वाशरी
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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.
The Washed Coking Coal is meant for Steel Plants. The Washed Power Coal/Washed Non-Coking Coal/Middlings is dispatched to various Power Houses.
Washing Process: |
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| Washery | System of Washing | ||
| Dugda-II | HM Cyclone (13-0.5mm), Flotation (-0.5mm) | ||
| Bhojudih | Deshaling Jig (75-0mm), HM Bath (75-25mm), | ||
| Batac Jig (25-0.5mm), Flotation (-0.5mm) | |||
| Patherdih | Deshaling Jig(75-0mm), HM Bath(75-13mm), | ||
| HM Cyclone (13-0.5mm) | |||
| Sudamdih | 2 Stage HM Cyclone (37-0.5mm), Flotation (-0.5mm) | ||
| Moonidih | 2 Stage HM Cyclone (30-0.5mm),W/O Cyclone(-0.5mm) | ||
| Mohuda | HM Cyclone (25-0.5mm), Flotation (-0.5mm) | ||
| Madhuban | Batac Jig (13-0.5mm), Flotation(-0.5mm) |
| Name of Washery | Year of Commissioning | Operable Capacity(MTY) | |
A. Coking Coal: |
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| 1 | Dugda-II | 1968 | 2.00 |
| 2 | Bhojudih | 1962 | 1.70 |
| 3 | Patherdih | 1964 | 1.60 |
| 5 | Moonidih | 1983 | 1.60 |
| 4 | Sudamdih | 1981 | 1.60 |
| 6 | Mohuda | 1990 | 0.63 |
| 7 | Madhuban | 1998 | 2.50 |
| TOTAL (Coking Coal) | 11.63 | ||
| B. Non-Coking Coal: | |||
| 1 | Dugda – I | 1961/1998 | 1.00 |
| TOTAL (Non-Coking Coal) | 1.00 | ||
| GRAND TOTAL | 12.63 |
| Remarks: | |||
| 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. | |||
| 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. | |||
| Modernization of Washeries: | |||
| ► | Revival Plan of BCCL provides Rs. 125 Crores for Renovation of Washeries. | ||
| ► | Study was undertaken by CMPDI for performance improvement. | ||
| ► | 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. |
PERFORMANCE OF BCCL WASHERIES
| (Fig in ‘ 000 T) | |||
| Year | R/C Feed | W/C Prodn. | W/C Desp. |
| Coking: | |||
| 2006-07 | 3129.1 | 1660.4 | 1665.8 |
| 2007-08 | 3177.2 | 1661.5 | 1679.8 |
| 2008-09 | 3313.8 | 1604.5 | 1588.6 |
| Non-Coking | |||
| 2006-07 | 4349.1 | 2717.3 | 1072.2 |
| 2007-08 | 890.9 | 788.4 | 822.4 |
| 2008-09 | 794.4 | 868.5 | 876.7 |
CONSUMERWISE DESPATCH:
| a) Washed Coal : | (Fig in ‘ 000 T) | ||
| Steel Plant | 2006-07 | 2007-08 | 2008-09 |
| B S L | 559.7 | 670.7 | 441.5 |
| B S P | 353.2 | 353.4 | 451.7 |
| D S P | 222.5 | 313.2 | 231.2 |
| R S P | 291.7 | 304.7 | 261.5 |
| IISCO | 238.8 | 18.9 | 23.2 |
| DPL | – | – | 15.2 |
| RINL | – | 18.8 | 164.2 |
| Total | 1665.8 | 1679.7 | 1588.6 |
| b) W/Power Coal : | (Fig in ‘ 000 T) | ||
| Power Plant | 2006-07 | 2007-08 | 2008-09 |
| BSL | 209.3 | 7.0 | 11.7 |
| BSP | – | – | 8.2 |
| BPSCL | – | 84.2 | 131.3 |
| DSP | 21.0 | 3.8 | 88.5 |
| RSP | – | 3.6 | 14.3 |
| DCOP | 838.4 | – | – |
| KTPP | – | 3.6 | – |
| Panipath | – | 720.1 | 618.9 |
| Ropar | 3.6 | 0.0 | 3.7 |
| Total | 1072.3 | 822.5 | 876.7 |
| c) Middlings : | (Fig in ‘ 000 T) | ||
| Power Plant | 2006-07 | 2007-08 | 2008-09 |
| Bhatinda | – | – | – |
| BPSCL | – | 93.3 | 28.7 |
| BSL | 288.3 | 24.9 | 16.1 |
| BSP | – | – | 3.0 |
| DSP | 260.1 | 174.3 | 164.2 |
| IISCO | 0.7 | – | – |
| KTPP | 7.2 | 32.3 | 156.6 |
| MTPS | 346.5 | 553.2 | 416.6 |
| NALCO | – | 14.3 | – |
| Panipath | 3.8 | – | – |
| RSP | – | 3.8 | 17.6 |
| STPS | 120.8 | 139.4 | 104.7 |
| Total | 1027.3 | 1035.5 | 907.5 |
| DESPATCH OF SLURRY & REJECTS: | (Fig in ‘ 000 T) | ||
| By-Product | 2006-07 | 2007-08 | 2008-09 |
| Slurry | 120.6 | 62.7 | 420.1 |
| Reject | 183.8 | 85.7 | 80.6 |
| 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:-
- 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%.
