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REVISED CONCEPTUAL REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0_22_May... · B. SUMMARIZED DATA.....4 C. LIST OF ABBREVIATION ... adb

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Page 1: REVISED CONCEPTUAL REPORT - environmentclearance.nic.inenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0_22_May... · B. SUMMARIZED DATA.....4 C. LIST OF ABBREVIATION ... adb
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REVISED CONCEPTUAL REPORT

FOR

SETTING UP OF IB-VALLEY WASHERY AT

LAKHANPUR AREA

(MAHANADI COALFIELDS LIMITED)

ON BOM CONCEPT

(Capacity : 10.0 MTY)

October 2014

COAL & MINERAL PREPARATION DIVISION CENTRAL MINE PLANNING & DESIGN INSTITUTE LTD.

GONDWANA PLACE, KANKE ROAD RANCHI - 834031

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311713098 i

CONTENT

Chapter/ Para No.

Particulars Page No.

A. EXECUTIVE SUMMARY ......................................................................................1

B. SUMMARIZED DATA.................................... .......................................................4

C. LIST OF ABBREVIATION............................... .....................................................6

CHAPTER - 1 : INTRODUCTION............................................................................. 1-1

1.1 BACKGROUND ........................................................................................................................................1-1

1.2 OBJECTIVE ..............................................................................................................................................1-2

1.3 RAW COAL LINKAGE TO THE PROPOSED WASHERY...............................................................1-3

1.4 LOCATION AND OTHER DETAILS OF LINKED MINES ...............................................................1-3 1.4.1 Location ..................................................................................................................................................1-3 1.4.2 Communication.......................................................................................................................................1-3 1.4.3 Topography & Drainage .........................................................................................................................1-4 1.4.4 Climate & Rainfall ..................................................................................................................................1-5

1.5 COAL PRODUCTION PROGRAMME & HEAT VALUE..................................................................1-5

1.6 GRADE WISE MINEABLE COAL RESERVE.....................................................................................1-6

1.7 QUALITY OF RAW COAL FEED TO THE WASHERY....................................................................1-7

1.8 LIFE OF THE PROPOSED WASHERY & CONSTRUCTION SCHEDULE ...................................1-8

CHAPTER - 2 : RAW COAL CHARACTERISTICS ........................... ...................... 2-1

2.1 RAW COAL LINKAGE ...........................................................................................................................2-1

2.2 SAMPLE COLLECTION.........................................................................................................................2-1

2.3 TEST PROCEDURE.................................................................................................................................2-2

2.4 WASHABILITY TEST RESULTS ..........................................................................................................2-3 2.4.1 Screen Cum Ash & Moisture Analysis of Raw Coal ..............................................................................2-3 2.4.2 Screen Cum Ash: Raw Coal Sample Crushed to 100 mm ......................................................................2-4 2.4.3 Screen Cum Ash & Moisture: Raw Coal Sample Crushed to 50 mm.....................................................2-5 2.4.4 Float & Sink Tests : Lajkura Seam, Rampur seam & IB seam of integrated Lakhanpur- Belpahar- Lilari OCP. 2-5 2.4.5 Wet Sieve Analysis .................................................................................................................................2-7 2.4.6 Generation of Washed Coal at Lab Scale................................................................................................2-7

2.5 PROXIMATE ANALYSIS, GCV & HGI OF RAW COAL & WASHED COAL ..............................2-8

2.6 MOISTURE% OF RAW COAL, WASHED COAL & REJECT.........................................................2-8

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311713098 ii

2.7 ULTIMATE ANALYSIS AND ASH FUSION TEMPERATURE OF RAW COAL AND WASHED COAL 2-9

2.8 PETROGRAPHIC ANALYSIS OF RAW COAL AND WASHED COAL .........................................2-9

2.9 HEAVY METAL TEST FOR RAW COAL AND GENERATED WASHED COAL & REJECT..2-10

CHAPTER - 3 : CAPACITY & OPERATING CONDITIONS OF THE WASHERY ... 3- 1

3.1 CAPACITY ................................................................................................................................................3-1

3.2 OPERATING CONDITIONS OF DIFFERENT SECTION .................................................................3-1 3.2.1 Raw Coal Receiving Section...................................................................................................................3-1 3.2.2 Washery Section .....................................................................................................................................3-2 3.2.3 Loading & Dispatch Section ...................................................................................................................3-2

CHAPTER - 4 : PROCESS FLOWSHEET & BALANCE OF PRODUCTS ............ .. 4-1

4.1 SELECTION OF PROCESS ....................................................................................................................4-1

4.2 PROCESS FLOWSHEET ........................................................................................................................4-1

4.3 BALANCE OF PRODUCTS ....................................................................................................................4-3 4.3.1 Based on Laboratory Scale Tests ............................................................................................................4-3 4.3.2 Projected Balance of Products on Average Raw Coal Ash.....................................................................4-3

CHAPTER - 5 : INFRASTRUCTURE FACILITIES.......................... ......................... 5-1

5.1 WASHERY SITE.......................................................................................................................................5-1

5.2 SUPPLY OF RAW COAL ........................................................................................................................5-1

5.3 AVAILABILITY OF WATER .................................................................................................................5-1

5.4 AVAILABILITY OF POWER .................................................................................................................5-2

5.5 RAILWAY SIDING FOR LOADING & DISPATCH OF WASHED COAL......................................5-2

5.6 REJECT DISPOSAL/ UTILIZATION....................................................................................................5-2

5.7 RESIDENTIAL AND WELFARE FACILITIES ...................................................................................5-2

CHAPTER - 6 : ECONOMICS .................................................................................. 6-1

6.1 CAPITAL ESTIMATE .............................................................................................................................6-1

6.2 COST BENEFIT ANALYSIS...................................................................................................................6-2 6.2.1 Sensitivity Analysis ................................................................................................................................6-3

CHAPTER - 7 : PROJECT CONSTRUCTION MANAGEMENT.................... ........... 7-1

7.1 GENERAL .................................................................................................................................................7-1

7.2 CONSTRUCTION SCHEDULE..............................................................................................................7-1

7.3 SCOPE OF WORK OF BOM OPERATOR (BOMO)...........................................................................7-1

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311713098 iii

7.4 SUPPORT BY MCL..................................................................................................................................7-2 7.4.1 During Construction................................................................................................................................7-2 7.4.2 During Operation & Maintenance...........................................................................................................7-3 7.4.3 During Construction & Operation Both..................................................................................................7-3

7.5 PROJECT MONITORING ......................................................................................................................7-4

CHAPTER - 8 : DATA/ INFORMATION FOR CUSTOMIZATION OF BID DOCUMENT 8-1

8.1 RAW COAL AVAILABILITY ................................................................................................................8-1

8.2 SUPPLY OF RAW COAL TO BOM OPERATOR BY MCL...............................................................8-1

8.3 LAND FOR WASHERY & REJECT DUMPING..................................................................................8-1

8.4 WATER ......................................................................................................................................................8-2

8.5 POWER ......................................................................................................................................................8-2

8.6 QUALITY OF RAW COAL FEED TO WASHERY FROM LINKED MINES .................................8-3

8.7 RAILWAY SIDING FOR LOADING & DISPATCH OF WASHED COAL......................................8-3

8.8 REJECT DISPOSAL.................................................................................................................................8-3

8.9 DESIGNATED POINT FOR RECEIPT OF WASHED COAL............................................................8-4

8.10 APPROVAL OF CONCEPTUAL REPORT ..........................................................................................8-4

8.11 INFORMATION REGARDING MCL....................................................................................................8-4

8.12 DRAFT FOR BID DOCUMENT .............................................................................................................8-4

8.13 LEGAL JURISDICTION .........................................................................................................................8-4 ���������� ............................................................................................................................................... B ������.................................................................................................................................................... D ���� ����...............................................................................................................................................E

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311713098 1

A. EXECUTIVE SUMMARY

1.0 MCL intended to set up a 10 Mty coal washery at Ib Valley in Lakhanpur area

on Build-Operate-Maintain (BoM) concept. Accordingly, a conceptual report

was prepared and submitted by CMPDI in January 2010. Further, CMPDI was

entrusted the job of preparation of revised conceptual report (CR) vide letter

No. ����������������� ������������ LKP/14-15/250 dt. 18.06.2014 (copy

enclosed).

2.0 Coal samples from Lakhanpur, Belpahar and Lilari integrated OCP were

tested at CMP Lab, CMPDI for generation of necessary data, based on which

this Conceptual Report has been prepared.

3.0 The study of test results revealed that treatment of 50-13 mm and 13-2 mm

size fractions in two product electronically-controlled jigs and upgradation of -2

mm coal in a suitable beneficiation equipment can yield washed coal of about

33.5±0.5% ash for use in thermal power stations.

4.0 The washing scheme is briefly given hereafter:

� Receiving raw coal of (-)100 mm from linked mines by two nos. of belt

conveyors, each of 1200 tph capacity.

� Screening and crushing of 100-50 mm fraction down to. 50 mm. Storing

entire -50 mm coal in 15000 t ground storage.

� Washing of entire 50-13 mm fraction in two product jigs to produce

washed coal (float) and rejects (sinks).

