coal washeries in india_infraline energy
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Coal Washeries in India: A $5 billion Opportunity
© 2010 InfralineEnergy Research & Informati on Services. htt p://www.infraline.com
Table of Contents
Executi ve Summary ............................................................................... 1
Chapter 1 - Introducti on .......................................................................................... 5
Indian Coal Industry ............................................................................................. 6
Coal Producti on and Consumpti on in India ........................................................ 7
Coal Imports in India ........................................................................................... 9
Chapter 2 - Coal Benefi ciati on in India .................................................................. 11
Coal Benefi ciati on in India ................................................................................... 11
Existi ng Scenario of Coal Benefi ciati on in India ................................................... 11
Chronology of Development of Coking Coal Plants in India ................................ 11
Future Scenario of Coal Benefi ciati on in India..................................................... 16
Chapter 3 - Benefi ts of Coal Washing ................................................................... 19
Savings in Transportati on Cost............................................................................. 19
Savings in the Capital and Operati ng Cost .......................................................... 23
Reducti on in Cost of Energy produced ................................................................ 23
Regulati ng the Quality of Coal Feed .................................................................... 24
Reducti on in Consumpti on of Secondary Specifi c Oil ......................................... 24
Thermal Effi ciency Imrovement .......................................................................... 24
Reducti on in Capital Investment in New Thermal Power Plants ......................... 24
Use of By-products of Coal Benefi ciati on ............................................................ 25
Chapter 4 - Technological Opti ons ........................................................................ 27
Existi ng Technology ............................................................................................. 27
Jigs ....................................................................................................................... 27
Coal Processing with Jigs ..................................................................................... 28
Batac and Baum Jig ........................................................................................ 28
Coal Washeries in India: A $5 billion Opportunity
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Deshaling and Komag Jig .............................................................................. 28
Froth fl otati on ..................................................................................................... 30
Heavy Media Baths .............................................................................................. 31
Heavy Media Cyclone .......................................................................................... 33
Water Only Cyclone ............................................................................................. 34
Dense Media Separator ...................................................................................... 36
Emerging Technologies ....................................................................................... 37
Barrel Washer ................................................................................................ 38
Spiral Concentrator ....................................................................................... 39
Column Flotati on ........................................................................................... 40
Air dense fl uidised bed separator .................................................................. 42
Multi Gravity Separator ................................................................................. 43
Shaking Table ................................................................................................ 45
Pilot Study for Upcoming Technology .................................................................. 47
Indigenous Vs. Imported Coal Benefi ciati on Technology ..................................... 47
Current Status of Coal Preparati on Technologies in India,
China and South Africa ....................................................................................... 50
Chapter 5 - Pre-feasibility Analysis ....................................................................... 50
Project Preparati on Phase ................................................................................... 50
Environmental Scan ....................................................................................... 51
Raw Coal Characteristi cs ................................................................................ 53
Project Planning Phase ........................................................................................ 57
Process Flow Sheet ........................................................................................ 57
Layout Preparati on ....................................................................................... 58
Economic Planning ........................................................................................ 59
Implementati on Phase ........................................................................................ 60
Plant Scheduling for Coal Washing ................................................................ 60
Procurement Services .................................................................................... 60
Contracts ....................................................................................................... 60
Coal Washeries in India: A $5 billion Opportunity
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Chapter 6 - Setti ng Coal Washery in India ............................................................. 62
