UTILIZATION OF WASHERY REJECTS IN GENERATION OF
UTILIZATION OF WASHERYREJECTS IN GENERATION OFPOWERINCENTRAL COALFIELDS LIMITEDbyR.P.RITOLIA, CMD, CCL AND A.K.SINGH,DT(O),CCL
Central Coalfields LimitedCCL inJHARKHAND
CCL – LOOKING AHEAD2016-17 : 115 MT Coal(Terminal Year of XII Plan)2011-12 : 78 MT Coal(Terminal Year of XI Plan)2006-07 : 41.32 MT Coal(Terminal Year of X Plan)2001-02 : 33.81 MT Coal(Terminal Year of IX Plan)
Central Coalfields Limited THEN & NOWTHEN1956 :1972 :1973 :1975 :1986 :Formation Of Public Sector Company –National Coal Development Corporation Ltd.Nationalisation of Coking Coal Mines.Nationalisation of Non-Coking Coal Mines.CENTRAL COALFIELDS LIMITED – Reorganisedunder Coal India Limited - Holding CompanyTruncation of CCL , Formation of NCL(Singrauli) &MCL (Talcher)INHERITED- a large number of small mines WITH Large workforceRESULTED9 CCL was left with 55% production capacity with 85%manpower of erstwhile Company9 Large and productive mines producing high volume (45%production) with less men (15% men) have gone to otherCompaniesNOW : 11 Areas , 63 Mines
Presently CCL has Operating Mines : 63 Mines grouped in 11 Areas(26 Underground 37 Opencast)Washeries: 7 (4 Medium Coking Coal 3 Non-Coking Coal)Operating Coalfields: 6 (East Bokaro, WestBokaro, North Karanpura ,South Karanpura, Ramgarh,& Giridih)Workshop: 1 Central Workshop (ISO 9001Certified) 5 Regional Workshops(3 of them ISO 9001 Certified )
OPERATING COALFIELDS OF CCL COMMAND AREA66. Giridih4. West Bokaro1541. North Karanpura5. East Bokaro233. Ramgarh2. South KaranpuraCOALFIELDSRANCHIAREAS1. NKPANK , Piparwar, Rajhara2. SKPABarka-Sayal,Argada3. RAMGARHRajrappa4. WEST BOKAROHazaribagh,Kuju5. EAST BOKAROB&K, Dhori, Kathara
Coal Reserves of CCL, BCCL & ECL in Jharkhand State up to1200 meter in Billion Tonnes (As on 1.4.07)ECLCCL38.41 (52%)16.55 (22%)19.43 (26%)BCCLCCL Coal Reserve is 38.41 billion tonnes ascompared to country coal reserve of 257.38 billiontonnes (i.e. 15% of the country total Coal reserve )
Geological Coal Reserves in CCL Command Area Up to300m & above depth (as on 1.4.2007)ReserveDepth 0-300mDepth 300-1200 mTotal(BT)Proved(BT)Indicat Inferreedd(BT)(BT)Total(BT)Proved(BT)Indicat Inferreedd(BT)(BT)Total(BT)Coking Coal5.8713.731 0.0489.6500.9604.962 1.6137.47517.125Non-CokingCoal10.533 3.490 1.090 15.1130.5763.481 2.1156.17221.285Total16.404 7.221 1.138 24.7631.5368.383 3.728 13.64738.410(65%)(35%)Depth 0 -1200 015.6044.86638.410
BACKGROUNDIndia is embarking on transformation fromdeveloping economy to developed economy. Electricity Act 2003 and National Electricity Policycreated conducive environment for growth ofPower Sector commensurate with economy. Need of the hour – Strategic planning of energyresources for sustainable development over longtime horizon. Washing of non-coking coal for power utilizationmay become the norm in future. Gainful utilization of reject produced bybeneficiation of raw coal has evoked considerableinterest in recent / future times.
INTRODUCTION Indian economy has grown at 6.1 per cent during Xthand IXth Five Year PlansProjected growth rate of economy at 8 per cent and9.3 per cent respectively for the Xth and XIth FiveYear PlansRate of growth demands a commensurate growth inpower generation. Hence required to produce 1029Bkwh unit of electricity by 2011-12 (the terminal yearof 11th Plan )For growth, power is essential but with minimumimpact on environment. Hence, clean coaltechnology is required.