� Washing of 13 - 2 mm fraction in two product jigs to produce washed

coal (float) and rejects (sinks).

� Washing of - 2 mm fraction, after passing through classifying cyclones,

in suitable beneficiation equipment to produce washed coal (float) and

rejects (sinks).

� Collection of all the floats (washed coal) from above three streams on

the covered ground storage of 20,000 tonne capacity,

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Executive Summary

311713098 2

� Reclamation of washed coal from covered ground storage and

conveying the same to Silo near the proposed Railway siding at a

distance of about 1 to 2 km.

� Rejects will be conveyed by BOM operator to the temporary Reject

Storage Site (about 13 Ha) adjacent to the washery. Reject will be sold

to the prospective buyers via MoU or e-auction route.

� Provision of closed water circuit with zero effluent discharge and rain

water harvesting has been envisaged.

5.0 Infrastructure facilities :

a) Washery site : An area of approx. 18.5 ha land is available for setting up the washery including green belt, parking space for 2-wheelers & 3-wheelers etc.

Out of the available land, the 11.8 Ha virgin solid land will be utilized for construction of raw coal receiving pit, half-day storage of raw coal, screen-cum-crusher house, washery building, covered ground storage for washed coal, emergency slurry pond, radial thickener etc. administrative buildings and other allied structures as per the technological requirement.

Proposed washery site is approx. 5-6 km away from the linked mines.

b) Raw Coal Transport

: Raw coal supply to the proposed washery will be done by MCL through two nos. of Belt Conveyor @ 1200 tph at one point in the washery, for which scheme is being prepared separately by MCL.

c) Water : Water requirement for proposed washery is about 0.60 MGD. The intended water will be made available by MCL from Hirakud Back water through the existing dedicated pipeline of the OPGC - IWSS by tapping at a distance of approximately 4 km away from the washery.

Alternatively, mine water from the Quarry No. 5 of Belpahar OCP, which is approx. 1-2 km from the washery site and water from existing Eco-Tank (water catchment pond for rain water) can be supplied to the washery by MCL.

d) Power : Requirement of power is about 8.0 MVA for operation & maintenance of the proposed washery. Power shall be drawn by BOM operator through a separate overhead transmission line from existing 33 kV sub-station of Belpahar OCM, which is approx. 3 km from the washery site.

e) Railway siding for loading & dispatch of

: The BoM operator shall deliver washed coal at the top of the Silo situated near the Railway siding at a distance of 1 to 2 km. MCL shall make necessary arrangement for

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Executive Summary

311713098 3

saleable products

construction of Silo (one no.) along with Railway siding & RLS for evacuation and delivery of washed coal to the customer.

f) Reject disposal/ utilization

: Rejects produced from the washery will be dumped on the identified filled-up land adjacent to the washery in an environment friendly manner.

The rejects will finally be disposed off to the prospective buyers either by e-auction or MoU route.

6.0 Balance of products, operating conditions, capital cost, economics etc. are

given hereafter in Summarized Data.

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311713098 4

B. SUMMARIZED DATA

1. Capacity and Operating Conditions :

a) Annual Capacity : 10.0 Mty

b) Daily throughput : 30,300 tonne

c) Hourly throughput : 1,700 tonne

d) No. of effective working hours : 6,000 per year

2. Raw Coal Linkages : Integrated Lakhanpur-Belpahar-Lilari

OCP

3. Development Period in Years : 3

4. Life of the washery (after commissioning) : 18.0 years (for computation of Economics only)

5. Quality of ROM coal :

a) Average Ash% : 41.5

b) Moisture%

i. Surface Moisture : 7.0

ii. Inherent Moisture : 5.2

iii. Total Moisture% : 12.2

c) Annual Average GCV (kcal/kg) : 3924

d) Grade : G12

6. Projected Balance of Products :

Product Wt% Ash% Qty. (Mty) Washed coal 74.62 33.5 7.46 Rejects 25.38 65.0 2.54 Total 100.0 41.5 10.00

7. Broad initial capital investment : � 336.90 Crore

8. Estimated operating cost/ te of Raw coal input : � 114.81

9. Estimated cost of production/ te of washed coal : � 1,348.153

10. Desired Selling Price of Washed Coal at 12% IRR,: ��1423.45 per tonne

11. Selling Price per tonne of washed coal : � 1,746.42 (Ref : Piparwar Ws)

12. Profit per tonne of washed coal (Ref : Piparwar Ws) : � 397.89 per tonne

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311713098 5

13. Annual Profit (Ref: Piparwar Ws) : � 296.89 Crore

14. Payback Period, (Ref: Piparwar Ws), : 1.13 Year

15. Construction period including trial run, : 18 Months PGT & commissioning

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311713098 6

C. LIST OF ABBREVIATION

adb Air Dried Basis

apb As Produced Basis

arb As Received Basis

BOM Build-Operate-Maintain BOMO/BOM Operator Build-Operate-Maintain Operator

CIL Coal India Limited

EMP Environmental Management Plan

GCV Gross Calorific Value

INR Indian National Rupee

IB Ib-valley Bottom

IWSS Integrated Water Supply Scheme

MCL Mahanadi Coalfields Limited

mm Milimetre

Mty Million tonne per year

NIT Notice Inviting Tender

OPGC Odisha Power Generation Corporation

RFQ Request for Qualification

RFP Request for Proposal

RLS Rapid Loading System

tph tonnes per hour

UHV Useful Heat Value

VM Volatile Matter

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�����������

��� ����� ��

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311713098 1-1

CHAPTER - 1 : INTRODUCTION

1.1 BACKGROUND

MCL intended to set up a 10 Mty coal washery at Ib Valley in Lakhanpur area

on Build-Operate-Maintain (BoM) concept. Accordingly, a conceptual report was

prepared and submitted by CMPDI in January 2010. Further, CMPDI was entrusted

the job of preparation of revised conceptual report (CR) vide letter No.

����������������� ������������ LKP/14-15/250 dt. 18.06.2014 (copy enclosed).

The raw coal feed to the washery was proposed to link with integrated

Lakhanpur, Belpahar and Lilar Opencast Project. The washed coal is to be linked

with thermal power plants; accordingly the target ash of washed coal would be 34%

in accordance with MoEF notification.

Coal samples from Lakhanpur, Belpahar and Lilari integrated OCP were

collected in April-May 2014 and tested at CMP Lab, CMPDI for generation of

washability and other data, based on which Draft Revised Conceptual Report was

prepared and submitted in July 2014. The Draft Revised CR was put up to the MCL

Board. MCL vide letter no. ����������������� ������������LKP/14-15/567 dt.

06.10.2014 (copy enclosed) communicated comments of MCL for finalization of draft

revised CR. Accordingly, this revised CR has been prepared.

This report (CR) has been prepared considering the following:

i) Raw coal throughput of 10.0 Mty will be supplied from the integrated

Lakhanpur-Belpahar-Lirari OCP, which has been projected in the mine

PR to produce 27.25 Mt coal in 2014-15, 28.50 Mt in 2015-16, 30 Mty

coal from 2016-17 till 2049-50 and thereafter 24.50 Mty in 2050-51, 19.10

Mty in 2051-52, 13.70 Mty in 2052-53, 8.30 Mty in 2053-54 and finally

2.87 Mty in 2054-55 before the OCP is totally exhausted.

ii) Raw coal to the proposed washery will be supplied by MCL through two

nos. Belt Conveyors of 1200 tph capacity each at one point in the

washery,

iii) Top size of the feed to the washery will be 100 mm.

v) The proposed washery site is 5-6 km from the linked OCP.

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Introduction

311713098 1-2

vi) Water requirement for the proposed washery is about 0.60 MGD.

Available source of water are:

The intended water will be made available by MCL from Hirakud Back

water through the existing dedicated pipeline of the OPGC-IWSS by

tapping at a distance of approximately 4 km away from the washery.

Alternatively, mine water from the Quarry No. 5 of Belpahar OCP, which

is approx. 1-2 km from the washery site and existing Eco-Tank (water

catchment pond for rain water) are also available.

Requirement of power is about 8.0 MVA for operation & maintenance of

the proposed washery. Power shall be drawn by BOM operator through a

separate overhead transmission line from existing 33 kV Belpahar sub-

station, which is approx. 3 km from the washery site.

vii) Washed coal from the covered storage will be reclaimed and conveyed

through belt conveyors to the proposed Silo located near the Railway

siding at a distance of 1 to 2 km.

viii) Responsibility of transportation of washed coal from Silo to customer

through Railway siding lies with MCL. Construction/ Modification/

strengthening of Railway siding along with RLS shall also be dealt

separately by MCL

ix) Rejects produced from the washery will be dumped on the identified site

(approx 13 Ha) adjacent to the washery in an environment friendly

manner. Finally, it will be disposed off to the prospective buyers either

through e-auction or MoU route.

1.2 OBJECTIVE

The objective of this conceptual report is to preliminarily assess the

conceptualization and feasibility of setting up of Ib-Valley washery of 10.0 Mty

capacity in Lakhanpur Area, MCL for supply of washed power coal with 33.5±0.5%

ash to thermal power stations especially with the raw coal of integrated Lakhanpur-

Belpahar-Lilari OCP.

