revised conceptual report - welcome to...
TRANSCRIPT
REVISED CONCEPTUAL REPORT
FOR
SETTING UP OF JAGANNATH WASHERY (10.0 MTY)
at JAGANNATH AREA
(MAHANADI COALFIELDS LIMITED)
ON
BUILD-OPERATE-MAINTAIN “BOM” CONCEPT
OCTOBER 2014
STRICTLY RESTRICTED
FOR COMPANY USE ONLY
The information given in this report is not to be communicated either directly or indirectly to the press or to any person not holding any official position in CIL/ Government.
REVISED CONCEPTUAL REPORT
FOR
SETTING UP OF JAGANNATH WASHERY (10.0 MTY)
at JAGANNATH AREA
(MAHANADI COALFIELDS LIMITED)
ON
BUILD-OPERATE-MAINTAIN “BOM” CONCEPT
OCTOBER 2014
COAL & MINERAL PREPARATION DIVISION CENTRAL MINE PLANNING & DESIGN INSTITUTE LTD.
GONDWANA PLACE, KANKE ROAD RANCHI - 834031
CMPDI
311713059 (i)
CONCEPTUAL REPORT FOR SETTING UP OF JAGANNATH WASHERY (10.0 MTY), MCL
CONTENTS
Chapter No./
Para No. Description Page No.
EXECUTIVE SUMMARY iv-vii
1
INTRODUCTION
1-1 to 1-5
1.1 Background 1-1 1.2 Objective 1-1 1.3 Raw coal linkage to the proposed washery 1-1 1.4 Location and other details of Bhubaneswari OCP 1-2 1.5 Quality of Raw coal feed to the washery 1-4 1.5 Life of the proposed washery & construction schedule 1-5
2
RAW COAL CHARACTERISTICS
2-1 to 2-11
2.1 Raw coal linkage to Jagannath washery 2-1 2.2 Sample collection 2-1 2.3 Test procedure 2-2 2.4 Test results 2-3 2.5 Study of washability test results & selection of process 2-10
3
CAPACITY & OPERATING CONDITIONS OF THE WASHERY
3-1 to 3-2
3.1 Capacity 3-1 3.2 Operating conditions of different sections 3-1
4
PROCESS FLOWSHEET AND BALANCE OF PRODUCTS
4-1 to 4-3
4.1 Selection of process 4-1 4.2 Process flowsheet 4-1 4.3 Projected balance of products 4-3
5
INFRASTRUCTURE FACILITIES
5-1 to 5-3
5.1 Washery site 5-1 5.2 Availability of water 5-1 5.3 Availability of power 5-2 5.4 Railway siding for loading & dispatch of washed coal 5-2 5.5 Reject disposal/utilisation 5-2 5.6 Residential and welfare facilities 5-3
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Chapter No./
Para No. Description Page No.
6
ECONOMICS
6-1 to 6-3
6.1 Capital estimate 6-1 6.2 Cost benefit analysis 6-2
7
PROJECT CONSTRUCTION MANAGEMENT
7-1 to 7-4
7.1 General 7-1 7.2 Construction schedule 7-1 7.3 Scope of work of BOM operator 7-2 7.4 Support by MCL 7-2 7.5 Project monitoring 7-4
8
DATA & CONFIRMATION FROM MCL TO BE CONSIDERED FOR CUSTOMIZATION OF BID DOCUMENT
8-1 to 8-5
8.1 Raw coal availability & delivery 8-1 8.2 Land for washery & reject storage 8-2 8.3 Water 8-2 8.4 Power 8-3 8.5 Quality of raw coal feed to washery from linked mine (as
received basis) 8-3
8.6 Designated point for receipt of washed coal 8-4 8.7 Approval of revised conceptual report 8-4 8.8 Information regarding MCL 8-4 8.9 Draft for Bid Document 8-5
8.10 Legal jurisdiction 8-5
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LIST OF DRAWING
Drawing No. Particulars
HQ/CMP/311713059/04/001 Process Flowsheet
LIST OF APPENDICES
Appendix No. Particulars Page No.
1.1 Statement showing estimated capital investment with year-wise phasing
A-1
1.2 Statement showing the estimated cost of production & cost benefit analysis
A-2
LIST OF ANNEXURES
Annexure No. Particulars Page No.
1 Copy of Letter No.MCL/HQ/GM(CP&P)/13/410 dtd. 19.07.13 AN-1 2 3
Copy of Soil Investigation Report Copy of Letter no. MCL/HQ/GM (W)/JW/569 dated 06.10.14
AN-2 to14 AN-15
LIST OF PLATES
Plate No. Particulars 1 Washability curves for 50-0.5 mm coal of Bhubaneswari OCP 2 Washability curves for 50-13 mm coal of Bhubaneswari OCP 3 Surface layout plan showing location of Jagannath Washery alongwith
washed coal dispatch arrangement 4 Drawing showing coordinates of the boreholes done during soil investigation
of the washery site
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EXECUTIVE SUMMARY
1.0 MCL intended to install Jagannath Washery on Build Operate & Maintain (BOM)
concept having raw coal throughput capacity of 10.0 Mty in Talcher Coalfield with
the linkage of coal and site at Bhubaneswari OCP vide letter No. MCL/ HQ/
GM(CP&P)/ 134/ 410 dtd. 19.07.13 (Annexure-1). Further, MCL vide letter dtd.
24.12.13 requested CMPDI to take up the washability test of RoM coal sample of
Bhubaneswari OCP. Accordingly, the Conceptual Report (CR) was prepared
based on the washability test results of coal samples of Bhubaneswari OCP
carried out by CMP Laboratory, CMPDI, Ranchi in April 2014 and submitted to
MCL in July 2014.
2.0 The CR was presented in the MCL Board on 16.09.14. MCL vide their letter
dated 06.10.14 submitted comments for finalization of CR. Accordingly, the
report has been revised.
3.0 The washing scheme is briefly given below:
� Receiving raw coal of (-)100 mm from linked mine by belt conveyor.
� Crushing raw coal down to 50 mm.
� Deshaling of 50-13 mm fraction in two product improved type jigs to produce
deshaled coal (float) and rejects (sinks).
� Direct mixing of -13mm coal with deshaled coal from jig to obtain washed coal
of desired quality.
Provision of closed water circuit with zero effluent discharge and rain water
harvesting has been envisaged.
4.0 Infrastructure facilities:
a) Washery site The washery site is near the proposed raw coal receiving overhead bunker (15,000t) of Bhubaneswari CHP and between quarry limits of Ananta OCP & Lingaraj OCP and the same is under possession of MCL. Area: About 38 Ha land has been allocated for washery. An area of about 18 Ha having minimum width of 200m is to be demarcated for setting up of washery.
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b) Water Water requirement is about 0.60 MGD and is proposed to be met from Dhaba Quarry of Ananta OCP at a distance of about 3 kms. from the washery site. MCL shall arrange for availability of required quantity of water at the washery site (by laying water pipeline, pumping etc.) from Dhaba quarry upto the proposed washery site.
c) Power Requirement of power for operation & maintenance of the proposed washery is about 7.5 MVA and shall be available at 33kV by a separate overhead transmission line (OHTL). It has been envisaged that this OHTL will be drawn by MCL from Bhubaneswari sub-station adjacent to washery site.
d) Railway siding for loading & dispatch of washed coal
Washed coal from the washed coal covered storage will be reclaimed and conveyed through 2 nos. of belt conveyors of capacity 2000 tph each to the conveyor of MCL at Transfer House-6 (TH-6).
e) Reject disposal/
utilisation Rejects will be conveyed by BOM operator to Temporary Reject Storage Site (about 10 Ha) near to washery identified by MCL. MCL has decided to sell the rejects to prospective buyers either through e-auction route or through MoU route.