NEED FOR BENEFICIATION Less quantity of high quality coal reserves inrelation to growing demandHigh cost of transportation of dirt along with coaland its subsequent disposal as ash or slag addingto the cost, thus, more captive investment.Disposal of ash by consumers is a difficult problemIncreased demand of lower ash coal i.e. highcalorific value fuel.Environmental awareness and requirement at usersend.Greater concern and consciousness of consumersabout quality.
BENEFITS OF USING WASHEDNON-COKING COAL Improved Plant performance, Plant utilization factor(PUF), Capacity utilization.Reduction in specific fuel consumptionReduced down time and less corrosion, increased lifeand operating efficiency of boilersReduced capital cost on coal handling plants, downtime, auxiliary power consumptionReduced maintenance of boiler and its auxiliariesReduced smoke and dust omissionIncreased electricity generationSaving in land area for ash dumpingImprovement in environment by reduction ofemission of GHG.
Advantages of using beneficiated coal(study conducted by CMPDI at Satpura TPS )SNParametersBenefits1.CHPFrequent jamming that was taking place with ROMcoal was avoided with beneficiated coal due touniform size, absence of foreign materials.2.Coal MillsLow ash content in the beneficiated coal resulted inreduction of down time and the No. of mills in use.3.Furnace, Boilertube etc.With beneficiated coal furnace wall slagging / boilertube leakage / clinker formation /abnormal erosion,etc. was not reported.4.Low grade coalreserves.Exploitation of low-grade coal reserves which thecountry has in plenty is possible and whichotherwise could not be utilized without beneficiation.5.EnvironmentContribution to better surrounding environment atpower station due to less emission of smoke anddust.6.Railway utilityBetter utilization of railway rolling stock
Study conducted by CMPDI at Dadri TPSS. NO.ParametersQualitative Impacts1Saving in demurrage to RailwaysRe 1/te of coalreceived2Increase in operating hoursUpto 10%3Increase in PLFUpto 3.78%4Increase in PUFUpto 11.78%5Reduction in breakdown periodUpto 60%6Increase in overall efficiencyUpto 1.2%7Increase in generation / day2.4 MU8Reduction in support fuel oil0.35 ml/kwh9Reduction in sp. Coal Consumption0.048 Kg/kwh10Reduction in heat rateUpto 87 K.Cal/kwh11Reduction in sp.Coal Consumption0.048 Kg/kwh12Increase in total units sent out / day2.3 MU13Saving in land area for ash dumping1 acre in a year14Reduction in CO emission on accountof transportation & combustion of coal 6,00,000 te in a year
PROCESS FOR aracteristics and coal dirt size , the beneficiationprocess shall be selected which shall incorporateeither in separation or in combination the followingwashing equipments: Improved type jig Heavy media bath Heavy media drum separator Heavy media cyclone Dry processes
Piparwar Washery (Non Coking Coal)
COST SHEET OF A NON COKING COAL WASHERYS.NO.12345678COST/Te (clean coal)Raw coal costProcess costAdministrative costDepreciationInterestTotal CostSale value of productTotal ProfitAMOUNT (In Source : Cost Sheet of Kagali Washery , May’07 If reject value is Rs 400 per tonne the profit willenhance by Rs. 80 per tonne.