Pre-constructi on Phase ....................................................................................... 63
Site Selecti on ................................................................................................. 63
Approvals and Clearances .............................................................................. 64
Constructi on Phase .............................................................................................. 69
Selecti on of the Flow Sheet .......................................................................... 69
Tie –Up/Associati on ....................................................................................... 71
Financing ....................................................................................................... 71
EPC ................................................................................................................ 72
Post Constructi on Phase ...................................................................................... 72
Trial Run ......................................................................................................... 72
Monitoring .................................................................................................... 72
Chapter 7 - Economics of Coal Washing ................................................................ 73
Structure of Economic Analysis ........................................................................... 75
Identi fy .......................................................................................................... 75
Evaluate ......................................................................................................... 76
Compare and Summarise .............................................................................. 77
Project Cost and Benefi t in Economic Terms ....................................................... 77
Project Cost ................................................................................................... 77
Cost Externaliti es ........................................................................................... 79
Sectoral Macro-economic Eff ects ........................................................................ 81
Imapct at the Mine Site ................................................................................. 81
Impact on Transport Infrastructure ............................................................... 82
Impact on Performance of Power Plants ....................................................... 83
Impact on Environment ................................................................................. 83
Impact on General Economy ......................................................................... 83
Project Benefi t ..................................................................................................... 84
Alternati ve Opti ons to Coal Washing .................................................................. 84
Key Findings of Economic Analysis ...................................................................... 85
Coal Washeries in India: A $5 billion Opportunity
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Chapter 8 - Policies and Guidelines for Coal Washing in India ............................... 86
Coal Value Chain .................................................................................................. 86
Factors aff ecti ng Policy on Coal Washing ............................................................ 88
Coal Supply .................................................................................................... 89
Coal Pricing .................................................................................................... 90
Coal Distributi on ............................................................................................ 90
Coal and Environment ................................................................................... 91
Implicati ons of the MoEF Policy .......................................................................... 93
Chapter 9 - Financing of Coal Washery Project ..................................................... 95
Debt Financing ..................................................................................................... 96
Equity Financing .................................................................................................. 96
Third-party Financing .......................................................................................... 97
Lease Financing ............................................................................................. 97
Project Financing ........................................................................................... 98
Financing Perspecti ve of Lenders and Investors ............................................ 99
Financing Approaches ......................................................................................... 99
Addressing Project Risks ...................................................................................... 100
Capital Cost Eff ects of Financing Alternati ves ...................................................... 102
Case Study ........................................................................................................... 103
Chapter 10 - Managing Challenges and Business Risks .......................................... 104
Managing Challenges .......................................................................................... 104
Risks Associated ................................................................................................... 104
Market Risk .................................................................................................... 105
Legal and Regulatory Risk .............................................................................. 106
Financial Risks ................................................................................................ 107
Operati onal and Maintenance Risks .............................................................. 107
Project Risks................................................................................................... 109
