Detailed Project Report on Coal Washing Unit

COAL WASHING UNIT

[EIRI/EDPR/3417] J.C.: 1499XL

INTRODUCTION

Coal washing is a process that is undertaken in a coal washery or coal preparation plant (CPP) where coal is refined or cleaned of impurities. Coal washing involves using water, mechanical techniques and relies on gravity and the difference of density between coal and it's impurities which are usually more densely packed due to the fact that they are inorganic.

Benefits of Using Washed Coal:

• Increased generation efficiency, mainly due to the reduction in energy loss as inert material passes through the combustion process.

• Increased plant availability.

• Reduced investment costs.

• Reduced operation and maintenance (O&M) costs due to less wear and reduced costs for fuel and ash handling.

• Energy conservation in the transportation sector and lower transportation costs.

• Less impurities and improved coal quality.

• Reduced load on the air pollution control system; and Reduction in the amount of solid waste that has to be disposed off The following are the details of the coal washeries in India (2007-08).

COST ESTIMATION

Plant Capacity  12,000 MT/Day

Land & Building (1,60,000 sq.mt) Rs. 54.30 Cr

Plant & Machinery  Rs. 20.52 Cr

Working Capital for 2 Months  Rs. 3.31 Cr

Total Capital Investment  Rs. 80.46 Cr

Rate of Return  29%

Break Even Point 53%

CONTENTS

INTRODUCTION

BENEFITS OF USING WASHED COAL:

TYPES OF COAL

COAL GRADES

GRADES OF COKING COAL

GRADES OF NON-COKING COAL

GRADES OF SEMI-COKING AND WEAKLY COKING COAL

GRADES OF NEC COAL:

PRODUCT SPECIFICATION

PROPERTIES OF COAL

7. REACTIONS OF COAL:

8. FRIABILITY:

9. GRINDABILITY:

10. WEATHERING OR SLAKING INDEX:

11. AGGLUTINATING (COKING):

USES AND PPLICATION OF COAL WASHERY

COAL GRADES

COAL AVAILABILITY IN DIFFERENT GRADES, AVERAGE USEFUL

HEAT VALUE, GROSS CALORIFIC VALUE AND LINKED CONSUMERS.

B.I.S. SPECIFICATION

WASHING PROCESS OF COAL

DESCRIPTION OF PROCESS

PRE-TREATMENT SECTION

COAL PREPARATION

COAL PREPARATION PROCESS

TYPICAL STEPS IN COAL PREPARATION INCLUDE:

WASHING SECTION

MEDIA PREPARATION & REGENERATION CIRCUIT

MARKET POSITION

FUTURE OF COAL WASHING INDUSTRY

UPCOMING COKING COAL WASHERIES IN COAL INDIA LIMITED

SCOPE FOR RESEARCH AND DEVELOPMENT

CONCLUSIONS

COAL & LIGNITE

RESOURCES

COAL

LIGNITE

EXPLORATION & DEVELOPMENT

PRODUCTION AND STOCKS

COAL

PRODUCTION

DISPATCHES

STOCKS

LIGNITE

PRODUCTION

DISPATCHES

STOCKS

MINING & MARKETING

COAL

LIGNITE

POLICY–CAPTIVE COAL AND LIGNITE BLOCK ALLOCATION

FOREIGN COLLABORATION

COAL WASHERIES

IMPORT POLICY OF COAL

FDI POLICY

CLASSIFICATION AND GRADES

CONSUMPTION

DEMAND & SUPPLY

WORLD REVIEW

AUSTRALIA

CHINA

INDONESIA

RUSSIA

FOREIGN TRADE

EXPORTS

IMPORTS

FUTURE OUTLOOK

PLANT LAYOUT

MANUFACTURERS/SUPPLIERS OF WASHED COAL

SUPPLIERS OF RAW MATERIALS

SUPPLIERS OF RAW COAL

SUPPLIERS OF MAGNETITE POWDER

SUPPLIERS OF FLOCULANT CHEMICALS

SUPPLIERS OF PLANT AND MACHINERY

SUPPLIERS OF COAL WASHERY PLANT AND MACHINERY

EOT CRANE

SUPPLIERS OF POWER TRANSFORMER

SUPPLIERS OF ELECTRICAL PANEL

SUPPLIERS OF COOLING TOWER

EFFULENT TREATMENT PLANT

AIR POLLUTION CONTROL EQUIPMENTS

AIR CONDITIONING EQUIPMENTS

AIR COMPRESSORS

PLATFORM WEIGHING MACHINE

MATERIAL HANDLING EQUIPMENTS

FIRE FIGHTING EQUIPMENTS

SHOT BLASTING MACHINE

JIGS AND FIXTURE

SUBMERSIBLE WATER PUMP

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)