ISSUES TO BE ADDRESSED The MoEF stipulation of using coal having Ashbelow 34% in the power plants located at distancebeyond 1000 Km. needs to be implemented in viewof the savings on account of railway freight as wellas environmental requirement particularly reductionof CO2 emissions for reducing greenhouse gas effectLong term agreement between the consumer and thecoal producer to pay additional cost of thebeneficiated coal must be entered into at the time ofinvestment decisionCIL has directed to off-load the work of constructionof new non-coking coal preparation plants on BOMbasis
ISSUES TO BE ADDRESSED Utilization of rejects produced from the beneficiationplants at mine-head in PBC Boilers for PowerGeneration instead of back filling of voids in opencast mines . has to make the beneficiation of noncoking coal more attractiveAs Coal beneficiation makes feasible the adoption ofadvanced power generation technologies such asintegrated gasification and combustion cycle (IGCC)system and pressurized fluidized bed combustion(PFBC) attractive for the Engg., Economic andEnvironmental perspective, the futuristic approachshould be for adoption of these technologies toenhance the overall capacity of electricity generationand gainful utilization of even inferior grade of coal /by-product, to the extent possible
WASHERY REJECTS Coal beneficiation plants produce rejects incoking as well as non-coking coal washeriesvarying from 10 to 20% of the feedRejects contain around 15-20% carbon and1600 to 3100 Gross calorific valueDue to non availability of suitable technologyfor use of such low heat value coal washingrejects, CCL piled up a stock of 12.81 milliontones( coking coal washeries 8.15 milliontones and at non-coking coal washeries 4.66million tonne.)Existing washeries are producing about 2.3million tonne of reject every year
REJECT GENERATION BY EXISTING WASHERYName of washeryCapacity inMTY(A) Coking 9.35(B) NON COKING COALGIDI2.5PIPARWAR6.5KARGALI2.72TOTAL11.72Reject generatedper year0.360.090.360.3121.1220.51.30.5442.344
REJECT GENERATION BY PROPOSED WASHERYPROPOSED WASHERIESName of washeryCapacity in MTY Rejects generatedper year(A) Coking CoalDHORI2.50.306TOTAL2.50.30610.02.00PIPARWAR 90(B) NON COKING COALASHOKAGrand Total (Existing & Proposed)7.720
Existing and proposed capacityof washery in sed19.502.5022.00Total31.2211.8543.07
TOTAL POWER REQUIRED BY CCLBY 2011-12The estimated power demand of CCLis anticipated to go up from thepresent demand of 137 MVA to 215MVA by the year 2011-12 (terminalyear of XI th Plan )
AREAWISE ANNUAL AVERAGE ENERGY CONSUMPTION & COSTFOR THE YEAR 2006-07AreaAverage Powerconsumption inMKWHAverage Power cost in RS16.465.520TOTAL CCL667.97224.029
PRESENT UTILIZATION OF WASHERY REJECTS BY CCLCCL HAS INSTALLED 3 CAPTIVE POWER PLANTS OF 2X10 MWCAPACITIES EACH AT FOLLOWING PLACES BASED ON FBCTECHNOLOGY UTILIZING WASHERY REJECTS. ALL THESE CPPs AREBASED ON MODERN FLUIDISED BED COMBUSTION TECHNOLOGYBURNING WASHERY REJECTS CONTAINING ASH 60% AND GCVVARYING FROM 1600 TO 3100 KILO CAL. PER KG.S.NO.LOCATIONSIZE MW2500The plant erected by BHELon turnkey basis in 19952GIDI1X10 MW 2100M/s.DLF Power Co.Commissioned the plant onBuild, Own & Operate basisfor CCL in 19993RAJRAPPA1X10 MW 2550M/s.DLF Power Co.Commissioned the plant onBuild, Own & Operate basisfor CCL in 2000
FINANCIAL BENEFITS FOR CCL FROM EXISTING 40MW CPP’s UTILISING WASHERY REJECTS FORGENERATION OF POWER2X10 MW KATHARA CPP TOTAL ENERGY GENERATED BY 2X10 MW KATHARACPP 80.95 MKWHTARIFF AT WHICH PAYMENT IS MADE Rs.2.75/UNITAVERAGE TARIFF OF SUPPLY AGENCY AS ON TODAY Rs.3.35/UNITSAVING PER ANNUM Rs. 4.85 CRORES1X10 MW GIDDI & 1X10 MW RAJRAPPA CPP’s TOTAL ENERGY GENERATED BY 1x 10 MW GIDI &1X10 MWRAJRAPPACPP’s PER YEAR 58 MKWH TARIFF (ADHOC) AT WHICH PAYMENT IS MADE RS. 2.07/UNIT AVERAGE TARIFF OF SUPPLY AGENCY AS ON TODAY Rs. 3.35/UNIT SAVINGS PER ANNUM Rs.7.42 CRORESTOTAL PROFIT FOR CCL Rs.12.27 CRORES
Kathara CPP
PROCESS FLOW CHART OF FBCTECHNOLOGY BASED CPP1. WASHERY REJECT CIRCUITWASHERY REJECTGRIZZLY HOPPER 6MMVIBRATING SCREEN-6MMCRUSHERCOAL BUNKERCOAL FEEDERAIR COAL MIXINGNOZZLEFURNACEFLUE GAS PATHSUPER HEATERECONOMISERAIR PREHEATERELECTROSTATICPRECIPITATORCHIMNEY