5.0 The summarized data are given hereafter:
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SUMMARISED DATA
1. Capacity & Operating conditions a) Annual : 10.0 Mty b) Daily : 30300 c) No. of effective working hours per year : 6000 d) Hourly : 1700 t 2. Raw coal linkage : Bhubaneswari OCP 3. Development period in years : 3
(including construction period)
4. Life of the washery after commissioning for computation of economics (in years) : 18
5. Quality of raw coal feed a) GCV (kcal/kg) : 4058
b) Grade : G-11 6. Balance of Products : As per Raw coal ash based on
washability test results i.e. 36.3%
Product Wt% Ash% Qty. (Mty) Washed coal 89.0 33.5 8.9 Rejects 11.0 59.0 1.1
Total 100.0 36.3 10.0 7. Balance of Products : as per likely Avg. Raw Coal ash
i.e. 40.1%
Product Wt% Ash% Qty. (Mty) Washed coal 78.8 33.5 7.88 Rejects 21.2 64.7 2.12 Total 100.0 40.1 10.0
8. Broad initial capital investment (Rs. in Crores) 265.35
9. Estimated Operating cost per tonne of raw coal (Rs.) 75.34
10. Cost of production per tonne (Rs.) 1284.70
11 Desired selling price of washed coal (at avg. RC Ash i.e. 40.1%) at 12% RoI
1331.33
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12 Selling price per tonne of washed coal (Rs.) 1746.42
13
14
15
Annual profit (Rs. Crores) (as per RC Ash based on washability
results i.e. 36.3%)
Annual profit (Rs. Crores) (as per avg. Raw Coal Ash i.e. 40.1%)
Payback Period (as per RC Ash based on washability results i.e.
36.3%)
359.57
363.84
9 months
16 Payback period (as per avg. Raw Coal Ash i.e. 40.1%) 9 months
17 Construction period including trial run, PGT & commissioning 18 months
*****
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1 - 1
Chapter – 1
INTRODUCTION
1.1 BACKGROUND
MCL intended to install Jagannath Washery on Build Operate & Maintain
(BOM) concept having raw coal throughput capacity of 10.0 Mty in Talcher Coalfield
with the linkage of coal and site at Bhubaneswari OCP vide letter No. MCL/ HQ/
GM(CP&P)/ 134/ 410 dtd. 19.07.13 (Annexure-1). Further, MCL vide letter dtd.
24.12.13 requested CMPDI to take up the washability test of RoM coal sample of
Bhubaneswari OCP. Accordingly, the Conceptual Report (CR) was prepared based
on the washability test results of coal samples of Bhubaneswari OCP carried out by
CMP Laboratory, CMPDI, Ranchi in April 2014 and submitted to MCL in July 2014.
The CR was presented in the MCL Board on 16.09.14. MCL vide their letter
dated 06.10.14 submitted comments (copy enclosed as Annexure-3) for finalization
of CR. Accordingly, the report has been revised.
1.2 OBJECTIVE
The objective of this conceptual report is to preliminarily assess the feasibility
for setting up of Jagannath washery of 10.0 Mty capacity at Bhubaneswari OCP,
MCL for supply of washed coal with 33.5+0.5% ash to thermal power stations.
1.3 RAW COAL LINKAGE TO THE PROPOSED WASHERY
The linkage of raw coal feed to the proposed Jagannath washery of 10.0 Mty
capacity is from Bhubaneswari Opencast Project. Raw coal will be supplied through 2
nos. of belt conveyors of capacity 1250 tph each from overhead bunker of
Bhubaneswari CHP.
A brief description of location, communication, physiography, drainage and
climate in respect of Bhubaneswari OCP is given hereafter:
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1.4 LOCATION AND OTHER DETAILS OF BHUBANESWARI OCP
1.4.1 Location
Bhubaneswari mining block comprising of an area of 5.8 sq.km is surrounded
by NH 23 and Sakhigopal block in the east, Lingaraj project in the south, Ananta
expansion project in the west & Arkhapal block in the north. The area is connected by
all weather metalled road to Bhubaneswar which is at a distance of about 170 kms.
The limiting geographical co-ordinates of the block are as follows:
Latitudes 20o57'59" – 20o58'43" (North)
Longitudes 85o09'10" – 85o11'37" (East)
1.4.2 Communication
The proposed block is well-connected by road and rail. The nearest railhead is
Talcher on Bhubaneswar-Talcher-Sambalpur line of East Coast railway and is
located at a distance of 6km. NH-23 connecting Angul and Rourkela passes adjoining
the Kaniha STPS of NTPC.
1.4.3 Topography & Drainage
The area of the block is characterised by both level as well as undulating
topography. Elevations of the area vary between 85m to 110m above mean sea
level.
The main drainage is controlled by the southerly flowing Brahmani river,
situated at the eastern extremity of the coalfield and east of Talcher town. The
eastern boundary of the block is about 4 km west from this river. A small
seasonal nallah (part of Bangdu jhore) is flowing along the northern periphery of the
project.
1.4.4 Climate & Rainfall
The area being located in the tropical belt experiences a typical warm and
temperate climate with a short spell of winter. Summer is usually hot and humid. The
temperature shoots upto 49°C accompanied by high humidity during this season.
During the pre-monsoon period, rains are often accompanied with thunder storms
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and hail storms. Monsoon breaks out by the end of June and continues intermittently
till middle of October. The mean annual precipitation is 1277mm of which 85% occurs
during rainy season. Winter is mild and the minimum temperature recorded is 6.7°C
in the month of January. The relative humidity varies from 31% to 88%. The
maximum wind speed recorded is 61 km/hour on 15.4.83. The general wind direction
is from west to east. Occasionally, it is from SE to NW and E to W.
1.4.5 Coal Production Programme & Heat Value
The total balance reserve in Bhubaneshwari OCP is projected to be around
374.12 Mt. The yearwise production programme as per mine PR vis-à-vis Useful
Heat value (UHV) of insitu coal is given hereafter in Table - 1.1.
Table-1.1 : Production Programme
Year Total Coal (Mt) Weighted Avg. UHV (Kcal/Kg)
2014-15 0.00 -
2015-16 2.00 2891.33
2016-17 4.00 3238.42
2017-18 8.00 3287.61
2018-19 11.00 3079.69
2019-20 14.50 2929.13
2020-21 17.50 2901.41
2021-22 18.50 2894.03
2022-23 23.00 2894.42
2023-24 25.00 2891.34
2024-25 25.00 3256.07
2025-26 25.00 3228.29
2026-27 25.00 3220.55
2027-28 25.00 3221.54
2028-29 25.00 3210.54
2029-30 25.00 3166.15
2030-31 25.00 3131.83
2031-32 25.00 3148.45
2032-33 25.00 3146.82
2033-34 25.00 3228.70
2034-35 0.62 3337.48
Total 374.12 Source: PR for Bhubaneswari OCP dtd. May 2006
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1.4.6 Gradewise & Seamwise Mineable Coal Reserve
The Bhubaneswari OCP consists of multiple seams comprising of II, III, L1,
IV, V, VIA, VIB, VII, VIII & IX. The seamwise and gradewise reserves as well as
quality is given in Table-1.2 hereafter:
Table-1.2: Reserves and Quality - Seamwise & Gradewise
(figures in Mt)
Sl. No.
Coal seam Grade Total
D E F G
1 II 3.61 100.06 113.59 8.26 225.52
2 III 1.75 33.4 36.04 0.75 71.94
3 L1 0.74 0.77 0.28 0.79 2.58
4 IV 1.15 13.3 19.7 2.88 37.03
5 V - 3.44 14.09 6.61 24.14
6 VIA - - 4 1.5 5.5
7 VIB - - - 3.73 3.73
8 VII 1.62 1.25 - - 2.87
9 VIII - - 0.24 0.25 0.49
10 IX - - 0.32 - 0.32
Total : 8.87 152.22 188.26 24.77 374.12
%age 2.4 40.7 50.3 6.6 100.0
It can be seen from above table that the total mineable coal reserves is around
374.12 Mt and the coal grades varies from Grade “D” to ‘G’. Also it can be inferred
from the above table that coal of Grade E constitutes around 41% and Grade F
around 50% of total coal which collectively constitutes around 90% of the total
reserve.
1.5 QUALITY OF RAW COAL FEED TO THE WASHERY
The weighted average UHV of the insitu coal has been worked out on the
basis of Table-1.1 and it works out to be 3116 kcal/kg. The average moisture of coal
derived from testing of coal sample at laboratory is about 5%. Based on the average
UHV and moisture, raw coal feed ash% works out to be 36.9.
As the present notified price of raw coal is based on GCV, the average UHV
has been converted into GCV considering ash and moisture as 36.9% and 5%
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respectively. Thus, the corresponding GCV works out to be 4354 kcal/kg.