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Introduction

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1.3 RAW COAL LINKAGE TO THE PROPOSED WASHERY

The likely average production of coal from contributing seams are as follows:

Table – 1.1 : Percentage Contribution of Coal from Linked source

Sl. No.

Name of the Mine % Contribution

1 Lajkura seam 50 2 Rampur seam 35 3 IB seam 15

Total 100

1.4 LOCATION AND OTHER DETAILS OF LINKED MINES

1.4.1 Location

Lakhanpur-Belpahar-Lilari Integrated OCP (30.0 Mty) is proposed within

Combined Belpahar I, II & III Geological block of Rampur tract of Ib-valley

coalfield, in the district of Jharsuguda, Odisha. Lakhanpur OC, Belpahar OC

and Lilari OC are running opencast projects of MCL, which are proposed to be

integrated into one project.

Belpahar I, II & III combined block is situated between the latitude 21°42’12” –

21°47’20” N and longitude 83°48’00” – 83°52’41” E i n the district of

Jharsuguda, Odisha, covering an area of 42.81 sq. km.

1.4.2 Communication

The area under consideration is well connected by rail and road to all

important business and industrial centres of the country. The Mumbai-Howrah

main line of the SE Railway passes close to the northern boundary of

Belpahar I, II & III combined block.

The Belpahar Railway station is situated at a crow fly distance of about 5 km

from the northern boundary of the block. Jharsuguda, the District Headquarter

is 30 km from the area and is connected by the Belpahar-Jharsuguda all

weather road (the Odisha District Road-5). Jharsuguda is connected with

Sambalpur-Rourkela and Bilaspur by a State Highway No. 10. The District

Headquarter Raigarh of the Chhattisgarh State is also around 70 km away

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Introduction

311713098 1-4

from Belpahar and is well connected by the Belpahar–Kuraloi-Lakhanpur–

Kalarbaga–Bhikampal-Raigarh all weather pitch road (NH-200).

The block is also connected with different working opencast coal mines of

MCL viz. Lakhanpur OCP, Belpahar OCP and Lilari OCP (all within the block).

Samaleswari OCP, Lajkura OCP, HR collieries, Orient collieries, Hirakud

Bundia Inclines etc. of MCL are all within 5 to 15 km away from the block. Tata

Refractories Limited (TRL) is situated in the Gomodera small township, 2 to 3

km away in the north western corner of the block. Ib Thermal Power Station of

OPGC (Odisha Power Generation Corporation of Govt. of Odisha) is situated

about 1 to 2 km away, from the southern boundary in the south-east corner of

the block and is well connected with all weather pitch road.

The nearest port at Bay of Bengal is Paradip and situated at a distance of

about 360 km from the block.

The Biju Pattanaik International Airport, located at the state capital

Bhubaneswar, is the nearest airport from the block.

1.4.3 Topography & Drainage

The area is represented by gently rolling undulating topography with the softer

formations like coal seams and shale, forming linear depressions and

occupied by paddy fields and relatively harder sandstones forming the ridges

and knolls. However, as the area has undergone to active opencast coal

mining activities the natural/original topography of the block has undergone

lots of changes with the occurrence of opencast quarry pits, overburden

dumps, coal stocks, haul roads, colliery infrastructures, running opencast

projects office, residential establishments, ancillary townships, roads etc.

The lowest elevation is about 193.00 m and lies near borehole no. CMIB-057

(RL 192.90 m) in the north-eastern part and the highest elevation is about

252.00 m and is located in southern part near borehole no. CMIB-310 (RL

250.39 m).

The Ib River, after which the coalfield is named, flows southerly along the

eastern boundary of the coalfield, constitutes the main drainage of the

coalfield. The easterly flowing Lilari nala, a tributary of the Ib river, flows

across the area in the northern part of the block, controls the drainage pattern

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Introduction

311713098 1-5

of the block. In addition to it, a few nalas flow into the Lilari nala. Besides, a

number of artificial water logged depressions have been formed by fire clay

quarries, which were mined by TISCO, in the northern part of the block,

abandoned opencast coal mines/ pits / benches mined by MCL in and around

Belpahar OCP in the eastern, Lakhanpur OCP in the central and Lilari OCP in

the northern parts of the block.

1.4.4 Climate & Rainfall

The area falls in sub tropical climate. During summer (March–May), the

temperature can go upto 40.0°C, which even reaches up to 46.9°C during the

extreme summer. In winter (December to February) the temperature varies

from 7.0°C to 36.4°C (From January 1990 to February 2010).

The average rainfall in the area is around 1519 mm recorded for the period of

1990 to 2007. Most of the rainfall occurs during the end of June to September.

1.5 COAL PRODUCTION PROGRAMME & HEAT VALUE

The total balance reserve in the integrated Lakhanpur-Lilari-Belpahar OCP is

projected to be around 1144.22 Mt.

The projection of coal production from the integrated Lakhanpur-Lilari-

Belpahar OCP is 27.25 Mt coal in 2014-15, 28.50 Mt in 2015-16, 30 Mty coal from

2016-17 till 2049-50 and thereafter 24.50 Mty in 2050-51, 19.10 Mty in 2051-52,

13.70 Mty in 2052-53, 8.30 Mty in 2053-54 and finally 2.87 Mty in 2054-55 before the

OCP exhaust totally.

The yearwise production programme as per mine PR vis-à-vis Useful Heat

value (UHV) of insitu coal is given in Table - 1.2 hereafter:

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Table-1.2 : Production Programme

(in Million tonne)

Coal, Mt UHV, kcal/kg2014 - 15 27.25 28852015 - 16 28.50 29062016 - 17 30.00 29292017 - 18 30.00 29782018 - 19 30.00 29932019 - 20 30.00 29852020 - 21 30.00 29452021 - 22 30.00 27252022 - 23 30.00 28422023 - 24 30.00 28412024 - 25 30.00 28422025 - 26 30.00 33722026 - 27 30.00 33702027 - 28 30.00 32052028 - 29 30.00 28522029 - 30 30.00 28522030 - 31 30.00 28502031 - 32 30.00 28512032 - 33 30.00 28502033 - 34 30.00 28512034 - 35 30.00 28512035 - 36 30.00 28512036 - 37 30.00 28652037 - 38 30.00 28632038 - 39 30.00 28642039 - 40 30.00 28632040 - 41 30.00 28642041 - 42 30.00 28622042 - 43 30.00 28642043 - 44 30.00 28632044 - 45 30.00 29112045 - 46 30.00 29152046 - 47 30.00 29162047 - 48 30.00 29152048 - 49 30.00 29152049 - 50 30.00 29152050 - 51 24.50 29142051 - 52 19.10 29142052 - 53 13.70 33122053 - 54 8.30 32952054 - 55 2.87 3501

1144.22

Year

TOTAL (Source: Mine PR of integrated Lakhanpur-Lilari-Belpahar OCP)

1.6 GRADE WISE MINEABLE COAL RESERVE

The integrated Lakhanpur-Lilari-Belpahar OCP consists of multiple seams

comprising of IB Bottom seam, IB Top seam, Rampur Bottom-II seam, Rampur

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Introduction

311713098 1-7

Bottom-I seam, Rampur Middle seam, Rampur Top-II seam, Rampur Top-I seam,

Local seam, Lajkura seam, Parkhani Bottom seam and Parkhani Top seam. The

total mineable coal reserves is around 1144 Mt.

The Seamwise and gradewise reserves as well as quality is given in Table-

1.3 hereafter:

Table-1.3 : Reserves and Quality : Seamwise and gradewise

(Qty in Million tonne)

Name of Horizon

Grade-C Grade-D Grade-E Grade-F Grade-G TOTAL

IB Bottom seam 38.15 65.86 13 1.92 0.33 119.26

IB Top seam 0.38 21.06 22.91 9.54 0.8 54.69

Rampur Bottom-II seam

1.88 13.83 111.55 15.07 142.33

Rampur Bottom-I seam

0.04 25.86 80.25 106.15

Rampur Middle seam

0.01 0.12 6.78 32.96 39.87

Rampur Top-II seam

2.94 34.21 27.04 64.19

Rampur Top-I seam

0.28 9.72 32.24 3.26 45.5

Local seam 3.51 18.49 17.17 0.2 39.37

Lajkura seam 5.51 320.17 205.95 531.63

Parkhani Bottom 1.21 1.21

Parkhani Top 0.02 0.02 Total Coal 38.53 92.6 86.56 560.65 365.88 1144.22

Contribution, % 3.37 8.09 7.56 49 31.98 100 (Source: Mine PR of integrated Lakhanpur-Lilari-Belpahar OCP)

From the perusal of above, it is noted that the seamwise grades of coal

reserves varies from Grade-C to Grade-G and the majority constitutes grade ‘F” and

‘G’, which jointly contributes 80% share.

1.7 QUALITY OF RAW COAL FEED TO THE WASHERY

The weighted average UHV of insitu coal based on the Table 1.2 above works

out to be 2926 kcal/kg. The average moisture of coal derived from testing of coal

sample at laboratory is about 5%. Considering the above, the percentage of raw coal

feed ash corresponding to average UHV of 2926 kcal/kg and moisture as 5% works

out to be 38.3%.

