Feasibility Report of Madhuban coal washery

Transcription

1 Feasibility Report of Madhuban coal washery September 2018

2 DESIGN DATE OF MADHBAN WASHERY 1. Feed rate Primary Gyratory crusher section Tph ( output- 200mm) 3. Secondary Double Roll crusher section 400 Tph ( output- 50mm) 4. Tertiary crushing section -800 Tph 5. Storage and blending- 10,000 Tph 6. Vibrating screen 500 Tph 7. Sizing screen 400 Tph 8. Impact crusher 300 Tph (-13mm)

3 History of madhuban coal washery. Status : coking coal washery. Date of commissioning : march, Conversion to non coking coal washery : june, Revert back to coking coal washery : October, 2008 Capacity ( Designed) Yearly: 2.5 milliion tones Daily: 8333 tones Hourly: 625 tones MANPOWER RECENT REQURIED Executives 7 35 Non Executives Total Source of Raw Coal and its Characteristics SOURCE Block 2 OCP Jamunia OCP INDIAN COALS

4 Indian coals are mostly of bituminous type having 22-32% of volatile matter on unit coal- basic. Total carbon varies 60-80% hydrogen % and oxygen 2.5 %. According to ISS Indian coals of bituminous type may be divided into six groups, B 1 to b 6. Characteristics tht are taken into account in this classification are (a) Volatile matter content, (b) moisture content, (c) calorific value caking index and swelling index and swelling index which are generally taken into consideration for classification are not satisfactory parameters for Indian coals because of their high mineralmatter content. After classification various other parameters that are taken into consideration for qualitative assessment of coal are (1) mineral matter content (2) Ash fusion temperature, (3) Sulphur content (4) phosphorous content, (5) Grindability, (6) Amenability to beneficiation processes. Depending on the caking properties, Indian coking coals used for steel industry can be broadly divided into following categories: (a) Prime coking coal (b) Medium coking coal (c) Semi- coking coal (d) Weakly coking coal Total reserve of prime coking coal is about 5166 million tons. These coals can take substantial amounts of blends of other coals and are capable of producing metallurgical coke suitable for use in balst furnace and foundry. Estimated reserve of medium coking coal is 7554 million tons. These coals can be blended with suitable matching coal to produce metallurgical coke. Non- coking coals can not be blended with these coals for production of metallurgical coke. Semi-coking and weakly coking coals are incapable of production of metallurgical coke by themselves. A substantial quantity of these coals can however be blended with prime coking coals for production of coke of metallurgical grade.

5 The following features became apparent from the study of the classification of Indian coking coals and their availability. 1. Reserves of prime coking ccoal are localised in the coalfields of Jharia and Giridih only. 2. Medium coking coals are widely distributed over various coalfields. Those from Raniganj and East Bokaro coalfields have stronger caking properties than those from other coalfields.

6 MADHUBAN WAHSERY UNDER BLOCK II AREA UNIT OF BHARAT COKING COAL LIMITED IS CATOGARIES IN DIFFERENT SECTION. 1. ROM SECTION 2. MAIN WASHING BUILDING SECTION 3. LOADING SECTION 4. ELECTRICAL SECTION 5. WORKSHOP 6. LABORATORY 7. STORE & 8. VEHICLE

7 SECONDARY CRUSHING SECTION:- This section consists of two parallel steams of 800 TPH.one running and one standby. Each stream will consist of two classifying screens (503), two picking belt conveyors and one double roll crusher. Raw coal (- 200mm) in each stream will be fed to two numbers of vibrating screen which will classify the coal at -50mm size. The overflow of the screens (200-50mm) will be discharged over two picking belt conveyors. The nonmetallic foreign material present will be hand picked and discharged over a refused belt convebeyor 601 which will carry the refuse material to a refuse bin. The picking belt conveyors (504 ABCD) will feed the coal to the secondary crusher (505) double roll for crushing (200-50mm) coal down to 50mm size. The product of secondary crusher (505) will be mixed with the underflow of sizing screen (503) and then will be trandported to the storage and blending bunkers.

8 PROCESS DESCRIPTION ROM Coal receiving and primary crushing section. Rom coal will be supplied by customers dumper to the hopper of 400 T capacity. The Rom coal of mm will be crushed down to -200 mm size by gyratory crusher. The crushed coal from gyratory crusher will be transported by to through appron belt conveyors and will be discharge to two belt conveyors running in parallel. The belt conveyor will discharge coal to a hopper. There will be provision for direct loading from hopper. Raw coal will be transported to S.C.H. through two vibro feeders and series of the belt conveyors.