Clearance Risks .............................................................................................. 109
Risks due to Mafi a/Naxalism ......................................................................... 110
Development of Risk Matrix for Diff erent States ................................................. 110
Coal Washeries in India: A $5 billion Opportunity
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Chapter 11 - Restraints and Drivers ...................................................................... 112
Restraints ............................................................................................................. 112
High Cost of Coal Washing ............................................................................. 113
Pricing based on UHV Concept ...................................................................... 114
No Incenti ve to Switch to Washed Coal ......................................................... 114
Infrastructure Constraint to Coal Handling .................................................... 115
Availability of Water for Coal Washing .......................................................... 115
Land Availability for Coal Washing ................................................................. 116
Environmental Clearances ............................................................................. 116
Project Financing ........................................................................................... 117
Naxal Menace ................................................................................................ 117
Drivers ................................................................................................................. 117
CIL’s initi ati ve to set up Coal Washery ........................................................... 118
MoEF’s Directi ve to use Washed Coal ........................................................... 119
Internati onal Pressure to reduce Carbon Footprint ...................................... 119
High Price of Imported Coal .......................................................................... 120
Swing in favour of Coal Washing: .................................................................. 121
Chapter 12 - Opportunity and Business Case for Stake Holders ............................ 122
Recent Initi ati ves for Private Players ................................................................... 122
Opportuniti es for Financing Agencies ................................................................. 123
Higher Rate of Returns .................................................................................. 124
Lack of Long-term Financing .......................................................................... 124
CIL’s Expansion plans for coal washing faciliti es ............................................ 125
Shift from monopolisti c public control to private parti cipati on .................... 125
Opportuniti es for Equipment Manufacturers ...................................................... 125
Upcoming Washeries ..................................................................................... 125
Capacity additi on for existi ng washeries ....................................................... 127
Opportuniti es for EPC Contractors ...................................................................... 128
Opportuniti es for Promoters ............................................................................... 130
Increasing growth rate for Coal Washeries .................................................... 130
Augmentati on in the installed capacity of washeries .................................... 131
Coal Washeries in India: A $5 billion Opportunity
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Case Study ........................................................................................................... 131
Chapter 13 - Market Assessment of Washed Coal ................................................. 134
Coal Crisis in India ................................................................................................ 134
Demand for Washed Coal from User Industries .................................................. 136
Market Assessment ............................................................................................. 137
Power Generati on................................................................................................ 138
Washed Coal Requirement for Power Sector ...................................................... 140
Washed Coal Requirement for Cement Sector .................................................... 141
Washed Coal Requirement for Steel Sector ........................................................ 142
Industrial Markets ............................................................................................... 143
Infraline Analysis on Market Potenti al ................................................................. 144
Chapter 14 - Business Models and best practi ces ................................................. 146
Existi ng Business Model ...................................................................................... 146
Business Model for Private Operators ................................................................. 149
BOM Model ................................................................................................... 151
BOOT Model .................................................................................................. 153
BOT Model ..................................................................................................... 154
Capti ve Washery Model ................................................................................ 154
Turnkey Model ............................................................................................... 155
MOU Model/BOO Model ............................................................................... 156
Independent/Standalone/Merchant Model .................................................. 158
Competi ti ve Bid Model .................................................................................. 159
Co-operati ve Model ....................................................................................... 159
