G C Mrig

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PRESENTATION ON COAL BENEFICATION AN AID TO
ENVIRONMENT PROTECTION

• By
• G C Mrig
• Managing Director
• Aryan Coal Benefications Pvt. Ltd.

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Introduction

• For meeting the requirement of Coal to Power
  Stations and other industries, coal production
  has rapidly increased from 1975 onwards.
• Most of the production came from open cast mining
  with inherent admixtures of stone/shale with
  coal. Therefore over the years there has been
  deterioration in the quality of coal.
• Moreover with depletion of good quality coal
  reserves, the problem of coal quality became
  more acute. Raw Coal being supplied at present is
  having a GCV of about 3900Kcal/kg and ash of
  39-42 .

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Role of Coal Beneficiation

• In 1998, Ministry of Environment Forest,
  Government of India, have stipulated that all
  Power Houses located in urban sensitive areas ,
  critically polluted areas or those located
  1000Kms. away from the pit head should
  necessarily use coal having less than 34 ash.
•  
• This has resulted in opening up of Coal
  Beneficiation sector in a very big way. It has
  an advantage of supply uniform size and quality
  of coal to the Power Stations.
• Coal Benefications is a generic term which is
  used for washing of coal and is done to lower the
  ash and increase the GCV.

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The Benefits At a glance

• Use of washed coal has resulted in substantial
  saving of transport cost, as the coal is carried
  over a long distance. The washed coal being
  supplied is having a GCV of 4700Kcal/kg and ash
  of 28-31. Use of washed coal results in less CO2
  emission.
• This has also reduced the quantity of fly ash
  produced by burning of coal. Less expenditure
  and less land are required for ash handling.
• A number of cement plants have constructed their
  grinding units near these Power Houses for use of
  fly ash in cement manufacturing. Most of the
  Cement so produced from these units was consumed
  in the nearby markets. Obviously, there are
  limitations to the use of fly ash in and around
  the Power Houses.

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ENVIRONMENTAL EFFECTS (The most important
aspects)

• Reduction in ash handling and saving in ash
  disposal land requirement.
• Improvement of the overall thermal efficiency
  resulting in lower CO2 emission for the nominal
  power generation.
• Savings in transport capacity between mines and
  power stations resulting in lower demand of
  diesel fuel for the railway engines and
  consequently lower CO2 emissions.

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Impact on Air Quality

• The air pollution level in respect of SPM will be
  reduced due to
• Lower dust emission during unloading and stocking
  of supplied coal as beneficiated coal has more or
  less a constant moisture content.
• Lower dust emission during the pre-crushing
  operations before milling. The beneficiated coal
  has a maximum top size of 50 mm. There is less
  crushing activities for beneficiated coal in
  comparison to raw coal which has sometimes a top
  size of more than 200 mm.
• The use of low ash coal, the concentration of SPM
  in the flue gas will get reduced resulting in
  reduced load of particulate in the ESP/ bag
  filter. At any particular efficiency level of
  operation for ESP/ bag filter, reduction in the
  particulate load of inlet gas shall reduce the
  emission of SPM thus improving the quality of
  air.

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Ash Generation Land Requirement for Disposal of
Ash
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Rejects

• While washed coal improves the efficiency of
  Power Stations and lowers the unit cost of
  generating power, they are facing the problem of
  accumulation of rejects _at_ 20-25 in the pit-head
  washereis.
• These rejects have a GCV of 1800Kcal/kg with ash
  per cent age of 60-63. This was one of the
  biggest challenges which were being faced by the
  washery operators. They were to ensure
  environmental friendly disposal of rejects.
  friendly disposal of rejects.
• A time had also come when the washery operators
  were forced to close down their washeries as
  they were left with no space for the storage of
  these accumulated washery rejects.

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The solution

• After a detailed study, we found that these
  rejects can be used as a Fuel for generation
  thermal power, with a blend of right technology.
• Using the Fluidized Bed Boiler Technology , Aryan
  started its first Thermal Power Project at
  Chakabura in Korba District of CG. The Present
  capacity of this project is 30MW

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The Process at a Glance

• Improving of Quality of Rejects by
• Blending with Raw Coal or
• By Reprocessing of Rejects

Reject Repro-cessing Unit
Raw Coal from Coal Mine
Coal Washery
Rejects
Power to Local Power Station
Clean Coal to distant Power Houses
Fly ash to local Cement Plants Brick
Manufacturers
Power Grid
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The Future

• Aryan Coal Benefications is also planning for
  another 30MW Power station and one Power Station
  of 2x135MW capacity based on rejects so as to
  ensure 100disposal of rejects in an environment
  friendly manner.
• As an off-shoot of these efforts, not only Aryan
  has been able to dispose of the rejects
  environment friendly and cost effectively but has
  become a good source for supply of fly ash for
  various cement plants which are located in and
  around the Bilaspur-Raipur Belt.

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To sum-up

• For an end-user who require lt34 ash coal, (like
  Thermal Power Plants), Coal Beneficiation /
  Washing is the main solution.
• The requirement of Coal in 2006-07 was is 345
  Million Tonnes and this will touch 500 Million
  Tonnes by end of 2011-12. gtgtgtgtgt

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• Distance wise requirement of thermal coal

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Future Scenario

• With an estimated requirement of 501 Million
  Tonnes of Coal by 2011-12, around 370 million
  tones of washed coal would be required.
• At present the present capacity is around 100
  million tones. (Source Website of Ministry of
  Coal, Government of India) .
• More coal washeries would be required to keep
  our environment in a safe side.
• And with the power projects like of Aryans , the
  rejects can also be disposed in a very
  environment friendly manner.

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