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Bharat Coking Coal Limited Mahuda Coal Washery

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Bharat Coking Coal Limited Mahuda Coal Washery BHARAT COKING COAL LIMITED (A Subsidiary of Coal India Limited) FEASIBILITY REPORT OF MAHUDA COAL WASHERY NORMATIVE CAPACITY : 0.63 MTY Western Washery Zone October - 2018 CMPDI CONTENTS SL. PARTICULARS NO. 1. INTRODUCTION 2. LINKAGE OF COAL 3. WASHABILITY DATA 4. MASS BALANCE OF PRODUCTS 5. ENVIRONMENTAL MEASURES 6. BREAK UP OF CAPITAL ESTIMATE LIST OF PLATES SL. PLATE PARTICULARS NO. NO. 1. PROCESS FLOWSHEET 1 2. PLANT LAYOUT 2 Job No. 200313003 1 CMPDI INTRODUCTION Mahuda 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) are produced. Washed coal dispatched to different Steel plant by rail and middling / washed coal (Power) dispatched to different Power plant by rail or road. Mahuda Coal Washery is constructed by McNally Bharat Engg. Co. Ltd. and commissioned in the year 1989 by the agency. Brief History of Mahuda Coal Washery Name of the plant & address : Mahuda Coal Washery Western Washery Zone, Mahuda P.O. - Mahuda Dist. - Dhanbad (Jharkhand) PIN - 828305 Location : 1.5 Km East from Mahuda Railway Station 5.0 Km North from Damodar river 20 Km West from Dhanbad & 0.5 Km South from NH-32. Latitude & Longitude : 23°44’31.20” N, 86°09’53.02” E 23°44’29.42” N, 86°09’58.37” E 23°44’25.79” N, 86°09’56.23” E 23°44’25.70” N, 86°09’56.72” E Year of commissioning : 1989 Designed Capacity : 0.63 MTPA Throughput Rate : 150 tph Raw material : Raw Coal Raw Coal Bunker Capacity : 2800 MT Finished Products : Clean Coal/Washed Coal & Middling/ Washed Coal (Power). Clean Coal Bunker Capacity : 4700 MT Middlings Bunker Capacity : No Bunker. Only ground stock up to 1200 MT (approx.) Method of Washing : Heavy Medium Cyclone Job No. 200313003 2 CMPDI Present Clean Yield : About 44% Washing System Raw coal transported from underground mines and open cast mines at the rate of 500 to 800 tones per day to Mahuda Washery dump hopper. Raw coal is carried from dump hopper to primary crusher by belt conveyor and crushed down to 100 mm size coal and stacked in the raw coal bunkers. For washing, coal is reclaimed from raw coal bunker and crushed in secondary crusher up to (-)25/30 mm size coal. Thereafter, the (-)15 mm size of coal is dry separated mainly because of its low ash content, and directly mixed with the final product i.e. washed coal. The (+)15 mm to (-)25/30 mm fraction is them mixed with media and fed to dense mixed cycloids where coal is separated into two fraction viz. clean coal and middlings. Due to dry separation of (-)15 mm size as stated earlier, there is no generation of slurry, which is reported as NIL. The plant is run under closed water circuit and discharge of effluent (i.e. slurry and slurry water during the washing process) is NIL. But sometimes Raw coal received from mines whose ash content is more than required value. Under such condition, all the fraction of coal i.e. from (-) 0 mm to (-) 25/30 mm size coal are process. During process of all size coal, slurry is generated which is 3% of raw coal feed. Washed coal is loaded by belt conveyor system, weighed and dispatched to different steel plant. washed coal (POWER) is dispatched to Thermal Power & Steel Plant by Rail . A process flow sheet is attached. MAN POWER AS ON 15-01-2013 Executives - 08 Male - 204 Female - 015 Total - 227 PRESENT POWER SUPPLY Name of Feeder - Feeder No. 2 Source of Supply - DVC Supplied from - Madhuban Sub-Station. via Murulidih 20/21 Pit. Voltage Level - 11 KV Job No. 200313003 3 CMPDI WORKSHOP There is a work shop near Mahuda Office for repairing work of equipment, spares of equipment etc. The following machines are available in the workshop of Mahuda Coal Washery. 