The above quality of coal is ‘insitu’ and some dilution is expected during actual
mining operation. Considering dilution at the rate of 10% subject to a maximum of
300 kcal/kg, the likely annual average quality of actual production shall be around
4054 kcal/kg and the corresponding ash of coal is expected to be 40.1% at 5%
moisture.
Therefore, the likely average feed ash of raw coal to the proposed washery
has been considered as 40.1%.
1.6 LIFE OF THE PROPOSED WASHERY & CONSTRUCTION
SCHEDULE
It can be seen from Table 1.1 that life of Bhubaneswari OCP is 21 years
including production build up period, production period and tapering period.
Considering time required for bid process management of about 6 months and a
period of further 30 months for construction and commissioning of the washery
including Environmental Clearances, trial operation and Performance Guarantee
Tests (PGT) upto 2017-18, raw coal feed for commercial operation of the washery
will be available for 16 years only starting from 2018-19.
After depletion of coal reserves of running Bhubaneswari OCP, further
requirement of raw coal for Jagannath washery will be met from Bhubaneswari
(North) OCP, which is expected to be opened in future and that will meet the
requirement for balance life of the washery. The life of the washery has been taken
as 18 years for computation of economics keeping in view that life of major
equipment to be installed is 18 years.
*****
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CHAPTER – 2
RAW COAL CHARACTERISTICS
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2 - 1
Chapter - 2
RAW COAL CHARACTERISTICS
2.1 RAW COAL LINKAGE TO JAGANNATH WASHERY
The linkage of raw coal feed to the proposed Jagannath washery of 10.0 Mty
capacity is from Bhubaneswari Opencast Project. The test results of RoM coal
samples of Bhubaneswari OCP carried out by CMP Laboratory, CMPDI, Ranchi in
April 2014 are given hereafter:
2.2 SAMPLE COLLECTION
A team of CMP Laboratory, CMPDI, Ranchi visited Bhubaneswari OCP of
Jagannath Area of MCL for supervision of collection of sample for washability
investigation. The raw coal sample was collected by MCL team (approx.4.5 tonnes)
from exposed faces of Seam-II, III & IV of Bhubaneswari OCP on 29.01.2014 and
30.01.2014 under the supervision of CMPDI team.
The particulars of the sample collected are given hereafter in Table-2.1.
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Table-2.1: Sample Particulars of Coal from Bhubaneswari OCP
Sl. No. Particulars 1 Company MCL 2 Area Jagannath 3 Name of colliery Bhubaneswari OCP 4 Sample No. CMPDI/CMP/CPL/550/13-14 5 Name of seam II, III & IV 6 Total thickness of seams (m) 25-40m, 3-14m, 4-10m respectively 7 Working thickness of seams (m) 33m, 14m, 10m respectively 8 No. of bands Nil 9 Wt of gross samples (approx) 25 tonnes 10 Weight of coal sample approx 4.5-5 tonnes 11 Nature of sample Run of Mine (RoM) coal 12 Date of collection 29.01.2014 and 30.01.2014 13 Purpose of investigation To generate data for washability study
2.3 TEST PROCEDURE
The coal sample collected at Bhubaneswari OCP of Jagannath area of MCL
was received at CMP Laboratory on 06.02.2014 wherein it was thoroughly mixed and
divided into parts for various tests as per testing procedure given below:
i) Screening of coal sample, as received in laboratory at 200mm, 150mm,
100mm, 50mm, 25mm, 13mm, 6mm, 3mm & 0.5mm screen aperture and
determination of ash% & moisture% of each screened fraction.
ii) Proximate analysis of as-received coal sample under air-dried and
equilibrated condition i.e. 60% RH & 40°C including GCV & HGI.
iii) Crushing of as received coal sample down to 100mm size and screening at
50mm, 25mm, 13mm, 6mm, 3mm & 0.5mm screen apertures and
determination of ash% & moisture% of each screened fraction.
iv) Crushing of as received coal sample down to 50mm size and screening at
25mm, 13mm, 6mm, 3mm & 0.5mm screen apertures and determination of
ash% & moisture% of each screened fraction.
v) Further testing of coal crushed to -50mm as given below:
a) Float & Sink test of 50-25mm, 25-13mm, 13-6mm, 6-3mm & 3-0.5mm
size fractions of crushed coal and determination of wt% & ash% at each
specific gravity (from 1.4 to 1.9 at an interval of 0.1).
b) Generation of washed coal (50-0.5mm) at targeted ash of 34% based
on the float and sink test carried out as above.
c) Proximate analysis of generated washed coals (at about 34%) under
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air-dried and equilibrated condition i.e. 60% RH & 40°C including GCV
& HGI,.
d) Proximate analysis of generated rejects under air-dried and equilibrated
condition i.e. 60% RH & 40°C including GCV & HGI.
e) Determination of moisture% on as generated basis for generated
washed coals (at about 34%) and rejects.
f) Wet sieve analysis of -0.5 mm
g) Ultimate Analysis and Ash Fusion Temperature of raw coal, generated
washed coal (at about 34%) and rejects.
2.4 TEST RESULTS 2.4.1 Screen-cum-Ash & Moisture Analysis 2.4.1.1 Screen-cum-Ash & Moisture Analysis of Raw Coal
Representative raw coal sample of seams II III & IV of Bhubaneswari OCP
was drawn after coning & quartering and was subjected to screen analysis at 200,
100, 50, 25, 13, 6, 3 and 0.5 mm aperture screens. Weight%, ash% and moisture%
were determined for respective size fractions. The test results are given in Table-2.2.
The gross calorific value (GCV) of raw coal sample (adb) is 4430 kcal/kg.
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Table-2.2: Screen-cum-Ash & Moisture Analysis
Colliery/Mine : Bhubaneswari OCP Seam : II, III & IV Sample No. : CMPDI/CMPLab/550/13-14 Nature of sample : Run of Mine (RoM) Coal
Size (mm) Wt % Ash % Moisture% +200 2.2 32.8 4.9
200-150 8.8 29.7 5.1 150-100 16.8 35.1 4.4
100-50 19.1 40.1 4.2 50-25 23.3 38.2 3.8 25-13 11.6 36.6 4.1 13-6 7.1 37.3 3.2 6-3 5.0 34.9 4.3
3-0.5 2.9 31.6 4.2 -0.5 3.2 32.7 4.7
Total 100.0 36.4 4.2
2.4.1.2 Screen-cum-Ash & Moisture Analysis of Raw Coal Sample Crushed Down to 100 mm Screen analysis of representative raw coal sample crushed down to 100
mm was carried out at 50, 25, 13, 6, 3 and 0.5 mm aperture screens. Weight%, ash%
and moisture% were determined for respective size fractions. The results are given in
Table-2.3.
Table-2.3: Screen-cum-Ash & Moisture Analysis
Colliery/Mine : Bhubaneswari OCP Seam : II, III & IV Sample No. : CMPDI/CMPLab/550/13-14 Nature of sample : Run of Mine (RoM) Coal crushed
to (-) 100 mm
Size (mm) Wt % Ash % Moisture% 100-50 35.6 37.3 3.9 50 - 25 29.3 37.1 4.2 25 - 13 13.1 35.8 4.8 13 - 6 9.3 34.9 5.1 6 - 3 5.6 32.4 4.2
3- 0.5 3.2 30.7 4.6 -0.5 3.9 32.2 4.3 Total 100.0 36.1 4.3
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2.4.1.3 Screen-cum-Ash & Moisture Analysis of Raw Coal Sample Crushed Down to 50 mm Screen analysis of representative raw coal sample crushed down to 50
mm was carried out at 25, 13, 6, 3 and 0.5 mm aperture screens. Weight%, ash%
and moisture% were determined for respective size fractions. The results are given in
Table-2.4.
Table-2.4: Screen-cum-Ash & Moisture Analysis
Colliery/Mine : Bhubaneswari OCP Seam : II, III & IV Sample No. : CMPDI/CMPLab/550/13-14 Nature of sample : Run of Mine (RoM) Coal crushed
to (-) 50 mm
Size (mm) Wt % Ash % Moisture% 50 - 25 55.7 38.4 4.0 25 - 13 17.3 35.2 3.9
13 - 6 10.4 34.6 4.5 6 - 3 6.8 31.5 5.3 3- 0.5 4.6 30.0 4.8 -0.5 5.2 31.9 4.7 Total 100.0 36.3 4.2
2.4.2 Float & Sink Tests of Different Size Fractions Float and sink tests of representative raw coal sample of seams II , III & IV
of Bhubaneswari OCP (crushed to 50 mm size) has been carried out at 1.4, 1.5, 1.6,
1.7, 1.8 & 1.9 specific gravities for different size fractions of 50-0.5 mm. The results
are given in Table-2.5. The results of the float & sink analysis of 50-0.5 mm size
fraction are shown graphically in the form of washability curves in Plate-1.
