Table of Contents 1.0 INTRODUCTION...2 1.2 Acknowledgement...2 2.0 Executive Summary...3 3.0 Project at a Glance:...4 4.0 PRODUCT & ITS USES AND MARKET...5 4.1 Washed Coal:...5 5.0 Availability of Raw Material...8 5.1 Sources of Raw Materials:...8 6.0 Availability of Utilities...9 7.0 Selection of Site & LOCATION OF PLANT...10 8.0 Manufacturing Process...11 8.1 Process of Coal Benefication:...11 8.1.1 Raw Coal Receipt and Handling Arrangement:...11 8.1.2. Washing Section:...11 9.0 Advantages of Using Washed Coal...13 10.0 Water System & Plant Utilities:...14 10.1 Source of Water...14 10.2 Water Consumption...14 11.0 ENVIRONEMENTAL MANAGEMENT PLAN...15 - :: 1 :: -
1.0 INTRODUCTION Hind Energy and Coal Beneficiation (P) Limited incorporated on 25.04.2005 with Registrar of Companies, Gwalior (M.P.). Considering the potential of Steel Industries in India and the experience gained by the group in this sector, HECBIPL decides to install the Coal Washery unit in the District of Bilaspur. 1.1.1 Coal Washery: HECBIPL propose to install coal Washery unit with annual installed capacity of 1 x 0.96 Million Tons/ Year. In addition to all the above positives, the promoters are locally based and have excellent rapport with the District and state government authorities, who are extending their full co-operation and assistance to encourage upcoming Industrial units in the state. 1.2 Acknowledgement We wish to express sincere gratitude to the management of M/s HECBIPL for the confidence reposed in entrusting this valued assignment and for spontaneous and timely cooperation by their Management and Officials in preparation of this Feasibility Report. - :: 2 :: -
2.0 Executive Summary 2.1 Hind Energy and Coal Beneficiation (P) Limited (HECBIPL) has been promoted by well established entrepreneur belonging to Bilaspur in Chhattisgarh state and already engage in Washing of coal in big way in the state of Chhattisgarh. Seeking the huge gap in demand and supply of washed coal; HECBIPL propose to install the 1 x 0.96 MTPA Coal Washery. 2.2 HECBIPL proposed to acquire about 12 acres of land for the Installation of coal washery at Village: Dhatura, Tehsil: Pali??, District: Koraba (C.G.). 2.3 Requirement of Water for proposed unit will be 495 KL/ Day, required for Washing of coal and domestic purpose which will be met through ground water sources. 2.4 The project cost estimated for installation of the proposed plant works out to Rs. 14.25 Crores. This is inclusive of equipment cost as erected including civil and structural works, taxes & duties and contingencies. - :: 3 :: -
3.0 Project at a Glance: 1. Name of the proposed unit : Hind Energy and Coal Bneficiation (P) Limited 2. Registered Office : Near Sai Parisar, Shrikant Verma Marg, Bilaspur, 495001 (C.G) 3. Unit Location : Village Tehsil District : Dhatura : Pali, : Koraba (Chhattisgarh) 4. Name of Directors : i. Shri Pawan Agrawal, Director ii. Shri Sanjay Agrawal, Director iii. Shri Rajiv Agrawal, Director iv. Shri Satish Agrawal, Director 5. Industry : Washing of Coal 6. Proposed Install Capacity : 0.96 Million Tons/ Year 7. Project cost (Rs. in Lakhs) Particulars i. Land & Site Development 68.00 ii. Building & Civil Works 102.00 iii. Plant & Machinery 950.00 iv. Electrical Installation 102.00 v. Preliminary & Pre-operative Expenses 58.00 vi. Contingencies 68.00 vii. Deposits 7.00 viii. Pollution control Equipments 27.00 ix. Other Fixed Assets 6.00 x. Margin Money for Working Capital 37.00 Total Investment 1425.00 8. Means of Finance Rs. in Lakhs Particulars i. Share Capital 500.00 ii. Term Loan 925.00 Total Investment 1425.00 9. No. of working Days : 335 days - :: 4 :: -
4.0 PRODUCT & ITS USES AND MARKET 4.1 Washed Coal: India is a strong player in the sponge iron business. The installed capacity of Sponge Iron in the country increased from 1.52 million tons per annum in 1990-91 to 7.032 million tons per in 2002-03. There are 53 sponge iron units in the country producing 7 million tons per annum and 3 gas based units covering a capacity of 3.76 million tons per annum. Despite the lower number of gas based plants gas based sponge iron production accounted for 44% of the total domestic production, the rest 56% being coal-based. In the year 2002, with 6.53 million tones of production, India had become the world s largest producer of sponge iron. It recorded a 16.87% increase in production from 5.59 to 6.53 million tones. Domestic Scenario In order to push up the production of sponge iron in the country and to gainfully utilize natural resources, the Government is encouraging the development of coal washery. The factors in favor of sponge iron industry:- It reduces dependency on imported scrap. Global sponge iron prices are on an upswing as demand for steel seems insatiable and domestic prices have followed suit. Off take in sponge iron demand by EAF (Electric Arc Furnace) and Induction Furnaces will continue to remain firm even as price of scrap increases. - :: 5 :: -