2.WATER CIRCUITDEAERATOR TANKFEED PUMPECONOMISERSTEAM DRUMWATER WALLAFTER HEATEREVAPORATORPRIMARY SUPERHEATERSECONDARYSUPER HEATERGENERATORTURBINECONDENSER
ECONOMICS OF POWER STATIONS INDIFFERENT CASESCase I - Comparison of Economics for coal basedThermal Power Station using Raw Coal /Clean CoalS. No.ASH PERCENTAGE OFCOAL140 % ASH CONTENT ROMCOST OFELECTRICITYGENERATIONRS. 1.55 PER UNIT244 % ASH CONTENT ROMRS. 1.52 PER UNIT340 % ASH CONTENT ROMWASHED TO 34 %RS. 1.61 PER UNIT444% ASH CONTENT ROMWASHED TO 34 %RS. 1.64 PER UNIT
ECONOMICS OF POWER STATIONS INDIFFERENT CASESCASE-II. Cost of generation for 20 MW FBC thermalPower Plant without fuel cost for Power generation 1Crore unit/ month at Kathara(A) Fixed CostAmount in Rs.i) Interest & Depreciation of the Plant0.70ii) Repair & maintenance including store 0.30iii) Salary & Wages0.12TOTAL1.12(B) Variable Cost0.08(C) Total cost of generation withoutConsidering fuel(Reject ) Cost1.30
ECONOMICS OF POWER STATIONS INDIFFERENT CASESCASE –III. Cost of generation for 20 MW FBC Plantincluding fuel( Reject ) Cost for generation 0f 1Crore unit/ monthi) Consumption of fuel ( Reject) - 2.3 Kg/ unitii) Cost of reject/tonne including - Rs 400/ tonnetaxes as applicableiii) Fuel ( Reject) charge for- Rs. 0.92generation of one unitiv) Cost of generation- Rs. 1.30v) Total Cost of generation- Rs. 2.22with fuel ( Reject)
FINANCIAL BENEFITS FOR CCL AFTER PROPOSEDUTILIZATION OF REJECTS IN GENERATION OF POWER: Captive Power Plants to be installed: 140 MW(including existing 40 MW)Assuming PLF of 80%, the net capacity : 112 MWwould beTotal energy to be generated by the CPPs : 967.68 M.unitsAverage tariff of supply agency as on today: Rs.3.35/UnitTotal amount to be paid: Rs.324 CroresTotal amount to be paid @Re.2.75/unit :Rs.266 Crores(Present interim tariff to CPP Operator)NET SAVING:Rs.58 Crores
PhotographsofNon coking coal washeryandlinked power plantbased on rejectatArgada Area in CCL
Giddi Washery(A Non coking coal washery)
Primary Crusher
Raw Coal receive section
Heavy Media Disha bath
Komag Jig
Vibrating screen
Thickner
Loading of clean coal
Reject heap
Power plant based on utilisation of Rejectgenerated from Non coking coal washery
Coal bunkers and Boiler
Inside view of boiler
Burnt coal from Power plant
Steam Propeller
Generating unit
Coal bunkers at CPP
CONCLUSION For the economic growth of country, one has todepend on coal and its reserve.To enhance the life of reserve, gainful utilizationof washery rejects must be thought which ishaving 10-20% carbon.As the existing utilization of reject coal is verymeager ,more capacity addition is required tostop the drainage of energy as such effectivereject utilization has been considered a thrustarea with the following emphasisAdoption of super critical technologyCirculating Fluidised bed combustion technologyPressurised Fluidised bed combustiontechnology
CONCLUSION This will also facilitate pollution freeatmosphere.Instead of using washery reject for filling thevoids of mines, fly ash produced by FBCpower plant can be utilized and top layershould be covered by soil for properplantation.
SUGGESTION Assistance from partner countries for developmentof suitable economical technology for utillizationof low value Coking/Non Coking washery rejectswhich will ultimately help the improvement inenvironment by reduction of emission of GHG.Assistance from Govt. in the form of tax–rebate &other commercial duties in order to establish lowcost FBC Technology power Houses to make themCommercially ViableAssistance from partner countries is needed foradoption of Super Critical Technology ,so thatutilization of washery Rejects having GrossCalorific value varying from 1600-2100 kcals/kg.may be efficiently utilized
National Coal Development Corporation Ltd. 1972 : Nationalisation of Coking Coal Mines. 1973 : Nationalisation of Non-Coking Coal Mines. 1975 : CENTRAL COALFIELDS LIMITED – Reorganised under Coal India Limited - Holding Company 1986 : Truncation of CCL , Formation of NCL(Singrauli) & MCL (Talcher) INHERITED
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