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Table-2.5: Float & Sink Test Results
Colliery : Bhubaneswari OCP Seam : II, III & IV Nature of sample : RoM coal crushed down to 50mm. Sample No. : CMPDI/CMPLab/550/13-14 Size of coal tested : 50-25, 25-13, 13-6, 6-3 & 3-0.5 mm % of coal tested on raw coal basis : 94.8
Size(mm) 50 - 25 25 - 13 13 - 6 6-3 3 - 0.5 50 - 0.5
Wt %100 58.8 18.0 11.0 7.2 5.0 100.0
Sp.gr. Wt. % Ash % Wt. % Ash % Wt. % Ash % Wt. % Ash % Wt. % Ash % Wt% Ash% Cu.
Wt% Cu.
Ash%
Cu.Wt. %
(total raw coal
basis )
<1.40 22.1 17.3 25.8 12.0 26.4 12.7 29.2 9.3 30.8 6.5 24.2 14.3 24.2 14.3 22.9
1.40-1.50 19.8 28.5 18.4 23.4 19.7 26.5 17.7 22.4 15.6 20.6 19.2 26.7 43.4 19.8 41.1
1.50-1.60 20.5 37.9 16.2 35.7 21.1 36.3 16.1 33.8 14.5 31.7 19.2 36.9 62.5 25.0 59.3
1.60-1.70 10.3 46.4 8.6 41.6 6.9 42.7 8.6 39.9 5.8 37.9 9.3 44.6 71.8 27.6 68.1
1.70-1.80 9.3 50.6 10.2 49.4 8.7 49.1 10.3 46.5 12.7 43.0 9.6 49.4 81.4 30.1 77.2
1.80-1.90 9.8 61.3 13.1 59.1 9.8 59.5 11.3 57.1 11.4 53.6 10.6 59.9 92.0 33.6 87.2
>1.90 8.2 70.6 7.7 71.2 7.4 72.8 6.8 69.5 9.2 70.7 8.0 70.9 100.0 36.5 94.8
Total 100.0 38.5 100.0 35.0 100.0 34.7 100.0 31.5 100.0 30.1 100.0 36.5 - - -
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2.4.3 Wet Sieve Analysis
Wet sieve analysis of -0.5 mm fraction of raw coal crushed down to 50
mm size has been carried out at 72#, 100#, 200# & 300# sieve apertures and
wt% & ash% of each fraction was determined. The results are given in Table-
2.6.
Table-2.6: Wet Sieve Analysis of –0.5mm coal
Size(mesh) Wt % Ash %
+ 72 57.0 30.7
72 - 100 6.8 31.8
100 - 200 11.4 31.4
200 - 300 3.8 31.2
-300 21.0 36.3
Total 100.0 32.0
2.4.4 Generation of Washed Coal from Coal Sample (+ 0.5 mm to 50mm) at about 34% Ash Level and Reject Based on the float & sink data, the washed coal (at about 34% ash level)
and reject has been generated for the size fraction 50-0.5 mm and the results
are given in Table-2.7.
Table-2.7: Results of Generated Washed Coal at about 34% Ash of
50-0.5 mm Size Fraction
Particulars Sp.gr. of cut Wt % Ash %
Washed coal 1.90
92.2 33.7
Reject 7.8 70.9 Total 100.0 36.6
2.4.5 Proximate Analysis, GCV and HGI of Raw Coal, Washed Coal (at about
34% ash level) and Reject
Proximate analysis on air-dried basis and equilibrated basis was carried
out for raw coal (as received), washed coal (at about 34% ash level) and reject.
HGI and GCV for raw coal (as received), washed coal and reject were also
determined. The results are given in Table-2.8.Surface moisture and Total
moisture of raw coal were also determined as 5.5% and 9.7% respectively.
CMPDI
311713059 2 - 8
Table-2.8: Proximate Analysis of Raw Coal, Washed Coal & Reject
2.4.6 Moisture% on As Generated Basis of Washed Coal (at about 34% ash level) & Reject The total moisture (air dried + surface moisture) percent on as generated
basis was determined for generated washed coal and rejects. The results are
given in Table-2.9. The surface moisture% of raw coal was also determined
separately and found as 5.5%.
Table-2.9: Moisture% on as Generated Basis for
Generated Washed Coal & Reject
Particulars Total moisture% on as generated basis
Washed coal 10.4 Reject 5.4
2.4.7 Ultimate Analysis and Ash Fusion Temperature of Raw Coal, Washed Coal & Reject (at about 34% ash level) Ultimate analysis and ash fusion temperature was conducted for raw
coal and washed coal (at about 34% ash level) and reject. The results are
given in Table-2.10.
Sl. No.
Particulars
Raw Coal (As received)
Washed coal
Rejects
Air dried basis
Equilibrated basis
Air dried basis
Equilibrated basis
Air dried basis
Equilibrated basis
1 Proximate Analysis
i) Moisture% 4.2 4.9 4.3 5.2 1.9 2.4
ii) Ash% 36.4 36.1 33.7 33.4 70.9 70.5 iii) VM% 27.0 26.8 27.9 27.6 15.5 15.4
iv) Fixed
Carbon% 32.4 32.2 34.1 33.8 11.7 11.7
2 GCV
(kcal/kg) 4430 - 4660 - 1490 -
3 HGI 65 - 68 - 52 -
CMPDI
311713059 2 - 9
Table-2.10: Ultimate Analysis of Raw Coal Sample, Generated Washed Coal and Reject
Particulars Raw Coal Generated Washed Coal Reject
Carbon % 44.85 47.42 15.93 Hydrogen % 3.01 3.17 1.08 Nitrogen % 1.37 1.34 1.08 Sulphur % 0.89 0.68 0.74
Table-2.11: Ash Fusion Temperature of Raw Coal Sample,
Generated Washed Coal and Reject
Particulars Raw Coal Generated
Washed Coal Reject
IDT(0C) > 1400 > 1400 1363 ST(0C) > 1400 > 1400 > 1400 HT(0C) > 1400 > 1400 > 1400 FT(0C) > 1400 > 1400 > 1400
Abbreviations used: IDT: Initial deformation temperature, ST: sphere temperature HT:
hemisphere temperature, FT: flow temperature. 2.4.8 Heavy Metals of Raw Coal, Washed Coal & Reject (at about 34% ash level) The testing of heavy metals of raw coal, washed coal (at about 34% ash
level) and reject was conducted and the results are given in Table-2.12.
Table-2.12: Heavy Metals in Raw Coal Sample, Generated Washed Coal (at 34% ash) and Reject
Particulars Arsenic
(As) Cadmium
(Cd) Chromium
(Cr) Lead (Pb)
Mercury (Hg)
Raw coal 1.57 0.52 110.03 105.8 <0.05 Washed Coal
1.43 0.36 102.27 99.19 <0.05
Reject 8.33 1.37 179.32 198.15 <0.05
CMPDI
311713059 2 - 10
2.5 STUDY OF WASHABILITY TEST RESULTS & SELECTION
OF PROCESS
The main washing process for the washery has been selected on the
basis of qualitative requirement of washed coal of 33.5+0.5% ash of the
thermal power stations and in line with the MOEF guidelines.
Selection of process is based on the test results of coal samples. The
results of screen analysis of coal sample crushed down to 50mm (refer Table-
2.4) reveals that the ash percentage of different size fractions is varying from
30.0 to 38.4 and the average ash of -50mm fraction coal is 36.3%. The screen-
cum-ash analysis of raw coal crushed down to 50mm and screened at 13mm
has been computed from Table-2.4 and given in Table-2.13.