Considering that the present notified price of raw coal is based on GCV, the

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Introduction

311713098 1-8

average UHV has been converted into GCV considering ash as 38.3% and moisture

as 5%. The corresponding GCV works out to be 4224 kcal/kg.

The above quality of coal is ‘insitu’ and some dilution is expected during actual

production. Considering dilution at the rate of 10% subject to maximum of 300

kcal/kg, the likely annual average quality of actual production would be around 3924

kcal/kg and the corresponding ash of coal is expected to 41.5% at 5% moisture.

Thus, the likely average feed ash of raw coal to the proposed washery has

been considered as 41.5% for projection of economics.

1.8 LIFE OF THE PROPOSED WASHERY & CONSTRUCTION

SCHEDULE

� The integrated Lakhanpur-Belpahar-Lilari OCP is projected to produce

more than 10 Mty coal from 2014-15 till 2052-53 continuously, which is

sufficient for this washery to operate subject to modification, as deemed

necessary time-to-time.

� It has been envisaged that the time required for bid process management

shall be about 6 months and a period of further 30 months has been

considered for construction and commissioning of the washery including

the environmental clearances, the trial operation and the performance

guarantee tests (PGT). Thus, total period of 3 years have been considered

for development of washery.

� Life of the washery has been taken as 18 years for computation of

economics keeping in view that the life of the major equipment to be

installed is 18 years,.

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311713098 2-1

CHAPTER - 2 : RAW COAL CHARACTERISTICS

2.1 RAW COAL LINKAGE

The raw coal requirement of 10.0 Mty for the proposed washery will be

supplied from the integrated Lakhanpur-Belpahar-Lilari Opencast Project having

normative capacity of 30 Mty. Lakhanpur OC, Belpahar OC and Lilari OC are running

opencast projects of MCL, which are proposed to be integrated into one project

named the integrated Lakhanpur-Belpahar-Lilari Opencast Project.

As such the run-of-mine coal samples of Lajkura seam of the existing

Lakhanpur OCP and Rampur & IB seams of Belpahar in proportion of 50:35:15 was

for assessment of washability characteristics.

2.2 SAMPLE COLLECTION

A team of CMPDI officials visited MCL for supervision during collection of coal

samples from Lajkura seam of Lahanpur OCP, Rampur seam & IB seam from

Belpahar OCP in proportion of 50:35:15 in the fourth week of April 2014. The

samples were received at CMP Laboratory, CMPDI on 17.05.2014. The particulars of

the samples collected is given in Table-2.1 & 2.2 hereafter:

Table-2.1: Sample Particulars - Lakhanpur OCP

Company : MCL

Area : Lakhanpur Area

Colliery : Lakhanpur OCP

Name of seam : Lajkura

Total Thickness : 30 m (approx.)

Working Thickness : 30 m (approx.)

Net Sample : 2.5 tonnes (approx.)

Bag Details : 50 bags

Nature of sample : Run of Mine (RoM) Coal

Date of sample collection : 22.04.2014

Purpose of investigation : To generate data for washability study

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Raw Coal Characteristics

311713098 2-2

Table-2.2: Sample Particulars - Belpahar OCP

Company : MCL

Area : Lakhanpur Area

Colliery : Belpahar OCP

Name of seams : (i) Rampur & (ii) IB

Total Thickness : (i) 20m (approx.) & (ii) 7m (approx.)

Working Thickness : (i) 20m (approx.) & (ii) 7m (approx.)

Net Sample : 2.5 tonnes (approx)

Bag Details : Rampur Seam - 35 bags

IB seam - 15 bags

Nature of sample : Run of Mine (RoM) Coal

Date of sample collection : 23.04.2014

Purpose of testing : To generate data for washability study

2.3 TEST PROCEDURE

The coal sample collected from Lajkura seam at Lakhanpur OCP and Rampur

& IB seam Belpahar OCP of Lakhanpur area (in the proportion of 50:35:15

respectively of each seam) of MCL was received at CMP Lab on 17.05.2014.

Representative samples were prepared by thoroughly mixing and dividing into four

equal parts (Part-I, Part-II, Part-III & Part-IV) as per IS 436 Part I. The testing of

samples were carried out as per relevant IS codes. The test procedure is given

hereafter:

i) Screening of coal sample, as received in laboratory (Part-I) at 200mm, 150

mm, 100 mm, 50 mm, 25 mm, 13 mm, 6 mm, 3 mm & 0.5 mm screen

aperture and determination of ash% & moisture% of each screened

fraction.

ii) Proximate analysis of as-received coal (Part-I) 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 100 mm size (Part-II) and

screening at 50 mm, 25 mm, 13 mm, 6 mm, 3 mm & 0.5 mm screen

apertures and determination of ash% & moisture% of each screened

fraction.

iv) Crushing of as received coal sample down to 50 mm size (Part-III) and

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Raw Coal Characteristics

311713098 2-3

screening at 25 mm, 13 mm, 6 mm, 3 mm & 0.5 mm screen apertures and

determination of ash% & moisture% of each screened fraction.

v) Further testing of Part-III (i.e. crushed to -50 mm) coal sample is given

below:

a) Float & Sink test of 50-25 mm, 25-13 mm, 13-6 mm, 6-3 mm & 3-0.5

mm 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 (50-0.5 mm) at targeted ash of 34% based

on the float and sink test carried out as above.

c) Proximate analysis of generated washed coal (at about 34%) under 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 coal (at about 34%) & rejects.

f) Wet sieve analysis of – 0.5 mm

g) Ultimate Analysis and Ash Fusion Temperature of raw coal and

generated washed coal (at about 34%) & rejects.

h) Petrographic analysis of raw coal and washed coal.

vi) Part-IV of the coal sample is kept as reserve.

The test results are given hereafter in subsequent paras.

2.4 WASHABILITY TEST RESULTS

2.4.1 Screen Cum Ash & Moisture Analysis of Raw Coal

Representative raw coal sample of Lajkura seam of Lakhanpur OCP and

Rampur seam & IB seam of Belpahar OCP was drawn after coning &

quartering and was subjected to screen analysis at 200, 150, 100, 50, 25,

13, 6, 3 and 0.5 mm aperture screens. Weight% & ash% were determined

for respective size fractions. The test results are given in Table-2.3. The

gross calorific value (GCV) of RoM coal sample is 3580 kcal/kg.

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Raw Coal Characteristics

311713098 2-4

Table-2.3: Screen-cum-Ash & Moisture Analysis

Colliery : Lakhanpur OCP & Balpahar OCP

Area : Lakhanpur

Seam : Lajkura, Rampur and IB (Ib-Bottom)

Nature of sample : As received representative raw coal sample

Size (mm) Wt % Ash %

+200 5.2 46.3

200-150 13.6 45.2

150-100 18.3 43.3

100-50 12.3 44.2

50-25 15.2 43.1

25-13 11.1 44.5

13-6 8.9 45.8

6-3 5.1 43.4

3-0.5 3.8 42.5

-0.5 6.5 47.3

Total 100.0 44.4

Surface Moisture of Raw coal = 7.0 %

Inherent Moisture of Raw coal = 5.2 %

Total Moisture Raw coal (‘as-received’ basis’) = 12.2 %

2.4.2 Screen Cum Ash: Raw Coal Sample Crushed 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% were determined for respective size fractions. The results are given in

Table-2.4.

Table-2.4: Screen-cum-Ash & Moisture Analysis

Colliery : Lakhanpur OCP & Balpahar OCP

Area : Lakhanpur

Seam : Lajkura, Rampur and IB

Nature of sample : Raw coal sample crushed down to 100 mm

Size (mm) Wt % Ash % 100-50 34.2 45.2 50-25 26.1 44.2 25-13 12.5 43.8 13-6 9.6 42.8 6-3 5.8 41.3 3-0.5 4.5 39.1 -0.5 7.3 46.2 Total 100.0 44.1

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Raw Coal Characteristics

311713098 2-5

2.4.3 Screen Cum Ash & Moisture: Raw Coal Sample Crushed 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-2.5.

Table-2.5: Screen-cum-Ash & Moisture Analysis

Colliery : Lakhanpur OCP & Balpahar OCP

Area : Lakhanpur

Seam : Lajkura, Rampur and IB

Nature of sample : Raw coal sample crushed down to 50 - 0 mm

Size (mm) Wt % Ash % Moisture%

50-25 49.6 45.6 4.9 25-13 18.8 44.1 5.1 13-6 11.1 40.8 5.5 6-3 6.9 38.6 6.2 3-0.5 5.5 37.4 6.3 -0.5 8.1 45.6 4.6 Total 100.0 43.9 5.1

Summarized data of screen analysis for 50-13 mm, 13-0.5 mm and -0.5 mm

fractions are given in Table-2.6

Table-2.6: Summarized Screen-cum-Ash Data

Size Wt % Ash %

50-13 68.40 45.2

13-0.5 23.50 40.0

-0.5 8.10 45.6

Total 100.00 43.9

2.4.4 Float & Sink Tests : Lajkura Seam, Rampur seam & I B seam of integrated Lakhanpur- Belpahar- Lilari OCP.

Float and sink tests of representative raw coal sample of Lajkura seam of

Lakhanpur OCP and Rampur seam & IB seam from Belpahar OCP (crushed

to 50 mm size) were 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-2.7. 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 No. 1.