Scrap as a percentage of total steel production has reduced significantly in the last few years leading to lower availability of scrap Lower ship breaking activities is also contributing to lower availability of scrap and hence higher sponge iron demand To boost productivity, sponge iron is also finding increased use in blast furnaces. This has furthered the metallic demand No major capacity coming up in the medium term. It will be at least two years before new capacity comes up Coal Quality for Sponge Iron making Coal plays a dual role in the sponge iron process by acting as reductant as well as a fuel for providing heat to maintain the requisite temperature inside the kiln at 950-1050ºC. For sponge iron industries, where the quality of coal varies widely depending on the variation in the technological propriety and process parameters, no stringent specification has been made till to date. Available Coal Quality The major production of the non-coking / steam coal (>85%) in the country is of inferior quality (Grades E, F & G) where as the Sponge Iron Industry needs coal of B & C Grades at the most. As such most of the sponge iron plants are not getting the coal of required quality from the coal-mines. The average ash in the coal being supplied is 25 to 30%. Apart from the inferior quality, there is a wide range of variation in the quality of coal being supplied on day to-day basis and this causes problem in optimization of the inputs to the Kiln and control of it s performance in terms of quality and - :: 6 :: -
quantity of the out-put. In case of the Consortium the present supplies of washed coal form the present Supplier neither consistent nor adequate. Conclusion As such there is a need for a Coal Washery with a superior technology not only to get better heat-value coal but also to get the consistency in the quality which lends itself for optimization of the inputs to the Kiln resulting in better performance and more profitability. - :: 7 :: -
5.0 Availability of Raw Material A brief description of potential sources of various raw materials, their availability and quality with respect to location and requirement of plant has been presented in this chapter. 5.1 Sources of Raw Materials: Raw Coal Run off mines (ROM): Only raw material required for coal washery is raw coal that will be taken from near by mine of SECL, Bilaspur. Annual requirement of raw coal for proposed washery will be 0.96 Million Tons/ Year. - :: 8 :: -
6.0 Availability of Utilities For successful running of any unit most important factor is the availability of Raw Materials, as well as Utilities & Power, Water Connectivity which are required to efficiently run the Equipment. The company has proposed to install their Plant & Machinery and for effective utilization and achieve desired production levels the aforesaid items are elementary and constitute the basis which was kept in mind for the purpose of the proposal: WATER: - It is required only for washing purposed under industrial usage of the said unit. Total amount of makeup water required for operation of plant is about 495 M 3 / day this is inclusive of Washing, dust suppression and Domestic Purposes. All the effluent generated shall be treated through ETP of appropriate size and treated water will be utilized for dust suppression. POWER: HECBIPL propose to draw power from CSPTDCL Grid. MANPOWER: Increased industrial activity and rise in establishments of industries in the last few years have lead to the availability of experienced Skilled & Unskilled, Technical, Professional & Administrative personal for the Coal Washery within the State of Chhattisgarh. - :: 9 :: -
7.0 Selection of Site & LOCATION OF PLANT Selection of the site for any project is the most important aspect for it s successful operation & better economic viability. Proximity to Raw material source, assured supply of fuel and other infrastructural support are required to be essentially examined while selecting the site of the plant. The following basic requirements are necessarily required to be fulfilled. i. Easy & nearer access to Raw Material sources as coal etc. ii. iii. iv. Availability of water from continuous source. Power supply/ evacuation arrangement. Nearer access through road. M/s HECBIPL decided to install proposed Coal Washery at Dhatura Village, Pali Tehsil, Koraba District. The above site has the following preliminary advantages. i. Major coal mines of SECL located within radial distance of 100 km from the site. ii. iii. iv. Ample water is available nearer to the site through out the year. The site is already well connected with Road as well as Rail. Thus the approach is excellent. Soil condition of the site is also favorable. - :: 10 :: -