Chapter 15 - Conclusion ....................................................................................... 162
Abbreviati ons ...................................................................................................... 221
Bibliography ......................................................................................................... 224
Coal Washeries in India: A $5 billion Opportunity
© 2010 InfralineEnergy Research & Informati on Services. htt p://www.infraline.com
Annexure I
Annexure-1: Existi ng Coking Coal Washing Capacity in India .................................... 168
Annexure-2: Existi ng Non- Coking Coal Washing Capacity in India ........................... 168
Annexure-3: Coal quality requirements for Power plants ......................................... 169
Annexure-4: Coal quality requirements for cement industry .................................... 170
Annexure-5: Coal Quality requirements for Sponge Iron .......................................... 170
Annexure-6: Washability Characterizati on of Coal under Study................................ 170
Proximate Analysis .................................................................................................... 170
Size Analysis ............................................................................................................... 171
Annexure-7: Practi cally achievable yield of washed coal in diff erent washers .......... 171
Annexure-8: Coal Linkages to TPP and Non-coking coal washeries ........................... 172
Annexure-9: Annual/ Esti mated Coal consumpti on and Ash generati on by
Coal-based Thermal Power Plants ............................................................................. 173
Annexure-10: Economic advantages of Benefi ciati on ............................................... 173
Annexure-11: Variati on of GCV of non coking coals ................................................. 173
Annexure-12: Petro Graphic Data of Low Volati le Coking Coal (LVCC) ...................... 174
Annexure 13: Chemical Data of Low Volati le Coking Coal (LVCC) .............................. 174
Annexure 14: Coke Properti es of Low Volati le Coking Coal (LVCC) ............................ 174
Annexure 15: Size Analysis of Washed Coal .............................................................. 175
Annexure-16: DM process – Flow Chart .................................................................... 176
Annexure 17: Guidelines for setti ng up coal washery on Coal Company’s land ........ 177
Annexure-18: Operati ng Guidelines for processing of consent to
establish applicati on for establishment of coal washeries in the State of Orissa ...... 179
Annexure 19: NCV and C02 emission factors of
diff erent types of fuel used for esti mati on ................................................................ 184
Coal Washeries in India: A $5 billion Opportunity
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Annexure 20: Environmental clearance process in India ........................................... 185
Annexure 21 Flow Sheet for Variant I (Deshaling with ROM JIG) .............................. 186
Annexure 22. Flow Sheet for Variant II ...................................................................... 187
Annexure 23: Standard Flow Sheet for Jigging process for Power Stati on Coals ....... 188
Annexure 24: Standard Flow Sheet for
Heavy Media Process for Power Stati on Coals .......................................................... 189
Annexure 25: Standard Flow Sheet
Heavy Media Single Stage Cyclone for Small Coal ..................................................... 189
Annexure 26: Flow Sheet for Two Stage Heavy Media Cyclone Process ................... 190
Annexure 27: Standard Flow Sheet for Uti lizati on of Rejects .................................... 191
Annexure 28: Consumer’s Coal quality need ............................................................ 192
Annexure 29: Indicati ve Quality of Thermal Coal of major coalfi elds in India ........... 192
Annexure 30: Likely Product Balance at
34% ash level in Major Coalfi elds in India (for use in Power Plants) ......................... 192
Annexure 31: Esti mati on of Coal washing problem from
the amount of near-gravity material (NGM) ............................................................. 193
Annexure 32: Washability Curves .............................................................................. 193
Annexure 33: GHG Emissions .................................................................................... 197
Annexure 34: Quanti ty of Disposable Ash generated at
diff erent ash levels of Raw/Washed coal................................................................... 198
Annexure 35: Land Requirement for Disposable Ash at
Diff erent Ash Levels of Raw/Washed Coal ................................................................. 199
Annexure 36: Water Requirement for Disposable Ash at
diff erent Ash Levels of Raw/Washed Coal ................................................................. 199
Annexure 37: Annual CO2 – Emission at Stack of
a 1,000 MW Power Plant at diff erent Ash Levels ...................................................... 199
Annexure 38: Achievable Yield of Washed coal by diff erent level of benefi ciati on .................................................................................. 200
Coal Washeries in India: A $5 billion Opportunity
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Annexure II
Status for Coking and Non-Coking Coal Washeries in India ....................................... 201
List of Tables
Table 1.1: Coal Producti on in India (FY 2009-10) ....................................................... 8
Table 1.2:- Coal Dispatches in India ........................................................................... 8
Table 2.1 Existi ng Coal Washing capacity of CIL for Coking and Non-Coking Coal .... 13
Table 2.2 Existi ng Private Washing Capacity of Coal in India ..................................... 14
Table 2.3 Existi ng Technologies adopted by the Coal Washeries in India ................. 16
Table 2.4 Proposed Coal Washing Faciliti es in India .................................................. 17