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Raw Coal Characteristics

311713098 2-6

Table-2.7: Float & Sink Test Results

Colliery : Lakhanpur OCP& Balpahar OCP

Area : Lakhanpur

Seam : Lajkura, Rampur and IB

Nature of sample : Raw coal sample crushed down to 50 mm

Size of coal tested : 50-25, 25-13, 13-6, 6-3 & 3-0.5 mm

Respective wt.% of coal tested on the : 54.0, 20.4, 12.1, 7.5, 3.05 basis of +0.5 mm size fraction

Size(mm) 50 - 25 25 - 13 13 - 6 6-3 3 - 0.5 50 - 0.5

Wt % of Raw Coal

91.9

Wt%100 54.0 20.4 12.1 7.5 6.0 100.0

Float Float Float Float Float Float Cum. Float Sp. gr.

Wt. % Ash % Wt. % Ash % Wt. % Ash % Wt. % Ash % Wt. % Ash % Wt% Ash% Cu.Wt% Cu. Ash% Cu. Wt% Raw Coal

<1.40 5.1 8.8 5.6 7.6 7.2 8.0 10.2 7.3 12.1 6.4 6.3 8.0 6.3 8.0 5.8

1.40-1.50 18.1 19.4 17.0 18.9 18.3 18.6 17.4 17.5 18.5 16.5 17.9 18.9 24.1 16.1 22.2

1.50-1.60 19.0 32.8 18.3 31.3 17.3 30.6` 16.6 27.5 12.2 25.2 18.1 31.6 42.2 22.2 38.8

1.60-1.70 13.2 42.0 13.5 40.7 14.6 37.0 15.5 35.8 10.1 32.3 13.4 40.1 55.6 26.9 51.1

1.70-1.80 14.2 55.3 15.7 49.5 12.2 41.8 11.7 41.2 14.7 40.6 14.1 50.8 69.7 31.7 64.1

1.80-1.90 9.5 65.3 8.6 58.9 8.8 52.4 8.3 51.7 12.9 50.5 9.3 60.5 79.1 35.1 72.7

>1.90 20.9 75.0 21.3 76.1 21.6 75.8 20.3 76.1 19.5 76.2 20.9 75.5 100.0 43.6 91.9

Total 100.0 45.5 100.0 43.9 100.0 40.8 100.0 38.5 100.0 37.5 100.0 43.6

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Raw Coal Characteristics

311713098 2-7

2.4.5 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-2.8.

Table-2.8: Wet Sieve Analysis of –0.5 mm coal

Colliery : Lakhanpur

Area : Lakhanpur

Seam : Lajkura from Lakhanpur, Rampur & IB from

Belpahar

Nature of sample : Raw coal crushed down to 50 mm

Size of coal tested : -0.5 mm

Size (mesh) Wt% Ash%

+ 72 59.5 43.1

72-100 6.1 46.8

100-200 10.0 42.7

200-300 3.0 41.3

-300 21.4 53.0

Total 100.0 45.4

2.4.6 Generation of Washed Coal at Lab Scale

Based on Float & Sink test data of 50-0.5 mm fraction coal, washed coal has

been generated at about 34% ash and the same has been obtained at 1.87 sp.

gr. The result is given in Table-2.9.

Table-2.9: Beneficiation of 50-0.5 mm coal

Sp. Gr. Wt % Ash %

< 1.87 76.1 33.9

> 1.87 23.9 73.7

Total 100.0 43.4

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Raw Coal Characteristics

311713098 2-8

2.5 PROXIMATE ANALYSIS, GCV & HGI OF RAW COAL &

WASHED COAL

Proximate analysis on air-dried basis and equilibrated basis was carried out

for raw coal (as received), generated washed coal (at about 34% ash level) & reject.

HGI and GCV for raw coal (as received) and generated washed coal & reject were

also determined. The results are given in Table No – 2.10.

Table-2.10: Proximate Analysis, GCV & HGI (on air d ried basis)

2.6 MOISTURE% OF RAW COAL, WASHED COAL & REJECT

The moisture percent was determined for raw coal on as received basis and

generated washed coal & reject (as mentioned in 4.6) on as generated basis and its

results are given in Table No-11.

Table No– 11 : Moisture% of Raw Coal and for Generated Washed coal & Reject.

Sl No Sample type Surface

Moisture%

Inherent Moisture%

(adb) Total moisture%

1 Raw Coal 7.0% 5.2% 12.2% (arb)

2 Generated Washed coal 8.5% 6.6% 15.1% (apb)

3 Generated Reject 2.0% 1.3% 3.3% (apb)

Raw Coal Washed coal Rejects Sl. No. Particulars Air

dried basis

Equilibrated basis

Air dried basis

Equilibrated basis

Air dried basis

Equilibrated basis

1 Proximate Analysis

i) Moisture% 5.2 6.7 6.6 8.5 1.3 1.9

ii) Ash% 44.4 43.7 33.9 33.2 73.7 73.3 iii) VM% 21.9 21.6 24.7 24.2 14.1 14.0

iv) Fixed Carbon%

28.5 28.0 34.8 34.1 10.9 10.8

2 GCV (kcal/kg) 3580 - 4368 - 1335 -

3 HGI 62 - 69 - - -

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Raw Coal Characteristics

311713098 2-9

2.7 ULTIMATE ANALYSIS AND ASH FUSION TEMPERATURE OF RAW COAL AND WASHED COAL

Ultimate Analysis and Ash Fusion Temperature was conducted for raw coal

and washed coal (at about 34% ash level) and reject. The results of the Ultimate

Analysis and Ash Fusion Temperature are given in Table No. 12 and 13 respectively.

Table No– 12 Ultimate Analysis of Raw Coal Sample and Generated Washed coal

Particulars Raw Coal Generated Washed coal

Carbon % 36.2 41.5 Hydrogen % 3.4 3.8 Nitrogen % 0.6 0.8 Sulphur % 0.4 0.5

Table No– 13

Ash Fusion Temperature of Raw Coal Sample and Gener ated Washed coal

Particulars Raw Coal Generated Washed coal

IDT(°C) 1395 1380 ST(°C) < 1400 < 1400 HT(°C) < 1400 < 1400 FT(°C) < 1400 < 1400

Abbreviations used: IDT: Initial deformation temperature, ST: sphere temperature HT: hemisphere temperature, FT: flow temperature.

2.8 PETROGRAPHIC ANALYSIS OF RAW COAL AND WASHED COAL

Petrographic Analysis was conducted for raw coal, washed coal (at about

34% ash level). The results of the petrographic analysis are given in Table No. 14.

Table No- 14

Petrographic Analysis of Raw Coal and Generated Washed coal

Maceral composition %

Maceral composition % (Vmmf %) Particulars

Vit Lipt Int Vmm Vit Lipt Int

Rr%

Raw Coal 35.9 15.6 26.4 22.1 46.1 20.0 33.9 0.51 Generated Washed coal at about 34% ash level

43.3 13.1 29.0 14.6 50.7 15.3 34.0 0.52

Abbreviations used: Vit: Vitrinite, Lipt: Liptinite, Int: Inertinite, Rr. Random Vitritnite Reflectance, Vmm: Visible Mineral Matter. Vmmf: Visible mineral matter free basis

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Raw Coal Characteristics

311713098 2-10

2.9 HEAVY METAL TEST FOR RAW COAL AND GENERATED

WASHED COAL & REJECT

Test for ascertaining heavy metal content were conducted on raw coal

(combined) and on generated washed coal and reject. The test results are given in

Table No. 15.

Table No- 15 Heavy Metals Analysis

Samples As Cd Cr Pb Hg S (Total) unit ppm ppm ppm ppm ppm %

Raw Coal 2.9 0.9 56.6 22.6 <0.05 0.4 Generated Washed coal

1.8 0.4 50.8 19.5 <0.05 0.5

Reject 3.7 1.2 64.4 27.2 <0.05 0.23

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311713098 3-1

CHAPTER - 3 : CAPACITY & OPERATING CONDITIONS OF T HE

WASHERY

3.1 CAPACITY

MCL has decided to set up Ib-valley coal washery of 10.0 Mty throughput

capacity in Lakhanpur Area. The raw coal requirement of 10.0 Mty is proposed to be

supplied from the integrated Lakhanpur-Belpahar-Lilari OCP. The washery has been

envisaged to produce two products viz. washed coal of 33.5±0.5% ash and rejects.

Keeping in view of the production programme of linked mines (Refer Tables-

1.2) and qualitative requirement of thermal power stations, the washery has been

envisaged to beneficiate 50-13 mm and 13-2 mm coal in electronically controlled jigs

and beneficiation of fine coal (-2 mm) in a suitable beneficiation equipment for

producing washed coal and rejects only.