Table-2.13: Screen-cum-Ash Analysis
Size (mm) Wt % Ash % 50-13 73.0 37.7 -13 27.0 32.6
Total 100.0 36.3
It can be seen from Table-2.13 that the ash% of 50-13mm fraction is
37.7 and that of -13mm fraction is 32.6% which is in and around the quality
requirement of washed coal. Hence, deshaling of 50-13mm fraction and direct
mixing of natural –13mm raw coal with deshaled coal has been envisaged to
get the desired washed coal ash of 33.5+0.5%. The proposed Jagannath
washery has been planned to produce two products i.e. washed coal and
rejects.
The float & sink analysis of 50-13 mm size fraction are given in Table-
2.14 and are shown graphically in the form of washability curves in Plate - 2.
CMPDI
311713059 2 - 11
Table-2.14: Float & Sink Test Results
Colliery : Bhubaneswari OCP Area : Jagannath Seam : II & III Nature of sample : Raw coal sample crushed down to 50 mm Size of coal tested : 50-25 & 25-13
Size(mm) 50 - 25 25 - 13 50 - 13
Sp.gr. Float Float Float Cum. Float
Wt.% Ash% Wt.% Ash% Wt% Ash% Cu.Wt% Cu.Ash%
<1.40 22.1 17.3 25.8 12.0 23.0 15.9 23.0 15.9
1.40-1.50 19.8 28.5 18.4 23.4 19.5 27.4 42.4 21.1
1.50-1.60 20.5 37.9 16.2 35.7 19.5 37.5 61.9 26.3
1.60-1.70 10.3 46.4 8.6 41.6 9.9 45.4 71.8 28.9
1.70-1.80 9.3 50.6 10.2 49.4 9.5 50.3 81.3 31.4
1.80-1.90 9.8 61.3 13.1 59.1 10.6 60.7 91.9 34.8
>1.90 8.2 70.6 7.7 71.2 8.1 70.7 100.0 37.7
Total 100.0 38.5 100.0 35.0 100.0 37.7 - -
The washing equipment available for treatment of 50-13 mm size coal is
jigs & heavy media cyclones. It can be inferred from Table-2.13 that the specific
gravity of cut for deshaling of 50-13 mm size fraction is higher & maintaining
the same is difficult in case of heavy media process due to high viscous media
and not in practice at present. Hence, deshaling of 50-13 mm size fraction in jig
has been considered, as the separation at high specific gravity of cut is feasible
in jig. Thus, the washing scheme selected is deshaling of 50-13 mm size
fraction in Jig and direct mixing of -13 mm fraction with the deshaled coal from
Jig to obtain washed coal of desired quality.
****
CMPDI
311713059
CHAPTER - 3
CAPACITY & OPERATING
CONDITIONS OF THE
WASHERY
CMPDI
311713059 3 - 1
CMPDI
311713059 3 - 2
Chapter - 3
CAPACITY AND OPERATING CONDITIONS
OF THE WASHERY
3.1 CAPACITY
MCL has decided to set up Jagannath washery of 10.0 Mty throughput
capacity in Talcher Coalfield with linkage of coal from Bhubaneswari OCP. The
washery has been envisaged to produce two products viz. washed coal of 33.5+0.5%
ash & rejects. The washery has been envisaged to deshale 50-13 mm coal in
improved type jigs and direct mixing of -13 mm coal with the deshaled coal from jigs
to obtain washed coal of desired quality.
The raw coal throughput capacity of this washery considered is mentioned
below:
a) Annual : 10.0 Mt
b) Daily : 30300 tonnes
c) Hourly : 1700 tonnes
3.2 OPERATING CONDITIONS OF DIFFERENT SECTIONS
It has been envisaged that -100mm size raw coal from the linked mine i.e.
Bhubaneswari OCP will be transported to the raw coal receiving section of the
washery by two belt conveyors (each of capacity 1250 tph). The proposed washery
has been designed to have raw coal receiving section, washery section (i.e. from raw
coal storage to storing of washed coal and conveying of rejects to reject ground
storage) and loading & dispatch section. The operating conditions of different
sections are given hereafter:
3.2.1 RAW COAL RECEIVING SECTION
The operating conditions of the raw coal receiving section have been
envisaged to match with the operating conditions of Bhubaneshwari CHP and are
given hereafter:
CMPDI
311713059 3 - 3
a) No. of working days per annum : 330
b) No. of working shifts per day : 3 (8 hours each)
c) No. of effective working hours per year : 5000
d) Hourly throughput capacity (tonnes) : 2000
3.2.2 WASHERY SECTION
The operating conditions of washery are given below:
a) No. of working days per annum : 330
b) No. of working shifts per day : 3 (8 hours each)
c) No. of effective working hours per year : 6000
d) Hourly throughput capacity (tonnes) : 1700
3.2.3 DELIVERY OF WASHED COAL
Washed coal from the washed coal covered storage will be reclaimed and
conveyed through 2 nos. of belt conveyors of capacity 2000 tph each to the conveyor
of MCL at Transfer House-6 (TH-6).
3.2.4. REJECT STORAGE
Rejects shall be stored at temporary reject storage site having an area of
about 10 Ha identified near the washery site.
*****
CMPDI
311713059
CHAPTER – 4
PROCESS FLOWSHEET &
BALANCE OF PRODUCTS
311713059 4 - 1
Chapter - 4
PROCESS FLOWSHEET & BALANCE OF PRODUCTS
4.1 SELECTION OF PROCESS
The raw coal ash as per the test results of CMPDI is 36.3% and the likely
average monthly raw coal ash considering dilution has been arrived as 40.1% (refer
Cl. No. 1.5 of this Report). Hence, the main washing process for the washery has
been selected on the basis of likely average monthly raw coal ash i.e. 40.1% and
qualitative requirement of washed coal of the thermal power stations. The ash
percentage of washed coal has been kept around 33.5+0.5%. The proposed
Jagannath washery has been planned to produce two products i.e. washed coal and
rejects.
Selection of process is based on the study of the test results given in Chapter-
2 and the likely average monthly raw coal ash of coal from Bhubaneswari OCP as
40.1%. As already mentioned in Chapter-2, the study of test results revealed that
washing of 50-13 mm coal and mixing of untreated -13 mm size fraction is suitable
for achieving the targeted washed coal ash. Thus, deshaling of 50-13 mm fraction in
improved type jigs and mixing of untreated -13 mm raw coal with deshaled coal has
been envisaged to get washed coal of desired quality.
4.2 PROCESS FLOWSHEET The process consists of deshaling of 50-13 mm coal in jig and direct mixing of
–13 mm raw coal with deshaled coal to obtain washed coal and rejection of 50-13
mm sinks fraction from jig. It has been envisaged that the washery will comprise of
four modules of 2.5 Mty capacity each. The salient features of process are shown in
Drawing No. HQ/311713059/4/001 and briefly described below:
- Receiving raw coal of (-) 100 mm from CHP of Bhubaneswari OCP by 2
nos. belt conveyors of capacity 1200 tph each.
- Screening at 50 mm to obtain two size fractions i.e. 100-50mm & (-) 50 mm
311713059 4 - 2
- Crushing of 100-50 mm coal down to 50 mm and mixing it with natural -50
mm coal.
- Storing of crushed coal (-50 mm) in 15000 t ground storage.
- Reclamation and conveying of -50 mm coal from ground storage to washery
building.
- Screening of (-) 50 mm coal at 13 mm on vibrating screens to produce two
size fractions i.e. 50-13 mm & -13 mm.
- Deshaling of 50-13 mm fraction in two product electronically controlled
improved type jigs to produce deshaled coal (float) and rejects (sinks).
- Dewatering of deshaled coal obtained from jigs in double deck dewatering
screens followed by dewatering of 25-13 mm fraction in basket type
centrifuge.
- Clarification of underflow of double deck screen, centrifuge & belt filter
press in radial thickener.
- Dewatering of thickened slurry (i.e. underflow of thickener) in belt filter press
and mixing of dewatered slurry with the product.
- Conveying of washed coal (i.e. deshaled coal 50-13 mm obtained from jigs,
untreated -13 mm raw coal fraction and dewatered fines from belt filter
press) from washery building to covered storage of 30000 t capacity.
- Dewatering of rejects produced from jigs in bucket elevators.
- Conveying of dewatered rejects to Temporary Reject Storage Site (about 10
Ha) for onward selling to prospective buyers either through e-auction route
or through MoU route.
- Reclamation of washed coal from covered storage and conveying to the
MCL conveyor at Transfer House-6 (TH-6) leading to the proposed Silo
(4000 t capacity) located at the loop line on southern side of the existing
Spur Siding III for onward loading into the railway wagons through rapid
loading system for dispatch to customers.