- Dispatches of Washed Power Coal also registered a growth of about 7% over Washed Power Coal dispatches during the year 2006-07.
- 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.
- BCCL Washeries (other than Madhuband) have recorded an increase in profit of 55.6% during 2008-09 as compared to 2007-08.
- Increase in the dispatch/sale of Slurry during 2008-09 as compared to 2007-08.
- All Washeries continue to maintain Closed Water Circuit and “Zero Discharge” is ensured.
- Employees’ welfare, safety, training and community development continued to be the other focus areas.
PROFIT/LOSS STATEMENT OF BCCL WASHERIES
Amt. in Rs. Lakhs
| Washery | 2006-07 | 2007-08 | 2008-09 |
| Dugda-I | 633.2 | 2.7 | -97.9 |
| Dugda-II | 2664.5 | 2066.8 | 6129.8 |
| Bhojudih | 2235.5 | 2429.1 | 7966.0 |
| Patherdih | -813.3 | -1438.0 | -3712.7* |
| Sudamdih | 1436.3 | 410.0 | 66.0 |
| Moonidih | 3713.4 | 3596.4 | 328.3 |
| Mohuda | 896.0 | -140.4 | 96.9 |
| Total | 10765.6 | 6926.6 | 10776.4 |
* The loss of Patherdih includes Rs. 24.0 Crores
provision for stock deterioration.
PROPOSED WASHERIES AT BCCL
| Name of the Washery | Capacity (Mtpa) |
| NLW: | |
| Madhuban | 5.0 |
| Patherdih | 2.5 |
| Dugda | 2.5 |
| Sub-Total | 10.0 |
| Non Coking: | |
| Patherdih | 5.0 |
| Bhojudih | 2.0 |
| Dahibari | 1.6 |
| Sub-Total | 8.6 |
| G.Total | 18.6 |
ENVIRONMENTAL AWARENESS Major Pollution Control Measures taken in BCCL Washeries:
- Effluent treatment / Re-circulation arrangement
- Water Sprinkling in a radius of nearly 2 km of the Washery
- Tree Plantation around Washery premises and colonies done every year.
- Rain Water Harvesting
Other key activities for effective pollution control:
- 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.
- The recycling pumps have been fully renovated and are operating under strict supervision to avoid any out flow of even clear water.
- 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:-
| By-Product | 2006-07(‘000T) | 2007-08(‘000T) | 2008-09 (‘000T) |
| Middlings | 1027.3 | 1035.5 | 907.5 |
| Slurry | 120.6 | 62.7 | 420.1 |
| Reject | 183.8 | 85.7 | 80.6 |
Future Plans:
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Capital replacements wherever required in the existing system of pollution control measure will be carried out.
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Fine coal circuit will be modernized with automation and instrument control system.
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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:
| Name of Unit | Camp Organised Date | |||
| Washery Division Dispensary | i. | Hypertension Camp | 4.12.08 | |
| ii. | Village Health Checkup camp | 22.12.08 | ||
| iii. | Health awareness camp | 9.01.09 | ||
| iv. | Aids awareness camp | 19.01.09 | ||
| v. | Mobile van-village health checkup done in different villages. | 4.02.09 to 06.02.09 | ||
| Dugda Coal Washery | i. | Baby Show | 12.02.09 | |
| ii. | School Health Checkup Programme | 26.02.09 | ||
| iii. | Health Awareness Camp | 28.02.09 | ||
| iv. | Wellness Clinic (CSR) at Hospital | Daily | ||
| v. | Mobile van-village health checkup done in different villages & medicine distributed | 17.02.09 to 21.02.09 | ||
| Bhojudih Coal Washery | i. | Health Awareness Camp | 14.12.08 to 09.01.09 | |
| ii. | Aids awareness programme | 27.01.09 | ||
| iii. | BP checkup Camp | 12.02.09 | ||
| Patherdih Coal Washery | i. | BP checkup Camp | 10.01.09 | |
| ii. | Diabetes detection Camp | 15.11.08 | ||
| iii. | Mobile van-village health checkup done in different villages. | 30.12.08 to 31.12.08 |