The raw coal throughput capacity of the washery is as mentioned below:

a) Annual : 10.0 Mt

b) Daily : 30,300 tonnes

c) Hourly :1,700 tonnes

3.2 OPERATING CONDITIONS OF DIFFERENT SECTION

It has been envisaged that raw coal from the linked mines will be transported

to the washery site through two nos. of Belt Conveyors (Capacity : 1200 tph each).

The distance of linked mines is about 5-6 km from the washery site. Top size of the

raw coal feed to the washery will be 100 mm. The proposed washery has been

conceptualized to have raw coal receiving & storage section, washery section (i.e.

from raw coal storage to storing of products) and loading & dispatch section. The

operating conditions of different sections are given below:

3.2.1 Raw Coal Receiving Section

The operating conditions of the raw coal receiving section are given hereafter:

a) No. of working days per annum : 330

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Capacity & Operating Conditions

311713098 3-2

b) No. of working shifts per day : 3 (8 hours each)

c) Hourly throughput capacity (tones) : 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 Loading & Dispatch Section

It has been envisaged that coal from the washed coal stock will be reclaimed

and dispatched to the consumers through Silo to be constructed on the

proposed Railway siding by MCL.

The operating conditions of loading & dispatch section are given below:

a) No. of working days per annum : 365

b) No. of working shifts per day : 3 (8 hours each)

c) No. of loading hours per year : round the clock

d) Loading rate (tph) : 5500

Provision has been considered for transportation of reject by Belt Conveyor for

temporary dumping on the adjacent back-filled land as identified by MCL in an

environmentally friendly manner before final disposal of the same through e-

auction or MoU route. The operating conditions for disposal of rejects will

match with the operating conditions of washery section as mentioned in

preceding Para no. 3.2.2.

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311713098 4-1

CHAPTER - 4 : PROCESS FLOWSHEET & BALANCE OF

PRODUCTS

4.1 SELECTION OF PROCESS

The washing process has been conceptualized on the basis of qualitative

requirement of washed coal of thermal power stations as per MoEF guidelines and

the ash percentage of washed coal has, accordingly, been considered as 33.5±0.5%.

Selection of process is based on the test data/ results given in Chapter-2. Ash

forming mineral matter is so thoroughly mixed that full-scale washing has been

envisaged to obtain the targeted washed coal of 33.5±0.5% ash.

4.2 PROCESS FLOWSHEET

The process consists of beneficiation of coarse coal fraction of 50-13 mm and

small coal fraction 13-2 mm coal in electronically controlled jigs and beneficiation of -

2 mm fine coal fraction in a suitable beneficiation equipment. Mixing of Jigs float and

beneficiated fine coal can yield the desired product of washed coal of 33.5±0.5% ash.

The washery will, thus, produce two products i.e. washed coal and rejects.

The salient features of process are shown in Drawing No. HQ/CMP/

311713098/04/001 Rev-3 and is briefly described hereunder:

- Receiving raw coal of -100 mm from linked integrated Lakhanpur-Belpahar-

Lilari OCP through two nos. Belt Conveyors @ 1200 tph each

- Screening at 50 mm to obtain two size fractions i.e. 100 - 50 mm & - 50 mm

- Crushing of 100 - 50 mm coal down to 50 mm and mixing it with natural -50

mm coal

- Storing of both crushed & un-crushed coal (-50 mm) in 15000 t ground

storage within the washery premises.

- Reclamation and conveying of -50 mm coal from ground storage to washery

building.

- Screening of (-) 50 mm coal at 13 mm to produce two size fractions, i.e. 50-

13 mm and -13 mm.

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Process Flow sheet & Balance of Products

311713098 4-2

- Screening/ Desliming of 13 mm at 2 mm to produce 13-2 mm and -2 mm

fractions. .

- Beneficiation of 50-13 mm in two-products electronically controlled coarse

coal jigs to produce washed coal (float) and rejects (sinks).

- Beneficiation of 13-2 mm fractions in two-products electronically controlled

small coal jigs to produce washed coal (float) and rejects (sinks).

- Dewatering of washed coal from coarse coal jig in dewatering screens

- Dewatering of washed coal of 13-2 mm size fraction in dewatering screen

followed by basket type centrifuge.

- Dewatering of rejects produced from jigs of both the fractions in in-built

bucket elevators followed by dewatering screens.

- Classification of the underflow of desliming screen, i.e. -2 mm) fraction in

Hydrocyclones to remove ultrafine fraction (-0.1 mm).

- Treating the 2 to 0.1 mm fraction in suitable beneficiation equipment.

- Dewatering of washed coal of 2 to 0.1 mm fraction in suitable fine coal

dewatering equipment, say Belt Filter Press.

- Collection of overflow of Hydrocyclones (i.e. ultrafine), effluent from Belt

Filter Press and tailings produced from beneficiation of 2 to 0.1 mm fraction

in Radial Thickener.

- Dewatering of Thickener underflow in a suitable dewatering equipment, say

Pressure Filters and mixing with rejects.

- Conveying of washed coal (i.e. washed coal 50-13 mm, 13-2 mm size

obtained from jigs duly dewatered and beneficiated fine coal of -2 mm size

duly dewatered) from washery building to covered ground storage of 20,000

tonne capacity.

- Reclamation of washed coal from ground storage and conveying the same to

Silo (to be constructed by MCL on the proposed Railway siding).

- Conveying of dewatered rejects (viz. rejects obtained from jigs and tailings of

fine coal beneficiation stream duly dewatered) by reject belt conveyors to

reject hopper for dumping to the identified back-filled land for the purpose, in

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Process Flow sheet & Balance of Products

311713098 4-3

an environment friendly manner for onward disposal to the prospective

buyers through MoU or e-auction route.

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 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 BALANCE OF PRODUCTS

4.3.1 Based on Laboratory Scale Tests

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 plant conditions, has been projected. The expected

yield of washed coal & rejects on the proposed scheme under practical

conditions based on test results has been estimated and shown in Table - 4.1.

Table- 4.1: Balance of Products (Actual Test Data)

Product Wt% Ash% Qty. (Mty)

Washed coal 67.0 33.5 6.7

Rejects 33.0 65.0 3.3

Total 100.0 43.9 10.00

4.3.2 Projected Balance of Product on Average Raw C oal Ash

Based on the above balance of product (Table No. 4.1), the likely balance of

product has been projected on the likely average feed to the washery

(Average Ash%, A = 41.5%) as follows (Table 4.2):

Table- 4.2: Projected Balance of Products at Avera ge Raw Coal Ash

Products Wt% Ash% Qty. (Mty) Washed Coal 74.6 33.5 7.46 Rejects 25.4 65.0 2.54

Total 100.0 41.5 10.00

*****

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311713098 5-1

CHAPTER - 5 : INFRASTRUCTURE FACILITIES

5.1 WASHERY SITE

An area of 19 ha land is available for setting up the washery including green

belt, parking space for 2-wheelers & 3-wheelers etc.

Out of the available land, the 11.8 Ha virgin solid land will be utilized for

construction of raw coal receiving pit, half-day storage of raw coal, screen-cum-

crusher house, washery building, covered ground storage for washed coal,

emergency slurry pond, radial thickener etc., administrative buildings and other allied

structures as per the technological requirement.

Proposed washery site is approx. 5-6 km away from the linked mines.

5.2 SUPPLY OF RAW COAL

The raw coal requirement of 10.0 Mty will be met from integrated Lakhanpur-

Belpahar-Lilari OCP and will be supplied by MCL to the proposed washery through

two nos. of Belt Conveyors @ 1200 tph per conveyor at one point in the washery

premises. The exact location and height of raw coal delivery point in the washery

shall be indicated by MCL.

5.3 AVAILABILITY OF WATER

Water requirement for the proposed washery is about 0.60 MGD. The

intended water will be made available by MCL from Hirakud Back water through the

existing dedicated pipeline of the OPGC-IWSS by tapping at a distance of

approximately 4 km away from the washery.

Alternatively, mine water from the Quarry No. 5 of Belpahar OCP, which is

approx. 1-2 km from the washery site and water from existing Eco-Tank can be

supplied to the washery by MCL.

MCL shall make necessary arrangement to provide requisite quantity of water

at one point in the washery.

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Infrastructure Facilities

311713098 5-2

5.4 AVAILABILITY OF POWER

Requirement of power is about 8.0 MVA for operation & maintenance of the

proposed washery. Power shall be drawn by BOM operator through a separate

overhead transmission line from existing 33 kV sub-station of Belpahar OCM, which

is approx. 3 km from the washery site.

5.5 RAILWAY SIDING FOR LOADING & DISPATCH OF WASHED

COAL

The BoM operator shall deliver washed coal at the top of the Silo situated on

the Railway siding at a distance of 1 to 2 km. MCL shall make necessary

arrangement for construction of Silo (one no.) along with Railway siding & RLS for

evacuation and delivery of washed coal to the customer.

5.6 REJECT DISPOSAL/ UTILIZATION

The likely generation of average quantity of rejects from the washery will be

around 3 Mty.

Rejects produced from the washery will be temporarily dumped on the

identified back-filled site (approx 13 Ha) adjacent to the washery in environment

friendly manner. The reject will finally be disposed off to the prospective buyers

through either by e-auction or MoU.