Table 3.1 Annual Coal Requirements (as per GCV and Ash Content) ........................ 20
Table 3.2 Annual Freight Savings ............................................................................... 21
Table 4.1 List of Technologies Existi ng in India with Washery and
Company Details ........................................................................................................ 37
Table 6.1 Land approving authoriti es according ti Type of land ................................ 66
Table 7.1 Coal Washing Comparison with technologies like CBM and CTL ............... 76
Table 7.2 Excluded items for taxati on and duti es ...................................................... 78
Table 7.3 Factors for Screening Criteria ..................................................................... 80
Table 9.1 Financing Sources of Infrastructure and other Projects ............................. 95
Table 9.2 Addressing Coal Washery Project Risks ...................................................... 101
Table 10.1 Market risk scenario ................................................................................. 106
Table 10.2 Risk Matrix ............................................................................................... 110
Table 10.3 Parameters for Ranking of States ............................................................. 111
Table 10.4 Scale and Points for Indicati ve parameters .............................................. 111
Table 10.5 Ranking of States most suitable for Coal Washing ................................... 111
Coal Washeries in India: A $5 billion Opportunity
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Table 11.1 Loss of Coal Producti on of CCL ................................................................. 118
Table 12.2 Major Contractors for Coal Washing in India ........................................... 126
Table 12.3 Scope of Work for Contractors ................................................................. 129
Table 12.4 Current Capacity: Monnet Ispat and Energy Ltd. ..................................... 132
Table 13.1 Coal Requirement for 2011 & 2012.......................................................... 133
Table 13.2 Infraline Analysis on Washing of Coal in future........................................ 144
Table 14.1 Details of CIL’s Operati ng Washeries ........................................................ 147
Table 14.2 Washery built by Private developers on CIL’s Land .................................. 147
Table 14.3 CIL Coal washery details as per contractors ............................................. 148
Table 15.1 Deciding factors and
Subsequent implementati on probability for Coal Washing List of Figures ................ 164
Coal Washeries in India: A $5 billion Opportunity
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List of Figures
Fig.1.1:- Geological Resources of Coal in India .......................................................... 7
Fig.1.2:- Sector Wise Coal Consumpti on in India ....................................................... 9
Fig.1.3:- Coal Producti on and Imports of India .......................................................... 9
Fig.2.1 Total Existi ng Washed Coal Capacity in
Million Tonnes for Coking and Non-Coking Coal ....................................................... 15
Fig. 2.2 Share of Private and Public Uti liti es in Washing Capacity additi on ............... 18
Fig. 3.1 Variati on of Coal requirement as per GCV .................................................... 20
Fig. 3.2 Distance wise Freight Savings at 34% ash levels ........................................... 22
Fig.3.3 Distance wise Freight Savings at 30% ash levels ............................................ 22
Fig. 3.4 Variati on of Freight, Freight Savings and RoM Coal ...................................... 23
Fig.3.5 Single Stage Washing (According to Products) ............................................... 25
Fig.3.6 Multi Stage Washing (According to Products) ................................................ 26
Fig.4.1 Baum Jig ......................................................................................................... 29
Fig.4.2 Batac Jig ......................................................................................................... 29
Fig.4.3 Deshaling Jig .................................................................................................. 30
Fig. 4.4 Froth Flotati on Chamber ............................................................................... 31
Fig.4.5 Heavy Media Bath Chamber .......................................................................... 32
Fig.4.6 Heavy Media Cyclone Chamber ..................................................................... 34
Fig.4.7 Water Only Cyclone Schemati c ...................................................................... 35
Fig. 4.8 Dense Media Separator Confi gurati on .......................................................... 36
Fig.4.9 Barrel Washer Confi gurati on .......................................................................... 39
Fig. 4.10 Spiral Concentrator Confi gurati on .............................................................. 40
Fig. 4.11 Column Flotati on Confi gurati on .................................................................. 41
Fig. 4.12 Air dense fl uidised bed separator confi gurati on ......................................... 43
Coal Washeries in India: A $5 billion Opportunity
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Fig.4.13 Multi -gravity Separator Confi gurati on ......................................................... 44
Fig.4.14 Shaking Table Schemati c .............................................................................. 45
Fig.4.15 Pilot Fine Coal Treatment Plant, CIMFR, Dhanbad ....................................... 46
Fig. 4.16:- Country Wise Technology Comparison Chart ........................................... 47
Fig.4.17:- Comparati ve Status of Technologies in India and China ............................ 48
Fig. 4.18 Comparati ve Status of Technologies in India and South Africa ................... 49
Fig.5.1Phases of Pre-feasibility study ........................................................................ 50