The process of the proposed washery is based on closed water circuit system.
All the water fed into the system will be collected after use and re-circulated after
treatment in various units and no effluent will be allowed to escape into the natural
drainage system. Provision of rain water harvesting of roof top water has been
311713059 4 - 3
envisaged by recharging the same to ground and/or by collecting the same into the
constructed/developed water bodies for use in the washery.
4.3 PROJECTED BALANCE OF PRODUCTS
4.3.1 Based on Laboratory Test
Considering the screen analysis of washery feed and the float & sink data of
raw coal crushed down to 50 mm, the yield of washed coal at 33.5+0.5% ash from
the washery under actual plant conditions has been projected. The expected yield of
washed coal & rejects on the proposed scheme under practical conditions as per raw
coal ash based on washability test results has been estimated and given hereafter in
Table-4.1.
Table- 4.1: Balance of Products as per Raw coal ash% based on washability test results
Product Wt% Ash% Qty. (Mty) Washed coal 89.0 33.5 8.9 Rejects 11.0 59.0 1.1
Total 100.0 36.3 10.0
4.3.2 Projected Balance of Products on Average Raw Coal Ash
The likely balance of products have also been projected on the likely average
quality of raw coal feed to the washery (Average Ash, A = 40.1%) and given hereafter
in Table-4.2.
Table- 4.2: Projected Balance of Products as per Average Raw Coal Ash
Products Wt% Ash% Qty. (Mty)
Washed Coal 78.8 33.5 7.88
Rejects 21.2 64.7 2.12
Total 100.0 40.1 10.00
*****
CMPDI
311713059
CHAPTER – 5
INFRASTRUCTURE FACILITIES
CMPDI
311713059 5 - 1
Chapter - 5
INFRASTRUCTURE FACILITIES
5.1 WASHERY SITE
The land requirement for setting up of the washery is estimated to be around
18 Ha including green belt of at least 15m width around the washery site as per the
guidelines of Odisha State Pollution Control Board. The land requirement has been
estimated considering receiving pit for receiving -100mm raw coal by belt conveyors
from CHP of Bhubaneswari OCP, storage of raw coal (15000 t), screen-cum-crusher
house, washery building, covered storage of washed coal (30000 t), emergency
slurry pond, radial thickener etc., administrative buildings and other allied structures
as per the technological requirement.
The proposed washery site is near the main access trench of Bhubaneshwari
OCP adjacent to raw coal receiving overhead bunker (15,000t) and between the
quarry limits of Ananta OCP & Lingaraj OCP and the same is under possession of
MCL. About 38 Ha land has been allocated for washery. An area of about 18 Ha
having minimum width of 200m is to be demarcated for setting up of washery. The
tentative requirement of land of about 10 Ha has been considered for temporary
storage of rejects prior to selling the rejects to prospective buyers either through e-
auction route or through MoU route. Drawing showing location of the Jagannath
washery site alongwith washed coal dispatch arrangement is given at Plate-3 and
Soil Investigation Report of the same is given at Annexure-2. Drawing showing the
co-ordinates of the four boreholes done during soil investigation of the washery site is
given at Plate-4.
5.2 AVAILABILITY OF WATER
The quantity of water required for operation & maintenance of the proposed
washery is about 0.60 MGD. The source of water is Dhaba quarry of Ananta OCP
which is about 3 kms. from the washery site. MCL shall arrange availability of
required quantity of water at the washery site (by laying water pipeline, pumping etc.)
from Dhaba quarry upto the proposed washery site.
CMPDI
311713059 5 - 2
5.3 AVAILABILITY OF POWER
The requirement of power is about 7.5 MVA for operation & maintenance of
the proposed washery and shall be available at 33kV through a separate overhead
transmission line (OHTL) to be drawn by MCL from Bhubaneswari sub-station
adjacent to washery site. It has been envisaged that an independent feeder (spare)
at 33 kV is available at Bhubaneswari sub-station which will send power to the
proposed washery. In absence of this, strengthening of Bhubaneswari sub-station
and provision of a separate 33 kV feeder for power supply to washery is to be
arranged by MCL.
5.4 RAILWAY SIDING FOR LOADING & DISPATCH OF WASHED
COAL
Washed coal from the washed coal covered storage will be reclaimed and
conveyed through 2 nos. of belt conveyors of capacity 2000 tph each to the conveyor
of MCL at Transfer House-6 (TH-6).
MCL will further transport washed coal from TH-6 to the proposed silo of 4000t
capacity located at the loop line on southern side of the existing spur siding III for
onward transportation to consumers through Rapid Loading System (RLS) (5500
tph).
The construction of conveyor, TH-6, Silo, RLS and strengthening of Railway
siding is under the scope of MCL.
5.5 REJECT DISPOSAL/UTILISATION
The washery has been designed for a throughput capacity of 10.0 Mty of raw
coal per annum. The washery will produce two products viz. washed coal for thermal
power stations and rejects.
Based on the technology selected, the likely average quantity of rejects to be
produced from the washery has been estimated as 2.12 Mty. MCL has decided to sell
the rejects to prospective buyers either through e-auction route or through MoU
route. The rejects will be conveyed to Temporary Reject Storage Site (about 10 Ha)
near to washery identified by MCL. If required, the rejects of higher GCV and rejects
of lower GCV will have to be stacked separately in the identified temporary reject site
CMPDI
311713059 5 - 3
for further disposing off by MCL either on the basis of e-auction route or through MoU
route. Conveying of rejects to temporary reject site will be done by the BOM
Operator.
MCL shall ensure that the above mentioned facilities shall be ready for use as
per the requirement for timely start of construction activities as well as commissioning
of the washery.
5.6 RESIDENTIAL AND WELFARE FACILITIES
The washery is proposed to be installed on Build, Operate & Maintain (BOM)
basis. It is expected that the residential facilities for the manpower will be arranged by
BOM operator. Hence, no capital provision has been kept for residential facilities
However, the available welfare facilities may be extended by MCL.
*****
CMPDI
311713059
CHAPTER – 6
ECONOMICS
CMPDI
311713059 6 - 1
Chapter - 6
ECONOMICS
6.1 CAPITAL ESTIMATE
Jagannath washery is to be set up under Build-Operate-Maintain (BOM)
concept. The BOM operator will be selected by global bidding. The BOM operator will
build the washery and operate & maintain the washery thereafter for a period of 10
years.
The broad initial capital estimate has been done considering the operating
conditions, washing scheme envisaged and infrastructure facilities. While estimating
this capital, following tentative provisions have been considered:
- Raw coal receiving by belt conveyors from linked mine.
- Screen-cum-crusher house
- Storage of raw coal (15000 t)
- Washery building
- Covered storage of washed coal (30000 t)
- Temporary storage of rejects
- Emergency slurry pond
- Conveying of washed coal to the MCL conveyor at TH-6 for onward
transportation to the proposed silo at existing Spur Siding No. III.
- Administrative buildings and other allied structures (viz. stores, workshop,
outdoor sub-station, water storage, first-aid centre, canteen, security check
post etc.)
- Major technological equipment alongwith two years critical spares
- Conveyor gantries, belt conveyors
- Plant control system, instrumentation, quality & quantity monitoring system
- Power and water supply arrangement
- Roads, culverts, green belt, boundary wall, environmental control units, fire
fighting equipment etc.
- Closed water circuit with zero effluent discharge and rain water harvesting.
Residential facilities for the manpower will be arranged by BOM operator.
CMPDI
311713059 6 - 2
Hence, no cost in this regard has been considered for estimation of broad capital.
However, the available welfare facilities may be extended by MCL.
It has been envisaged that laying pipeline for supplying water to the washery,
construction of Silo, strengthening/ modification of existing Railway line/ siding &
loading system etc. shall be dealt separately by MCL. Hence, no capital has been
considered on this account.
It has been considered that total capital will be funded from own resources of
MCL. Hence, 100% equity capital has been considered.
The estimated broad initial capital thus works out to about Rs.265.35 Crores
and the break up is given at Appendix 1.
6.2 COST BENEFIT ANALYSIS
The cost of production as calculated and given at Appendix-2 is broadly based
on the following considerations:
o Notified selling price of raw coal of MCL for Grade G-11 w.e.f.