5.7 RESIDENTIAL AND WELFARE FACILITIES

The washery is proposed to be installed on Build, Operate & Maintain (BOM)

concept. It is expected that the residential & welfare 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.

*****

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311713098 6-1

CHAPTER - 6 : ECONOMICS

6.1 CAPITAL ESTIMATE

The washery is to be set up under Build-Operate-Maintain (BOM) concept.

The BOM operator will be selected through global bidding. The selected 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, the washing scheme envisaged and the infrastructure facilities.

While estimating the capital cost, following tentative provisions have been

considered:

- Receiving of -100 mm raw coal at one point inside the washery premises

through belt conveyors (@ 2x1200 tph) of MCL.

- Screen-cum-crusher house

- Half-day ground storage of raw coal

- Washery building

- One-day covered ground storage of washed coal

- Emergency slurry pond

- Conveying of washed coal to Silo, which is about 1 to 2 km from the

washery premises

- Conveying of Rejects produced from the washery for temporary dumping

in environment friendly manner.

- 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 along with two years critical spares

- Conveyor gantries, belt conveyors etc

- Plant control system, instrumentation, quality & quantity monitoring system

- Power and water supply arrangement within washery

- Roads, culverts, green belt, boundary wall, environmental control units, fire

fighting system/ equipment etc.

- Closed water circuit with zero effluent discharge and rain water harvesting.

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Economics

311713098 6-2

Drawing electric power for operation & maintenance of the proposed washery

by BOM operator through a separate overhead transmission line from existing 33 kV

sub-station of Belpahar, which is approx. 3 km from the washery site.

Residential facilities for the manpower will be arranged by BOM operator.

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 �� 336.90 Crores

and the break-up is given at Appendix-1. This estimate does not cover the capital

required for transportation of raw coal from mine to washery, loading silo and Rapid

Loading System for washed coal.

6.2 COST BENEFIT ANALYSIS

The cost of production as calculated and given at Appendix-2 is broadly based

on the following considerations:

• Notified selling price of raw coal of MCL for Grade G-12 w.e.f.

17.12.2013, including royalty & SED and crushing charge of RoM coal.

• Estimated operating cost of washery per tonne of raw coal input as per

CMPDI practice.

• Projected yield of washed coal at 33.��±0.5 % ash.

The estimated operating cost at 100% capacity utilization has been worked

out to be �114.81 per tonne of raw coal input.

As there is no washery in MCL at present, the power coal (Ash-34%) selling

price of Piparwar washery has been considered, which is �� 1746.42/ per tonne for

estimating the annual profit of the washery. Thus, the annual profit has been

estimated as follows:

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Economics

311713098 6-3

Table- 6.1: Cost Benefit Analysis

Sl. No. Particulars Raw Coal Ash % - 41.50

1. Profit per tonne of washed coal,�� per tonne 397.89

2. Annual Profit � Crore 296.89

3. Payback Period, Year 1.13

6.2.1 Sensitivity Analysis

In case of setting up of washery on BoM concept, the raw coal ash can vary from

average ash (A) to A±4. Hence, average ash can vary from 41.5 up to 45.5% with the

following variation in profitability:

Raw Coal Ash Sl. No.

Parameters Average, A A+1 A+2 A+3 A+4

1.

Raw Coal Ash%

41.5 42.5 43.5 44.5 45.5

2.

Annual Profit, � Crore

296.89 241.47 186.06 187.64 132.23

3.

Payback Period, Year

1.13 1.40 1.81 1.80 2.55

*****

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311713098 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 the loading silo for loading of

washed coal through Rapid Loading System for onward dispatch by 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 structural

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 (BOMO)

The scope of work for BOM Operator will be as follows:

- Planning, design & engineering, selection of necessary equipment &

machinery, procurement, delivery, erection/ installation, testing, successful

commissioning including PGT of coal washing plant and all allied activities for

setting up of the Coal Washery.

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Project Construction Management

311713098 7-2

- Operation and maintenance of the plant initially for a period of ten (10) years

(after successful commissioning of the washery).

- Receipt of raw coal of -100 mm coal at one point in the washery premises

through belt conveyor from MCLs linked mines.

- Washing of raw coal to meet requisite quality & quantity of washed coal.

- Delivery of washed coal through belt conveyor to MCL in the identified Silo,

which is about 1 to 2 km from the washery premises.

- Transportation of Rejects produced from the washery for temporarily dumping

on the identified back-filled site adjacent to the washery. . The reject will be

finally disposed off to the prospective buyers either by e-auction or MoU by

MCL.

- Requirement of power is about 8.0 MVA for operation & maintenance of the

proposed washery. Power shall be drawn by BOM operator through a

separate overhead transmission line/ cable from existing 33 kV sub-station of

Belpahar OCM, which is approx. 3 km from the washery site.

- MCL shall be responsible for obtaining all statutory & regulatory clearances

including environmental and other clearances from Central/ State Pollution

Control Boards or any other agency as applicable. However, the successful

bidder shall provide all necessary assistance/ support in this regard as

necessary.

- Though, the responsibility of obtaining statutory and regulatory clearances

lies with MCL, the BOMO must comply all the statutory & regulatory

requirements while operating the plant.

7.4 SUPPORT BY MCL

MCL shall provide the following necessary supports to the BOM Operator:

7.4.1 During Construction

• Financing for setting up of the washery (including DG set as stand-by

power arrangement for critical equipment/ system)

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Project Construction Management

311713098 7-3

• Land (acquired and demarcated) free of any obstruction such as

abandoned structures, overhead electrical lines, debris/ dump materials,

hillocks, etc. with necessary approach road.

• Soil Investigation Report and Contour Map of the Project site indicative

for the bidding purpose only.

• Supply of water (within 100 m) and power at a single point (in the

washery) on chargeable basis up to successful PGT.

7.4.2 During Operation & Maintenance

• Assured raw coal supply of requisite quality and quantity of (-) 100 mm size

at designated point in the washery premises.

• Land required for temporary disposal of washery rejects till the contract

period.

• Assured evacuation of washed coal and rejects.

• Arranging/ indenting of Railway wagons as well as loading of washed coal

into the Railway wagons including the development of infrastructural facility

for Rapid Loading system.

• Railway siding/ Belt conveyors/ dumpers & tipping trucks (in case of

dispatch by road) for transportation of washed coal.

• Providing power at 33 kV sub-station of Belpahar OCM on the basis of

agreed demand.

• Reimbursement of additional operating expenses for DG set on actual.

• Assured supply of water from the identified source in the washery premises

at one point.

The above provisions & supports are to be confirmed/ ensured/ 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. The process of obtaining

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Project Construction Management

311713098 7-4

various clearances can take one year time from the date of identification of the

Lowest Bidder. After obtaining such clearances, issue of Letter of Acceptance/

Award (LoA) & signing of Contract will be executed and thereafter the

construction period of 18 months will start. The Lowest Bidder shall assist

MCL in all these activities.

7.5 PROJECT MONITORING

The construction period of the washery including trial runs, PGT and

commissioning is 18 months. Monitoring of progress of work by MCL during

construction of the project is essential to adhere to the envisaged time schedule. The

project activity chart viz. CPM/ PERT network chart agreed by BOM operator while

signing the contract agreement would form the basis for the purpose of monitoring

the progress of the project. This chart is required to be updated on the real-time

progress information received time-to-time. This will reveal the correct status of the

progress and help in taking subsequent corrective measures of reducing slippage, if

any. However, the critical path should never be allowed to be disturbed, if the time

schedule is to be maintained.

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311713098 8-1

CHAPTER - 8 : DATA/ INFORMATION TO BE CONSIDERED F OR

CUSTOMIZATION OF BID DOCUMENT

MCL shall confirm the following inputs prior to customization of Bid Document.

8.1 RAW COAL AVAILABILITY

The raw coal requirement of 10.0 Mty is proposed to be met from integrated

Lakhanpur-Belpahar-Lirari OCP. MCL will ensure the supply of (-) 100 mm size raw

coal of specified quality & quantity from the specified source to the proposed washery

prior to customization of RFP Document.

8.2 SUPPLY OF RAW COAL TO BOM OPERATOR BY MCL

As per provision of Model Bid Document, raw coal is to be supplied to washery

in all the three shifts in a year (all the days of the year except paid holidays of MCL).

However, supply of raw coal on paid holidays may also be done on written request of

BOM Operator, if possible.

It has been envisaged that raw coal from the linked mines will be transported

by two nos. belt conveyors, 1200 tph capacity each, to the proposed washery site.

The exact location and height of raw coal delivery point shall be indicated by MCL.

8.3 LAND FOR WASHERY & REJECT DUMPING

An area of 19 ha land is available for setting up the washery including green

belt, parking space for 2-wheelers & 3-wheelers etc.

Out of the available land, the 11.8 Ha is virgin solid land and will be utilized for

construction of raw coal receiving pit, half-day storage of raw coal, screen-cum-

crusher house, washery building, covered ground storage for washed coal,

emergency slurry pond, radial thickener, road weigh-bridge for raw coal & rejects etc.,

administrative buildings and other allied structures as per the technological

requirement. Proposed washery site is approx. 5-6 km away from the linked mines.

