Washery
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Introduction : |
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Coal Washing is a process of separation mainly based on difference in Specific Gravity of Coal and associated impurities like Shale, Sand & Stones etc so that we get relatively pure marketable coal without changing its physical properties. |
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The Washed Coking Coal is meant for Steel Plants. The Washed Power Coal/Washed Non-Coking Coal/Middlings is dispatched to various Power Houses. |
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Washing Process: |
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Washery |
System of Washing |
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Dugda-II |
HM Cyclone (13-0.5mm), Flotation (-0.5mm) |
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Bhojudih |
Deshaling Jig (75-0mm), HM Bath (75-25mm), |
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Batac Jig (25-0.5mm), Flotation (-0.5mm) |
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Patherdih |
Deshaling Jig(75-0mm), HM Bath(75-13mm), |
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HM Cyclone (13-0.5mm) |
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Sudamdih |
2 Stage HM Cyclone (37-0.5mm), Flotation (-0.5mm) |
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Moonidih |
2 Stage HM Cyclone (30-0.5mm),W/O Cyclone(-0.5mm) |
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Mohuda |
HM Cyclone (25-0.5mm), Flotation (-0.5mm) |
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Madhuban |
Batac Jig (13-0.5mm), Flotation(-0.5mm) |
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Details of Existing Washeries : |
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S. No. |
Name of Washery |
Year of Commissioning |
Operable Capacity |
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MTY |
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A. Coking Coal: |
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1 |
Dugda-II |
1968 |
2.00 |
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2 |
Bhojudih |
1962 |
1.70 |
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3 |
Patherdih |
1964 |
1.60 |
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5 |
Moonidih |
1983 |
1.60 |
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4 |
Sudamdih |
1981 |
1.60 |
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6 |
Mohuda |
1990 |
0.63 |
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7 |
Madhuban |
1998 |
2.50 |
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TOTAL (Coking Coal) |
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11.63 |
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B. Non-Coking Coal: |
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1 |
Dugda - I |
1961/1998 |
1.00 |
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TOTAL (Non-Coking Coal) |
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1.00 |
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GRAND TOTAL |
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12.63 |
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Remarks: |
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Dugda-I stoped since Oct.'96 for safety reasons and its Sink Upgradation Section is being used for production of washed power coal w.e.f. '98. |
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Madhuban Washery was originally designed for washing Coking Coal.Due to non-availability of Coking Coal because of stoppage of Block-II OCP, the Washery was temporarily converted for Washing Non-Coking Coal which has been reverted back to washing coking coal again from October 2008. |
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Modernization of Washeries: |
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Revival Plan of BCCL provides Rs. 125 Crores for Renovation of Washeries. |
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Study was undertaken by CMPDI for performance improvement. |
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In the 1st Phase, the Revival Schemes involving an expenditure of Rs. 54.80 Crores has been approved by BCCL Board for Dugda-I, Dugda-II, Bhojudih, Sudamdih, Moonidih & Mohuda Washeries and they are under various stages of implementation. |
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PERFORMANCE: |
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(Fig in ‘ 000 T) |
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Year |
R/C Feed |
W/C Prodn. |
W/C Desp. |
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Coking: |
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2006-07 |
3129.1 |
1660.4 |
1665.8 |
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2007-08 |
3177.2 |
1661.5 |
1679.8 |
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2008-09 |
3313.8 |
1604.5 |
1588.6 |
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Non-Coking |
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2006-07 |
4349.1 |
2717.3 |
1072.2 |
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2007-08 |
890.9 |
788.4 |
822.4 |
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2008-09 |
794.4 |
868.5 |
876.7 |
CONSUMERWISE DESPATCH:
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a) Washed Coal : |
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(Fig in ' 000 T) |
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Steel Plant |
2006-07 |
2007-08 |
2008-09 |
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B S L |
559.7 |
670.7 |
441.5 |
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B S P |
353.2 |
353.4 |
451.7 |
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D S P |
222.5 |
313.2 |
231.2 |
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R S P |
291.7 |
304.7 |
261.5 |
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IISCO |
238.8 |
18.9 |
23.2 |
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DPL |
- |
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15.2 |
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RINL |
- |
18.8 |
164.2 |
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Total |
1665.8 |
1679.7 |
1588.6 |
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b) W/Power Coal : |
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(Fig in ‘ 000 T) |
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Power Plant |
2006-07 |
2007-08 |
2008-09 |
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BSL |
209.3 |
7.0 |
11.7 |
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BSP |
- |
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8.2 |
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BPSCL |
- |
84.2 |
131.3 |
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DSP |
21.0 |
3.8 |
88.5 |
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RSP |
- |
3.6 |
14.3 |
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DCOP |
838.4 |
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- |
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KTPP |
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3.6 |
- |
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Panipath |
- |
720.1 |
618.9 |
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Ropar |
3.6 |
0.0 |
3.7 |
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Total |
1072.3 |
822.5 |
876.7 |
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c) Middlings : |
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(Fig in ' 000 T) |
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Power Plant |
2006-07 |
2007-08 |
2008-09 |
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Bhatinda |
- |
- |
- |
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BPSCL |
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93.3 |
28.7 |
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BSL |
288.3 |
24.9 |
16.1 |
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BSP |
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3.0 |
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DSP |
260.1 |
174.3 |
164.2 |
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IISCO |
0.7 |
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- |
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KTPP |
7.2 |
32.3 |
156.6 |
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MTPS |
346.5 |
553.2 |
416.6 |
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NALCO |
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14.3 |
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Panipath |
3.8 |
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RSP |
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3.8 |
17.6 |
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STPS |
120.8 |
139.4 |
104.7 |
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Total |
1027.3 |
1035.5 |
907.5 |
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DESPATCH OF SLURRY & REJECTS: |
(Fig in ' 000 T) |
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By-Product |
2006-07 |
2007-08 |
2008-09 |
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Slurry |
120.6 |
62.7 |
420.1 |
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Reject |
183.8 |
85.7 |
80.6 |
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Total |
304.4 |
148.4 |
500.6 |
Performance Highlights of the Year 2008-09
The company has concluded the year 2008-09 with excellent performance,
as mentioned hereunder:-
n Production of Washed Power Coal increased from 7.9 LT in FY 2007-08 to 8.7 LT
in the FY 2008-09 i.e. a growth of about 10%.