17.12.2013, including royalty & SED and crushing charge of RoM coal.
o Estimated operating cost of washery per tonne of raw coal input as per
CMPDI practice.
o Projected yield of washed coal at 33.5 ̉±0.5 % ash.
The estimated operating cost at 100% capacity utilization has been worked out
to be Rs. 75.34 per tonne of raw coal input.
As there is no washery in MCL at present, the selling price of Rs.1746.42 per
tonne for power coal produced from Piparwar washery has been considered for
estimating the annual profit of the washery. The estimated annual profit
corresponding to Raw coal ash on the basis of washability test result i.e. 36.3% and
average raw coal ash i.e. 40.1% are given hereafter in Table-6.1 & 6.2 respectively.
CMPDI
311713059 6 - 3
Table- 6.1: Cost Benefit Analysis
(As per Raw coal ash on the basis of washability test result i.e. 36.3%)
Sl. No. Particulars
1 Profit per tonne of washed coal (in Rs.) 404.02
2 Annual Profit (in Rs. Crore) 359.57
3 Payback Period (in months) 9
Table- 6.2: Cost Benefit Analysis
(at Average Raw coal ash i.e. 40.1%)
Sl. No. Particulars
1 Profit per tonne of washed coal (in Rs.) 461.72
2 Annual Profit (in Rs. Crore) 363.84
3 Payback Period (in months) 9
6.2.1 Sensitivity Analysis
In case of setting up of washery on BoM concept, the raw coal ash% may vary
within range of A±4, where A is the average raw coal ash i.e. 40.1% in this case. As
such, average ash% may increase from 40.1 to 44.1 and profitability which may vary
accordingly is given hereafter.
Sl. No.
Parameters Raw Coal Ash
Average, A
A+1 A+2 A+3 A+4
1.
Raw Coal Ash% 40.1 41.1 42.1 43.1 44.1
2.
Annual Profit at 100% Capacity Utilization, (in Rs. Crore)
363.84 353.34 297.24 241.15 242.05
3.
Payback Period (at 100% Utilization), (in months)
9 9 11 14 14
*****
CMPDI
311713059
CHAPTER – 7
PROJECT CONSTRUCTION
MANAGEMENT
CMPDI
311713059
7 - 1
Chapter – 7
PROJECT CONSTRUCTION MANAGEMENT
7.1 GENERAL
Project construction management is a highly specialized job and it is a vital
tool for the successful completion of a project as per schedule. This is achieved by a
well organized management system and proper planning which help in completion of
project on schedule.
This report envisages 10.0 Mty washery from planning, design &
engineering, selection of necessary equipment & machinery (including two years
critical spares), construction, successful commissioning, PGT (including
procurement, delivery, fabrication & erection of P&M equipment & civil works and all
associated works etc.) of washery from raw coal receiving arrangement at washery,
secondary crushing facilities, raw coal storage, washery, covered washed coal
storage, temporary storage of rejects and conveying of washed coal to MCL
conveyor at Transfer House-6 or through pipe conveyor leading to proposed loading
silo for loading of washed coal through rapid loading system for onward dispatch
through railway to the consumers by MCL.
7.2 CONSTRUCTION SCHEDULE
The 10.0 Mty washery on BOM basis is expected to be completed within 18
months period comprising various activities such as planning, design & engineering,
selection of equipment/ machinery, procurement, erection of P&M and structurals
associated with civil works including trial-run, commissioning, performance guarantee
tests etc. The zero date for construction activities has been considered as the
effective date of signing of Contract.
7.3 SCOPE OF WORK OF BOM OPERATOR
The scope of work of the BOM Operator is as follows:
- Planning, design & engineering, selection of necessary equipment &
machinery, procurement, delivery, erection/ installation, testing, trial-run,
CMPDI
311713059
7 - 2
successful commissioning including PGT of coal washing plant and all allied
activities for setting up of the Coal Washery.
- Operation and maintenance of the plant for a period of ten (10) years (after
successful commissioning of the washery).
- Receipt of raw coal (-100mm) from linked mine through belt conveyors at
washery premises.
- Washing of raw coal to meet requisite quality & quantity of washed coal.
- Delivery of washed coal and rejects to MCL at the designated delivery place
indicated by MCL.
- Though, the responsibility of obtaining statutory and regulatory clearances
lies with MCL but while operating, the BOMO must comply with all statutory
and regulatory requirements.
- MCL shall be responsible for obtaining all statutory & regulatory clearances,
environmental and other clearances from Central/ State Pollution Control
Boards or any other agency as applicable. However, the Bidder shall provide
all necessary assistance/ support in this regard as necessary.
7.4 SUPPORT BY MCL
MCL shall provide following necessary supports to the BOMO:
7.4.1 DURING CONSTRUCTION
- Financing for setting up of the washery (including DG set as stand-by power
arrangement for critical equipment/ system).
- Land (acquired and demarcated) free of any obstruction such as abandoned
structures, overhead electrical lines, debris/ dump materials, hillocks, etc. with
approach road.
- Soil investigation Report and Contour Map of the project site (indicative for
bidding purpose only).
- Supply of water (within 100m) & power at a single point (in the washery) on
chargeable basis up to successful PGT.
CMPDI
311713059
7 - 3
7.4.2 DURING OPERATION & MAINTENANCE
- Assured raw coal supply of requisite quality and quantity of (-) 100 mm size at
washery.
- Assured evacuation of washed coal and rejects.
- Arranging/ indenting of Railway wagons as well as loading of washed coal into
railway wagons including the development of infrastructural facility for rapid
loading system.
- Railway siding for transportation of washed coal.
- Providing power at 33 kV through OHTL upto the washery site on the basis of
agreed demand.
- Reimbursement of additional operating expenses for DG set on actual.
- Arrangement for drawl of water for operation & maintenance of washery from
Dhaba quarry of Ananta OCP within the washery premises and adequate
arrangement for charging of Dhaba quarry with other sources, if required.
The above provisions & supports are to be confirmed/ ensure/ accomplished
by MCL before customization of the Bid Document.
7.4.3 DURING CONSTRUCTION & OPERATION BOTH
MCL shall obtain all statutory & regulatory clearances including Environmental
Clearances from Central/ State Pollution Control Board or any other agencies on the
basis of technology of the Lowest Bidder. This process of obtaining various
clearances may require 12 months time from the date of identification of Lowest
Bidder. After obtaining such clearances, issue of Letter of Acceptance/ Award (LoA)
& signing of Contract will be done and thereafter construction period of 18 months
will commence. Moreover, Lowest Bidder will have to assist MCL in all these
activities.
7.5 PROJECT MONITORING
Monitoring of progress by MCL for construction of the project is essential to
adhere to the envisaged time schedule. The measurement of progress can be done
either in part or as a whole. CPM/PERT chart submitted by BOM executor will be
strictly followed for the purpose of monitoring the progress of the project. This chart is
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7 - 4
to be updated on the basis of feed back information, received from time to time
regarding progress of work. This will reveal the correct status of the progress and
subsequent corrective measures can be adopted. However, the critical path should
never be allowed to be disturbed, if the time schedule is to be maintained.
*****
CMPDI
311713059
CHAPTER - 8
DATA/ INFORMATION TO BE
CONSIDERED FOR
CUSTOMIZATION OF BID
DOCUMENT
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8 - 1
Chapter - 8
DATA / INFORMATION TO BE CONSIDERED
FOR CUSTOMIZATION OF BID DOCUMENT
8.1 RAW COAL AVAILABILITY & DELIVERY
The raw coal requirement for 10.0 Mty proposed washery is proposed to
be met from Bhubaneswari OCP. The balance life of Bhubaneswari OCP as on
01.04.2014 is 13 years. Considering 3 years for construction and commissioning
of washery including Environmental Clearances, trial operation and Performance
Guarantee Tests (PGT), coal for feed to washery will be available for about 10
years. After depletion of coal reserves from running Bhubaneswari OCP after 10
years, further requirement of raw coal for Jagannath washery will be met from
Bhubaneswari (North) OCP, which is expected to be opened in future and that
will meet the requirement for further 8 to 10 years. Thus, the life of the washery
has been taken as 18 years for computation of economics keeping in view the
availability of coal and also that life of the major equipment to be installed is 18
years for setting up of washery.
MCL will have to confirm the supply of raw coal of specified quality &
quantity for the life of the project prior to customization of Bid Document.