Mining is still in progress on the land identified now for temporary dumping of

rejects. MCL will ensure the availability of back-filled land for temporary dumping of

rejects to the tune of about 3 Mt per year prior to customization of Bid Document.

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Data/Information to be Considered for Customization of Bid Document

311713098 8-2

The land for washery and temporary reject storage is to be demarcated 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.

The suitable approach road for the proposed washery will be constructed/

upgraded through the existing available land of MCL.

8.4 WATER

The quantity of water required for operation of the proposed washery is about

0.60 MGD. The intended water will be made available by MCL from Hirakud Back

water through the existing dedicated pipeline of the OPGC-IWSS by tapping at a

distance of approximately 4 km away from the washery.

Alternatively, the mine water from the Quarry No. 5 of Belpahar OCP, which is

approx. 1-2 km from the washery site and water from existing Eco-Tank can be

supplied to the washery by MCL.

MCL shall also provide water for washery construction within 100m range from

the washery premises.

All necessary steps are to be taken by MCL for obtaining clearances/

approvals, if any.

8.5 POWER

Requirement of power for operation & maintenance of the proposed washery

to the tune of about 8.0 MVA shall be made available at 33 kV through a separate

overhead transmission line to be drawn by BOM operator from existing 33 kV sub-

station of Belpahar OCM which is approx. 3 km from the washery site.

As per provision of the Model Bid Document (MBD) duly approved by CIL

Board, MCL shall also provide power for washery construction within 100 m range

from the washery premises. MCL will ensure the tapping point for electrical power

accordingly before customization of Bid Document.

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Data/Information to be Considered for Customization of Bid Document

311713098 8-3

8.6 QUALITY OF RAW COAL FEED TO WASHERY FROM LINKED

MINES

Raw coal quality in terms of ash and moisture content, which will be supplied

to the washery needs to be confirmed prior to customization of Bid Documents:

a) i) Likely Total average moisture % : 11.3 (on day to day basis) (arb)

ii) Range of total moisture% (arb) : 10.1-12.6

iii) Likely average moisture% (adb) : 5.2 (on day to day basis)

b) Likely Monthly average Ash % : 41.5

c) Range of Monthly Average Ash % : 41.5 ± 4

d) Range of day-to-day basis Ash % : 41.5 ± 4

8.7 RAILWAY SIDING FOR LOADING & DISPATCH OF WASHED

COAL

The BOM operator will transport washed coal from washery to the Silo near

the separately-proposed Railway siding, which is about 1 to 2 km from the washery

premises.

Construction of Silo, Railway siding and Rapid Loading System for onward

transportation of washed coal shall be ensured by MCL.

8.8 REJECT DISPOSAL

The likely generation of average quantity of rejects from the washery will be

around 3 Mty. Rejects produced from the washery will be dumped on the identified

site in environment friendly manner. MCL has identified back-filled land (approx 13

Ha adjacent to the washery) for temporary dumping of reject. MCL will ensure

availability of sufficient land for rejects dumping before customization of Bid

Document and regular evacuation of rejects so that rejects dumping by BOM

operator would not be an impediment.

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Data/Information to be Considered for Customization of Bid Document

311713098 8-4

8.9 DESIGNATED POINT FOR RECEIPT OF WASHED COAL

It has been envisaged that BOM operator shall provide covered ground

storage of 20,000 tonne for washed coal to accommodate about one day production

with suitable reclamation & transportation arrangement up to the silo near Railway

siding (1 to 2 km from washery premises). Construction of the Silo and the Railway

siding along with RLS is to be looked after by MCL separately. The Rapid Loading

System at the 5500 tph can be considered for loading of washed coal.

MCL is required to confirm or indicate coordinates of Silo from a reference

point in the washery and height at which washed coal shall be delivered in the Silo

prior to customization of Bid Document. All necessary steps are required to be taken

by MCL so that the Silo as well as the Railway siding is completed before the

commissioning of the washery.

8.10 APPROVAL OF CONCEPTUAL REPORT

Approval of the Conceptual Report of 10 Mty Ib-valley washery at Lakhanpur

area by MCL is required before customization of Bid Document.

8.11 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 RFP/ Bid Document

or e-tendering.

c) E-mail address of MCL or that of the designated person concerned of MCL.

d) FAX no. of MCL for the purpose of communication with respect to bid.

8.12 DRAFT FOR BID DOCUMENT

Name in whose favour the Bank Draft for price of Bid Document is to be

issued need to be furnished.

8.13 LEGAL JURISDICTION

Name and place of court for legal jurisdiction is to be furnished.

*****

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B

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311713098 A-1

APPENDIX – 1

Statement showing Estimated Broad Capital Requirement with

Year-wise Phasing

���� in lakh

Sl. No.

Particulars Total Estimate, ��������

Year-wise Phasing

Yr - 1 Yr - 2 Yr - 3 1 Service Buildings, structures &

other civil works including water supply, roads & culverts and development works etc.

14723 0 8,834 5,889

2 Plant & Machinery 18,337 0 11,002 7,335 3 Others 3.1 Furniture & Fittings 30 0 18 12 3.2 CR Preparation, Bid Process

Management, EIA/EMP, Scrutiny of drawings, Author supervision during construction etc.

600 265 255 80

Total Initial Capital 33,690 265 20,109 13,316

(Rupees Three Hundred Thirty Sixty Crore Ninety Lak h only)

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APPENDIX – 2

311713098 A-2

Statement Showing Estimated Cost of Production of 33.5 � 0.5% ash Washed coal & Cost Benefit Analysis

Average, A A+1 A+2 A+3 A+41 Raw Coal Ash% 41.50 42.50 43.50 44.50 45.501 GCV, kcal/kg 3922.17 3828.06 3733.94 3639.83 3545.722 Grade of Coal G-12 G-12 G-12 G-13 G-133 Raw Coal Input, Mty 10.00 10.00 10.00 10.00 10.004 Yield of Clean Coal, % 74.62 71.44 68.27 65.10 61.925 Washed Coal Output, Mty 7.46 7.14 6.83 6.51 6.196 Yield of Rejects, % 25.38 28.56 31.73 34.90 38.087 Reject generation, Mty 2.54 2.86 3.17 3.49 3.81

1 a) RoM Coal, Grade's Basic Price 660.00 660.00 660.00 610.00 610.00b) Royalty 92.40 92.40 92.40 85.40 85.40c) Stowing Excise Duty (SED) 10.00 10.00 10.00 10.00 10.00d) Crushing Charges for top size 100 mm 79.00 79.00 79.00 79.00 79.00e) Clean Energy Cess 50.00 50.00 50.00 50.00 50.00f) Operating cost per tonne of Raw Coal Input 114.81 114.81 114.81 114.81 114.81

2 Cost of Washed Coal Production per tonne of Raw Coal Input [� a) to f)] 1006.21 1006.21 1006.21 949.21 949.21

3 Total Cost of Production per tonne of Washed Coal Output 1348.53 1408.42 1473.89 1458.17 1532.894 Desired Selling Price of Washed Coal at12% IRR,�� per tonne 1423.45 1486.67 1555.77 1539.33 1618.385 Selling Price of Washed Power Coal, Piparwar Washery , CCL (Exclusive

of ST & applicable levies)1746.42 1746.42 1746.42 1746.42 1746.42

6 Profit per tonne of washed coal (based on Piparwar Washed Coal Price), � per tonne

397.89 338.00 272.53 288.25 213.53

7 Annual Profit (based on Piparwar Washed Coal Price ) � Crore 296.89 241.47 186.06 187.64 132.238 Payback Period (based on Piparwar Washed Coal Price), Year 1.13 1.40 1.81 1.80 2.55

COST BENEFIT ANALYSIS AT DIFFERENT RAW COAL ASH

Sl. No.

Raw Coal AshParameters

NOTE : Selling Price of Washed coal of 34% ash is that prevailed at Piparwar washery, CCL = ��1746.42/ tonne.

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311713098 D-1

WASHABILITY CURVES

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311713098 D-2

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cmp

From: "Gm washery" <[email protected]>Reply -To: "Gm washery" <[email protected]>Date: Tue, 21/10/2014 12:35pmTo: cmp <[email protected]>Subject: Re: Request for price of washed coal of Piparwar Washery

Dear Sir, The price of Non-Coking Washed Coal in respect of Piparwar CPP for your needful is 1746.42 Rs ( exclusive Sales Tax & applicable Levies). On Tue, Oct 21, 2014 at 12:26 PM, cmp <[email protected]> wrote:

���������,

This has reference to the telephonic discussion had on date. We request you to kindly furnish price of washed coal of Piparwar washery.

(B.K.Dey) General Manager (CP) CMPDI (HQ), Kanke Road, Ranchi-834031 Contact : +91-651-2230141(O), CMPDI Official MAIL For Office Purpose Only

-- General Manager(WS/WCD) Central Coalfield Limited Ranchi CMPDI Official MAIL For Office Purpose Only

Page 1 of 1

21-Oct-2014http://mail.cmpdi.co.in/webmail/blank.jsp E - 2

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