1. Lathe M/C - 2 Nos. 2. Shaper M/C - 1 No. 3. Drill M/C - 1 No. 4. Press M/C - 1 No. 5. Power Hexshow - 1 No. PRESENT LINKAGE OF COAL (a) Gaslitand Opencast Project (b) Moonidih Mines, Chaitudih, Ena Colliery/OCP. Coal is transported from ENA Open Cast project & Chaitudih Colliery /OCP by road to the dump hopper of Mohuda Coal Washery. DETAILS OF SAMPLE Sample collected during unloading of coal from dumper at Mahuda Coal Washery near dump hopper dispatched from Gaslitand OCP (Katras Area) katras chaitudih Colliery/ OCP and analysed at Lab. of Mahuda Washery. CHARACTERISATION OF RAW COAL Proximate I.M % Ash % V.M % F.C % 1.25 30.50 22.15 46.10 SCREEN ANALYSIS OF RAW COAL Size (mm) Wt % Ash % 25-0.5 94.50 30.80 (-) 0.5 05.50 25.40 Job No. 200313003 4 CMPDI COMBINED WASHABILITY DATA DEVELOPED FROM FLOAT AND SINK TEST CARRIED OUT CRUSHED TO 25 mm AT SIZE 25-0.5 mm. Float Cum. Float Cum. Sink Sp. Gr. Wt% Ash% Wt% Ash% Wt% Ash% < 1.30 4.80 7.50 4.80 7.50 95.20 29.90 1.30-1.40 10.00 17.30 14.80 14.12 85.20 31.35 1.40-1.45 13.20 23.00 28.00 18.31 72.00 32.88 1.45-1.50 15.00 26.00 43.00 20.99 57.00 34.70 1.50-1.60 12.00 29.20 55.00 22.80 45.00 36.13 > 1.60 45.00 36.10 100 28.80 00 00 PERFORMANCE REPORT FOR LAST FIVE YEARS RAW COAL RAW COAL WASHED COAL YIELD YEAR RECEIVED FEED PRODUCTION % 2013-14 187154.13 189400 128640 67.92 2014-15 154633.36 155700 66540 42.74 2015-16 209229.13 202416 36043 17.81 2016-17 207627.94 215300 92440 42.94 2017-18 86557.07 86700 38720 44.62 RAW COAL INPUT FOR THE YEAR 1992-93 TO 1994-95 Year Raw coal input 1992-93 399536.000MT 1993-94 364460.000MT 1994-95 331198.000MT Job No. 200313003 5 CMPDI MASS BALANCE OF PRODUCTS FOR PCC YIELD SL. PRODUCT NO. Wt % Ash % 1. CLEAN COAL 44.00 20.96 Wash Coal 2. 56.00 34.00 (Power) 100.00 PCC: Prime coking coal 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. Truck 1 No. 2. Car 1 No. 3. Jeep 1 No. 4. Primary H.M. Cyclone 2 Nos. 5. Motorized winch 1 6. Single Roll crusher 1 No. 7. Double Roll crusher 1 No. 8. Double Drum Magnetis Separater 1 No. 9. Car Haul 1 No. 10. Thickener 1 No. 11. Sreen 7 Nos. Job No. 200313003 6 CMPDI 12. Pump 9 Nos. 13. Power Transformer 3 Nos. ENVIRONMENTAL MEASURES BEING TAKEN PRESENTLY 1. Water Pollution :- Mahuda Coal Washery is running under closed circuit. Water is taken from ground water which is used as make up water. Discharge of Mahuda Washery is Zero. 2. Air Pollution :- During transportation of coal from belt conveyor, dumper or during crushing of coal, fine dust generated which is suppressed by water sprinkling. 50 Nos. of automatic water sprinkles were installed around the washery plant but at present some of them are out of order which will be repaired in near future. 3. Noise Pollution :- For controlling the Noise Pollution, the equipment are regular checked and greased for smooth running which reduces the Noise Pollution. In addition to this, Ear plugs have been provided to those workers who are working in noisy place (i.e. near crusher) to avoid impairing to hearing capacity. Location of Hospital, School, Habitation and there distance from the Washery : > KBR - High School - 1.0 Kms. > DAV - Public School - 5.5 Kms. > Mohuda College - 0.5 Kms. > Ravi Mahato School - 1.5 Kms. > Brahm Baba Mandir - 1.0 Kms. > Mohuda Basti Masjid - 1.5 Kms. > Mohuda Teliphone Exchange - 1.5 Kms. > Mohuda Basti (1162 Houses) - 1.5 Kms. > Chhatrutand Village (500 Houses) - 1.0 Kms. > Kumardih (1150 Houses) - 6.0 Kms. > Kachharra (300 Houses) - 5.0 Kms. > Lututand (150 Houses) - 6.5 Kms. Job No. 200313003 7 CMPDI > Modhudih (100 Houses) - 5.0 Kms. > Padugora (200 Houses) - 0.5 Kms. > Kanchanpur (150 Houses) - 7.5 Kms. Break up of Capital Estimate (F Year 2011-12) Sl. Description Total Cost Depreciation (` No. Gross Block in Lakhs) (` in Lakhs) 1. Service buildings, structures 206.55 150.14 & other civil works including water supply, roads & culverts and development works etc. 2. P&M 1276.74 1199.48 Total 1483.29 1349.62 Financial Year : 2017-18 Raw Coal Input (LT) : 0.865 Clean / Washed Coal (LT) : 0.387 Yield of Clean/Washed Coal (%) : 44.66 Wash Coal Power (LT) : 0.486 Yield of Wash Coal Power (%) : 56.14 Rejects (LT) : 0.03 Job No. 200313003 8 .
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