MCL has indicated that the top size of raw coal feed to washery is -100
mm. MCL shall confirm the raw coal delivery arrangement from CHP by belt
conveyor to the washery so that the tapping point for raw coal may be firmed up
for incorporation in the RFP document.
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8.2 LAND FOR WASHERY & REJECT STORAGE
The proposed washery site is near the main access trench of
Bhubaneshwari OCP adjacent to raw coal receiving overhead bunker (15,000t)
and between the quarry limits of Ananta OCP & Lingaraj OCP and the same is
under possession of MCL. About 38 Ha land has been allocated for washery. An
area of about 18 Ha having minimum width of 200m is to be demarcated for
setting up of washery. The tentative requirement of land of about 10 Ha has been
considered for temporary storage of rejects prior to selling the rejects to
prospective buyers either through e-auction route or through MoU route. Soil
investigation report of the project site indicating co-ordinates in meter on the site
map as per the format is given in Annexure-2.
The land for washery and temporary reject storage site is to be
demarcated by MCL prior to customization of Bid Document. Site plan indicating
the surface contours, existing structures, benchmarks, washery site, temporary
reject storage site, linked mines, roads for transport of coal, approach road,
source of power etc. is to be furnished for incorporation in the Bid Document.
8.3 WATER
The quantity of water required for operation & maintenance of the
proposed washery is about 0.60 MGD. The source of water is Dhaba quarry of
Ananta OCP which is about 3 kms. from the washery site. MCL shall arrange
availability of required quantity of water at the washery site (by laying water
pipeline, pumping etc.) from Dhaba quarry upto the proposed washery site.
However, a hydrological study is required to be carried out by MCL to
ascertain the availability of water & its quality for incorporation in the Bid
document. All necessary steps are to be taken by MCL for obtaining any statutory
clearances/ approvals.
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8 - 3
8.4 POWER
The requirement of power is about 7.5 MVA for operation & maintenance
of the proposed washery and shall be available at 33kV through a separate
overhead transmission line (OHTL) to be arranged by MCL upto washery site. It
has been envisaged that an independent feeder (spare) at 33 kV is available at
Bhubaneswari sub-station for supply of power to washery. In absence of this,
strengthening of Bhubaneswari sub-station and provision of a separate 33 kV
feeder for power supply to washery is to be arranged by MCL. MCL shall confirm
the availability of power at the washery site prior to customization of Bid
Document.
As per provision of the Model Bid Document (MBD) duly approved by CIL
Board, MCL will have to provide power at a single point within the washery
complex during construction of washery on chargeable basis. The confirmation of
the source of power and its availability is sought prior to customization of Bid
Document.
8.5 QUALITY OF RAW COAL FEED TO WASHERY FROM
LINKED MINE (AS RECEIVED BASIS)
a) i) Likely total average moisture% : 9.7
(day-to-day basis) (arb)
ii) Range of total moisture% (arb) : 8 to 12
iii) Likely average moisture% : 4.2
(day-to-day basis) (adb)
b) Likely monthly average ash % : 40.1
c) Range of monthly average ash % : 40.1+4
d) Range of day to day basis ash % : 40.1+4
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8.6 DESIGNATED POINT FOR RECEIPT OF WASHED COAL
It has been envisaged that BOM operator shall reclaim washed coal from
the washed coal covered storage and deliver the same through 2 nos. belt
conveyors (each of approx 200 m length and of capacity 2000 tph) to the MCL
conveyor at Transfer House-6 (co-ordinate of TH-6 has to be indicated in the Site
Plan) leading to the proposed Silo of 4000 t capacity located at the loop line on
the southern side of the existing Spur Siding III. The tentative distance from the
proposed washery site to Spur Siding is about 2.4 kms. The Silo for loading of
washed coal shall be constructed by MCL.
All the above necessary steps are required to be taken so that the
construction of the silo is co-terminous with commissioning of the washery.
8.7 APPROVAL OF REVISED CONCEPTUAL REPORT
Approval of Revised Conceptual Report of Jagannath washery by MCL is
required before customization of Bid Document.
8.8 INFORMATION REGARDING MCL
Provision / information as given hereafter are to be furnished by MCL:
a) Name & official address of designated person of MCL for the purpose
of Bid Notice.
b) Website address of MCL for the purpose of downloading of Bid
Document.
c) E-mail address of MCL or that of the concerned designated person of
MCL.
d) Fax no. of MCL for the purpose of communication with respect to bid.
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8.9 DRAFT FOR BID DOCUMENT
Name in whose favour the Draft for price of Bid Document is to be issued
need to be furnished.
8.10 LEGAL JURISDICTION
Name and place of court for legal jurisdiction is to be furnished.
*****
APPENDICES
311713059 A-1
APPENDIX – 1
Conceptual Report for Jagannath Washery, MCL
Statement Showing Estimated Capital Investment With Year-wise Phasing
(Rs.in Lakhs) Sl. No. Description Total Cost Year-1
(2014-15) Year-2
(2015-16) Year-3
(2016-17)
1 Service buildings, structures & other civil works including water supply, roads & culverts and development works etc.
14320 8500 5820
2 Plant & Machinery 11585 6950 4635
3 Others
a. Furniture & Fittings 30 18 12
b. CR preparation, Bid Process Management, EIA/EMP, Scrutiny of drawings, Author supervision during construction etc.
600 265 255 80
Total 26535 265 15723 10547
Appendix-2
Statement Showing Estimated Cost of Production of
33.5 ± 0.5% ash Washed Coal & Cost Benefit Analysis of Jagannath Washery (10 Mty), MCL
Sl. No.
Parameters Basis of Raw Coal Ash
As per Washability Test Result
Average, A A+1 A+2 A+3 A+4
1 Raw Coal Ash% 36.30 40.10 41.10 42.10 43.10 44.10
2 GCV, kcal/ kg 4411.54 4053.92 3959.81 3865.70 3771.59 3677.48
3 Grade of coal G-10 G-11 G-12 G-12 G-12 G-13
4 Raw Coal Input, Mty 10.00 10.00 10.00 10.00 10.00 10.00
5 Yield of Clean Coal, % 89.00 78.80 75.59 72.38 69.16 65.95
6 Washed Coal Output, Mty 8.90 7.88 7.56 7.24 6.92 6.60
7 Yield of Rejects, % 11.00 21.20 24.41 27.62 30.84 34.05
8 Reject generation, Mty 1.10 2.12 2.44 2.76 3.08 3.40
COST BENEFIT ANALYSIS AT DIFFERENT RAW COAL ASH 1 a) RoM Coal, Grade's Basic Price 860.00 700.00 660.00 660.00 660.00 610.00
b) Royalty 120.40 98.00 92.40 92.40 92.40 85.40
c) Stowing Excise Duty (SED) 10.00 10.00 10.00 10.00 10.00 10.00
d) Crushing Charges for top size 100 mm 79.00 79.00 79.00 79.00 79.00 79.00
e) Clean Energy Cess 50.00 50.00 50.00 50.00 50.00 50.00
f) Operating cost per tonne of Raw Coal Input 75.34 75.34 75.34 75.34 75.34 75.34
2 Cost of Washed Coal Production per tonne of Raw Coal Input [Σ a) to f)]
1194.74 1012.34 966.74 966.74 966.74 909.74
3 Total Cost of Production per tonne of Washed Coal Output (at different Yield) (in Rs.)
1342.40 1284.70 1278.96 1335.72 1397.76 1379.41
4 Desired Selling Price of Washed Coal @ 12% RoI (Rs. per tonne)
1391.13 1331.33 1327.54 1386.42 1450.96 1435.16
5 Selling Price of Washed Coal of 34% ash from Piparwar Washery, CCL (exclusive of ST & applicable levies)
1746.42 1746.42 1746.42 1746.42 1746.42 1746.42
6 Profit per tonne of washed coal (in Rs.) 404.02 461.72 467.46 410.70 348.66 367.01
7 Annual Profit (in Rs. Crore) 359.57 363.84 353.34 297.24 241.15 242.05
8 Retrurn on Investment at 100% Utilization, % 135.51 137.12 133.16 112.02 90.88 91.22
9 Payback Period (in months) 9 9 9 11 14 14
Note: Selling price of washed coal of 34% ash of Piparwar washery is Rs. 1746.42 per tonne