8.0 Manufacturing Process 8.1 Process of Coal Benefication: The entire process and operations to be carried out at the unit are described in brief as follows: 8.1.1 Raw Coal Receipt and Handling Arrangement: Raw coal in the size range 200-0mm, from the mines will be received by wagons at nearby railway siding. The stock pile will have a self flowing capacity of 600-700 tons. In addition arrangements for stocking of raw coal to an extent of 500 tons on the ground (close to the stock pile) will also be provided. A Pay loader will be used for reclamation of coal from ground stock. Two mechanical vibratory feeders, 500 TPH each have been provided for reclamation of coal from the stock pile for feeding to the Reclaim conveyor of 500 TPH capacity; which will carry the coal to the screen cum crusher house. The reclaim conveyor will feed the coal to a vibratory screen for screening the coal at 50mm. The 200-50 mm coal will then be fed to a 1200 mm wide picking conveyer for picking/removing the shales / stones which will be disposed off by trucks. The 200-50 mm coal form the picking conveyor, after removal of stones, will then be fed to a double roll crusher down to- 50mm. The crushed coal from the crusher and the 50-0mm undersize coal from the vibratory screen will be carried by belt conveyor to supply the coal to the washery. 8.1.2. Washing Section: The washery feed conveyor carrying crushed coal (50-0mm) will discharge on to a Desliming Vibrating screen for wet-removal of coal below 0.63mm. The over flow of this screen will be sent to a mixing box where the coal gets mixed with the magnetite medium of required specific gravity. The coal plus magnetite from the mixing box will be pumped to the Heavy Media Cyclone by a centrifugal pump. The HM Cyclones will separated - :: 11 :: -
washed/clean coal and rejects by density. The over flow (Clean coal) form the HM cyclone will be fed to a Draining and Rinsing horizontal vibrating screen for initial dewatering and for removal/recovery of magnetite. The overflow of this D & R screen will then be fed to a Vibrating Basket Centrifuge for further / final dewatering of clean coal. The underflow of the HM cyclones (rejects) will be fed to a Draining and Rinsing horizontal vibrating screen for dewatering and removal of media. The magnetite with correct density, from the D & R screens for clean and rejects will be fed to the Correct/Heavy media sump from where it will be pumped for reuse. The dilute media from the D & R screen will be fed to the dilute media sump from where it will be pumped to a magnetic separator to recover the magnetite. The effluent generated after recovery of magnetite from the magnetic separator will be pumped to a thickener to recover process water and to thicken the slurry. The underflow form the desliming screens and the under flow form the thickener will be charged/transported hydraulically to a tailings/slime pond from natural drying. The clear water form this pond will be pumped back to the system for reuse. The naturally dried material will be disposed of manually. It is proposed to use powdered magnetite as media which will be added by manual process. - :: 12 :: -
9.0 Advantages of Using Washed Coal Below mentioned are the uses of Washed/Beneficiated Coal: i) In the process of washing the coal the abrasive non-coaly mater like stones and shale will be removed from the raw coal. As such use of washed coal in the Sponge Iron plant will result in less wear and tear of the Machinery. The life of the Rotary Kiln will be prolonged with the use of washed coal. ii) iii) iv) Due to the uniform size of the washed coal and the uniform quality (Ash content being more or less uniform with a very little variation) as compared to much larger variation in the quality of Raw Coal form the coal mines, the operating parameters of manufacturing the sponge iron can be better regulated. Together with this and with the increased heat value of washed coal the productivity of the Rotary Kiln will increase by 15 to 20% Use of cleaner coal will improve the environmental conditions. Less production of char from the Kiln (which contains un-burnt coal & other nonmagnetic material) v) Use of Rejects from the coal Washery along with non-magnetic Kiln discharge/char and coal fines in a FBC will result in generation of additional electric power which will improve the financial performance of the Sponge Iron industry. * - :: 13 :: -
10.0 Water System & Plant Utilities: 10.1 Source of Water The desired amount of water will be met through ground water sources. 10.2 Water Consumption Make up water requirement for the project will be about 495 M 3 / day for operation of Coal Washery unit. - :: 14 :: -
11.0 ENVIRONEMENTAL MANAGEMENT PLAN The generated waste water from coal washery is fully recycled either in process or for dust suppression within plant premises. There will not be any waste water discharge outside the premises. Regarding air pollution control measures bag filters are installed at appropriate location. The entire material handling yard will be of RCC. Dust spraying and sprinkling system will be deployed. Apart from aforesaid measures good green belt in and around plant premises will be developed as per CPCB Guidelines. * - :: 15 :: -