dist. - Purulia(West Bengal) PIN - 723145 Location : 3.0Km North from Santaldih Railway Station 3.00 Km south from Damodar river 25 Km West from Raghunathpur Latitude & Longitude : LATITUDE - 23o 37’ 3” N LONGITUDE - 86o 28’ 56” E Year of commissioning : 1962 Designed Capacity : 1.7 MTPA Throughput Rate : 300 tph Raw material : Raw Coal Raw Coal Stock Pile : 4X5000 MT Capacity Finished Products : Clean Coal/Washed Coal, Middling/ Washed Coal (Power) and Slurry. Clean Coal Bunker Capacity : 5000 MT Middlings Bunker Capacity : 01 No Bunker of Capacity Method of Washing : Heavy Medium Bath (for +25mm size) and Batac Jig for(-25mm+0.5mm) Job No. 200313003 2 CMPDI Present Clean Yield : About 31 %( For FY 2018-19 till Aug) Washing System Raw coal receive from underground mines and open cast mines at the rate of 2000 to 2500 tones per day at Bhojudih Coal Washery through Rail. Raw coal is carried from BOBR hopper to Single Roll crusher by belt conveyor and crushed down to -75 mm size coal and stacked in the raw coal stock Pile. For washing, coal is reclaimed from raw coal Stock Pile and fed to vibrating Screen of 25mm aperture size. Overflow of screen i.e.+25mm is fed to Heavy media Bath and -25mm is surged in 02 Bins for further feed into Batac Jig for Washing . Heavy Media Bath- Heavy media bath Sepates Clean cloal/Washed Coal and middling/Washed Power coal by using a media of magnetite and water. Both products,Washed Coal and Middling are rinsed on a vibrating screen of 0.5mm aperture with water spray. Underflow of Rinsing screen contains diluted media with fine coal- 0.5mmCoal.Media is recovered by using Magnetic separator. Batac Jig- It washes Coal of -25mm+0.5mm size. Washing is done by stratification of different density coal particles by Pulsation.It is wet process where air is used to pulsate coal Bed from bottom of chambers filled with water. Washed Coal is recovers from upper strata and middling from lower strata of Coal Bed. Bucket Elevator with perforated bucket is used to collect middling. Washed coal is deslimed at a vibrating screen. Washed Coal from both Washing equipment is mixed and stocked at Washed Coal Bunker. Middling of Both Washing Equipment is mixed and collected at Middling Bunker from where it is transported to Middling Siding for Dispatch. Effluent containg Fines ( -0.5mm) goes into Slurry Pond where fines get settled and fresh water is taken back into circuit. MAN POWER AS ON 01.10.2018 Executives - 012 Male - 381 Female - 050 Total - 443 PRESENT POWER SUPPLY Name of Feeder - SB1& SB2 Source of Supply - WBSEDCL Supplied from - Bhojudih 33KV/11KV Sub-Station. Voltage Level - 11 KV Job No. 200313003 3 CMPDI WORKSHOP There is a work shop near ROM for repairing work of equipment, spares of equipment etc. The following machines are available in the workshop of Bhojudih Coal Washery. 1. Lathe Machine - 05 Nos. 2. Shaper Machine - 01 No. 3. Drill Machine - 02 Nos. 4. Press Machine - 01 No. 5. Power Hacksaw - 01 No. 6. Furnace - 01 No. PRESENT LINKAGE OF COAL (a) Bhowra Colliery (b) Damagoria (c) Gopalichak Presently Coal is transported presently from Bhowra siding and Damagoria Siding through Railway. PERFORMANCE REPORT FOR LAST FIVE YEARS YEAR RAW COAL RAW COAL WASHED COAL YIELD RECEIVED(in FEED(in PRODUCTION(in % Ton) Ton) Ton) 2017-18 345053.03 348700 121850 34.94 2016-17 511113 512000 195480 38.18 2015-16 7216535.37 717700 194180 27.05 2014-15 432073.46 432300 121645 28.14 2013-14 567416.18 565000 260180 46 Job No. 200313003 4 CMPDI MASS BALANCE OF PRODUCTS YIELD SL. PRODUCT NO. Wt % Ash % 1. CLEAN COAL 34.5 20.7 2. MIDDLING 58.2 33.98 3 SLURRY 7.3 28.00 STORE Store is located near main gate where Materials are received, stored or issued for day to day for plant use. List of Major Equipment 1. Single Roll Crusher 02 Nos. 2. Reclaimer 02 No. 3. Heavy Media Bath 01 No. 4. Batac Jig 01 Nos. 5. Magnetic Separator 03 Nos. 6. Pump 14 No. 7. Thickener 03 No. 8. Screen 06Nos. 9. Vibro feedrer 04 Nos. 10 Power Transformer 1500KVA 06 Nos. 11. Power Transformer 200 KVA 02 Nos. 12. Dozer 01 No. 13. Poclain 01 No. 14. Payloader 01 No 15. Hyva 05 Nos. Job No. 200313003 5 CMPDI ENVIRONMENTAL MEASURES BEING TAKEN PRESENTLY 1. Water Pollution :- Bhojudih Coal Washery is running under closed circuit. Water is taken from Damodar river and rain harvesting Ponds as make up water. Washery is Zero discharge. 2. Air Pollution :- Fugitive emission of dust take place during receiving, crushing and transportation of coal .Water sprinklers are installed at different point raw Coal Receiving Hopper, Raw coal receiving Belt, Feed belt. Fixed sprinklers are installed beside road in plant for dust suppression .A Mobile sprinkler is used to sprinkle on roads to mitigate fugitive emission. 3. Noise Pollution :- For controlling the Noise Pollution, the equipment are regular checked and greased for smooth running which reduces the Noise Pollution.. Location of Hospital, School, Habitation and there distance from the Washery : > Aguitard - 1.0 KM > Santaldih Basti - 0.5 KM > Kamargora - 1.5 KM > Kumardih - 2.0 KM > Nabagram - 2.0 KM > Ichhar - 3.0 KM . > Bhojudih Coal Washery Township- 0.5 KM - > Allahdih - 4.0 KM . > Bogra - - 3.5 KM > Chakbad - 3.5 Km > Ichchar High School - 1.5 Km. >Poradiha- - 3.5 KM > Joradih - 5.0 Kms. > Kanki Bazar - 4.5Kms. Job No. 200313003 6 CMPDI >Santaldih Thermal Power Station Township-5 Kms >VidyaVihar School -0.7 KM > SCW high School -0.7 KM Financial Year : 2017-18 1. Designed Capacity - 1.7 MTPA 2. Technology - 1.Heavy Media Bath 2. Batac Jig 3. Product of Washery - 1.Washed Coal 2.Washed Power Coal/Middling 3. Slurry 4. Location - LATITUDE - 23o 37’ 3” N LONGITUDE - 86o 28’ 56” E 5. Land Required - 59 Hectare (approx.) which vested land. 6. Total Water Required - 300 KL/Day 7. Source of Water - Damodar River 8. Man Power - 443 (As on 01 OCT 2018) Job No. 200313003 7 .