n Dispatches of Washed Power Coal also registered a growth of about 7% over Washed Power Coal dispatches during the year 2006-07.
n Increase in Stock Liquidation during 2008-09 as compared to 2007-08. The Stock liquidation during 2008-09 valued Rs. 40.01 Crores as compared to Rs. 5.94 Crores during 2007-08.
n BCCL Washeries (other than Madhuband) have recorded an increase in profit of 55.6% during 2008-09 as compared to 2007-08.
n Increase in the dispatch/sale of Slurry during 2008-09 as compared to 2007-08.
n All Washeries continue to maintain Closed Water Circuit and “Zero Discharge” is ensured.
n Employees' welfare, safety, training and community development continued to be the other focus areas.
PROFIT/LOSS STATEMENT OF BCCL WASHERIES
Amt. in Rs. Lakhs
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Washery |
2006-07 |
2007-08 |
2008-09 |
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Dugda-I |
633.2 |
2.7 |
-97.9 |
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Dugda-II |
2664.5 |
2066.8 |
6129.8 |
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Bhojudih |
2235.5 |
2429.1 |
7966.0 |
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Patherdih |
-813.3 |
-1438.0 |
-3712.7* |
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Sudamdih |
1436.3 |
410.0 |
66.0 |
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Moonidih |
3713.4 |
3596.4 |
328.3 |
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Mohuda |
896.0 |
-140.4 |
96.9 |
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Total |
10765.6 |
6926.6 |
10776.4 |
* The loss of Patherdih includes Rs. 24.0 Crores
provision for stock deterioration.
PROPOSED WASHERIES AT BCCL
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Name of the Washery |
Capacity (Mtpa) |
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NLW: |
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Madhuban |
5.0 |
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Patherdih |
2.5 |
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Dugda |
2.5 |
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Sub-Total |
10.0 |
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Non Coking: |
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Patherdih |
5.0 |
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Bhojudih |
2.0 |
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Dahibari |
1.6 |
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Sub-Total |
8.6 |
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G.Total |
18.6 |
ENVIRONMENTAL AWARENESS
n Effluent treatment / Re-circulation arrangement
n Water Sprinkling in a radius of nearly 2 km of the Washery
n Tree Plantation around Washery premises and colonies done every year.
n Rain Water Harvesting
Other key activities for effective pollution control:
n Systematic and scientific excavation of the slurry ponds to make the space available for settling of fines in the ponds / dyke area itself and recycle back the clear water through pumps for re-use in the plant as process water.
n The recycling pumps have been fully renovated and are operating under strict supervision to avoid any out flow of even clear water.
n Market has been found for sale of old stock of slurry of the Washery.
Disposal of Washery By-products during the period 06-07 to 08-09 has been as follows:-
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By-Product |
2006-07 (‘000T) |
2007-08 (‘000T) |
2008-09 (‘000T) |
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Middlings |
1027.3 |
1035.5 |
907.5 |
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Slurry |
120.6 |
62.7 |
420.1 |
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Reject |
183.8 |
85.7 |
80.6 |
n Capital replacements wherever required in the existing system of pollution control measure will be carried out.
n Fine coal circuit will be modernized with automation and instrument control system.
n General awareness for eco-friendly environment among all concerned.
WELFARE MEASURES
Social Welfare programmes organised at various hospitals / Dispensaries
during 2008-09 are as follows:
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Name of Unit |
Camp Organised |
Date |
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Washery Division Dispensary |
i. |
Hypertension Camp |
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4.12.08 |
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ii. |
Village Health Checkup camp |
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22.12.08 |
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iii. |
Health awareness camp |
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9.01.09 |
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iv. |
Aids awareness camp |
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19.01.09 |
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v. |
Mobile van-village health checkup done in different villages. |
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4.02.09 to 06.02.09 |
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Dugda Coal Washery |
i. |
Baby Show |
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12.02.09 |
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ii. |
School Health Checkup Programme |
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26.02.09 |
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iii. |
Health Awareness Camp |
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28.02.09 |
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iv. |
Wellness Clinic (CSR) at Hospital |
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Daily |
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v. |
Mobile van-village health checkup done in different villages & medicine distributed |
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17.02.09 to 21.02.09 |
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Bhojudih Coal Washery |
i. |
Health Awareness Camp |
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14.12.08 to 09.01.09 |
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ii. |
Aids awareness programme |
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27.01.09 |
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iii. |
BP checkup Camp |
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12.02.09 |
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Patherdih Coal Washery |
i. |
BP checkup Camp |
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10.01.09 |
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ii. |
Diabetes detection Camp |
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15.11.08 |
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iii. |
Mobile van-village health checkup done in different villages. |
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30.12.08 to 31.12.08 |