9 \TERTIARY CRUSHING SECTION On top of the tertiary crusher house a surge hopper will be provided to ensure uniform feed to tertiary crushers as well as to washery. Two vibro feeders (802) will give regulated feed to the two lines of sizing screen. (805) for crushing down to -13mm size. There will be one such crusher in each line. The product of each crusher will be fed to check screen (806) having effective aperature of 13mm. The uncrushed over size of the check screen will be further crushed by one impact crusher. The underflow of the sizing screens (803,804) and check screen (806) will be mixed will be transported to the washery by two belt conveyors running in parallel. Provided for each jigs. The clean coal will be reporting with the overflow of jigs and after initial dewatering over fixed screen (912) for further dewaters. Two vibrating screens will be provided with each jigs. The dewatering screens will discharge clean coal to chain conveyors which will distributed the same to four centrifuges for final dewatering will be discharged to clean

10 coal conveying system leading finally to clean coal storage silo of 5000 T capacity. The intermediate product of jigs will be discharged by elevator (917) to four desliming screens (920) which will discharge to H,M cyclones feed bon where it will get mixed up with circular heavy media supplied by H.M pump (939) There will be eight H.M. cyclones (922) of 600mm diameter for up gradation of entire intermediate products of both the jigs into clean coal and true middling. The clean coal reporting to the overflow of the H.m. cyclones will be initially de pulped and

11 STORAGE AND BLENDING SECTION The trippers will discharge coal to the storage and blending bunker. The bunker consists of two compartments having 5000T capacity (703) which will discharge local from the bunker to belt conveyor. (704 AB) the arrangement will be provided in a such a way that the bunkers will be filled in vertical layers and reclaiming will be done by to and fro movement of the reclaimer, to ensure proper blending of raw coal. After one line is properly filled, reclaiming will be started and at that time of filling other line will be continue. The belt conveyors (704 A & B) will discharge coal to two belt comveyors (801 A & B) feeding to tertiary crusher house.

12 BHARAT COKING COAL LIMITED PERFORMANCE REPORT FOR THE MONTH OF 'MARCH' 2018 Ref No- BCCL/MCW/PO/MPR/ /05 1 Raw Coal During The month Up to the month a) Opening stock(t) b) R/ Coal receipt (T) 12, , c) R/ Coal Feed(T) 13, , d) Closing stock e) Average Ash% g) Washed Coal During The month Up to the month a) Opening stock(t) b) W/Coal Production (T) 2, , d) W/Coal Dispatch(T) NIL 26, e) Closing Stock(T) f) Average Ash% NIL g) Average Moisture% NIL h) Yield% Slurry During of the month Up to the month a) Opening stock(t) b) Slurry Production(T) , c) Slurry Dispatch(T) NIL NIL d) Slurry Recycled in WPC e) Closing stock(t) f) Yield% WPC (Washed Power coal) During of the month Up to the month a) Opening stock(t) b) W.P.C Production (T) , c) W.P.C Dispatch(T) , d) Closing Stock(T) f) Yield% REJECT I. Process Reject During the month Up to the month a) Opening Stock b) Reject Production NIL NIL d) Closing stock(t) II Hand Picked Reject a) Opening Stock (HPR) NIL b) Production(T)

13 c) Consumption(T) d) Closing Stock(T) NIL e) Yield% 0.80 MASS BALANCE OF PRODUCTS SL. NO PRODUCT YIELD Wt% Ash% 1. CLEAN COAL MIDDLING CONSUMERWISE DISPATCH (WASHED COAL BY RAIL) DESTINATION No. of Wages Qty. During the Qty. Up to the month month R.S.P Rourkela NIL NIL B.S.P Bhillai NIL NIL NIL B.S.L Bokaro NIL NIL 7, D.S.P Durgapur NIL NIL 3, Total NIL NIL 26, DETAILS OF RAKEWISE ASH% OF WASHED COAL RAKE No. DESTINATION ASH% 1. R.S.P Rourkela NIL 2. D.S.P Durgapur NIL CONSUMERWISE DISPATCH (Washed POWER COAL BY RAIL) DESTINATION No. of Wagons Qty. During the month Qty. Up to the month D.S.P Durgapur 117(N) Boxes 6, R.S.P Rourkela NIL NIL B.P.S.C.L Bokaro 232(N) Boxes PANIPAT TPP NIL NIL NIL P.M.R.G Haryana NIL NIL NIL

14 W.B.P.B. NIL NIL SANTHALDIH M.T.P.S MEJAI NIL NIL NIL C.T.P.S DVC NIL TOTAL 349(N) BOXES BREAKDOWN ANALYSIS During the month Up to the month Total Available hrs Hrs Hrs. Total Feed hrs Hrs Hrs. Total Idle hrs Hrs Hrs. DONTROLLABLE art and stop Hrs Hrs Laint. Hold-up (ROM) Hrs Hrs. Laint Hold main plant NIL Hrs Electrical hold up NIL Hrs ELectrical B.D MAIN Plant NIL NIL Mechanical B.D (ROM) Hrs Hrs Mech B.D. (Main plant) NIL NIL Opreational problem Hrs Hrs. Other UN-CONTROLLABLE Power failure NIL Hrs. Raw Coal Shortage Hrs Hrs Chute Jam Hrs Hrs Rom charging problem NIL Hrs JIG HOLD UP NIL Hrs JIG BD 6.00 Hrs Hrs Average Feed rate TPH COLLIERYWISE RAW COAL RECIEPT COLLIERY/SIDDING DECLARED GRADE QUANTITY QUANTITY A BLOCK-II O.C.P W-IV 3, , (Deptt) JOCP G WMOCP W-IV 8, ,402.51

15 Kharkharee W-II Choltodih W-II NIL 51, Total 12, ,450.24