Fig. 5.2 Sub-Acti viti es of Project Preparati on Phase .................................................. 51
Fig.5.3 Fragmented Environmental Structure............................................................ 52
Fig. 5.4 Break of Main land area required for Coal Washery ..................................... 53
Fig. 5.5 Raw Coal Characteristi cs ............................................................................... 53
Fig.5.6 Coal Characterisati on ..................................................................................... 54
Fig.5.7 Washability curve for Variant II ...................................................................... 56
Fig.5.8 Stages of Planning Phase ............................................................................... 57
Fig.5.9 Stages of Raw Coal processing ....................................................................... 58
Fig.5.10 Stages of Implementati on Phase ................................................................. 60
Fig.6.1:- Phases of Setti ng a Coal Washery ................................................................ 62
Fig.6.2 Time Schedule for a washery Project ............................................................. 63
Fig.6.3:- List of Clearances required forestablishing a Coal Washing Facility ............ 65
Fig. 6.4 Process fl ow for Environmental Clearances .................................................. 68
Fig. 6.5:- Process Flow Sheet block diagram for Variant II ......................................... 70
Fig. 7.1 Savings in the operati on of Power Plants ...................................................... 73
Fig. 7.2 Structure of Economic Analysis ..................................................................... 75
Fig. 7.3 Additi onal Cost Components for Economic Analysis ..................................... 77
Fig. 7.4 Macro-Economic Eff ects of Coal washing on diff erent sectors .................... 81
Coal Washeries in India: A $5 billion Opportunity
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Fig. 7.5 Raw Coal Separati on into Clean Coal and
Rejects (With Heat Loss involved in the process) ...................................................... 82
Fig. 8.1 Coal Value Chain ........................................................................................... 87
Fig. 8.2 Stake Holders in Policy making for Coal Washing ......................................... 87
Fig. 8.3 Factors eff ecti ng Coal washing policy............................................................ 89
Fig. 8.4 Major Environmental Concerns .................................................................... 92
Fig. 8.5 Policies on Coal Washing ............................................................................... 92
Fig.9.1 Methods of Equity Financing ......................................................................... 97
Fig.9.2 Lease Variati on Concepts ............................................................................... 98
Fig.9.3 Financing Strategy Decision Process .............................................................. 100
Fig.9.4 Ranking of Financing Methods....................................................................... 102
Fig.10.1 Challenges for Coal Washeries ..................................................................... 104
Fig.10.2 Risks associated with Coal Washeries .......................................................... 105
Fig. 10.3 Process fl ow for Raw Coal to Washed coal ................................................. 107
Fig. 11.1 Key Restraints for Coal Washing .................................................................. 113
Fig.11.2 Drivers for Setti ng up of Coal Washery ........................................................ 118
Fig.12.1 Financing Agencies for Coal Washing........................................................... 123
Fig.12.2 Long term sources of Finance ..................................................................... 124
Fig. 13.1 Growth patt ern in Coal Producti on ............................................................. 134
Fig. 13.2 Coal Producti on Trend in India .................................................................... 134
Fig.13.3 Coal Producti on and Import Trends ............................................................. 136
Fig. 13.4 Demand patt ern for washed coal from user industries .............................. 136
Fig.13.5 Sector wise Consumpti on of washed coal ................................................... 137
Fig. 13.6 Indicati ve Parameters for market potenti al of washed coal ....................... 138
Fig.13.7 Growth patt ern for Coal based power generati on in India .......................... 139
Coal Washeries in India: A $5 billion Opportunity
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Fig. 13.8 Fuel-wise Capacity Shift by 2015, GW ......................................................... 139
Fig 13.9 Cement Capacity growth vis-à-vis rise in demand of coal ............................ 142
Fig. 13.10 Steel growth trend vis-à-vis rise in coal demand ...................................... 143
Fig. 14.1 Components for successful business strategy for coal washing .................. 145
Fig. 14.2 Business Model for Private Developers....................................................... 150
Fig. 14.3 BOM Model ................................................................................................. 151
Fig. 14.4 Procedure for BOM Scheme ....................................................................... 152
Fig. 14.5 Features of BOM Model .............................................................................. 153
Fig. 14.6 Capti ve Washery Model .............................................................................. 155
Fig. 14.7 MoU Model ................................................................................................. 157
Fig. 14.8 Revised MoU Model .................................................................................... 158
Fig. 14.9 Co-operati ve Model .................................................................................... 160
Fig. 15.1 Coal Washing Matrix ................................................................................... 163
Coal Washeries in India: A $5 billion Opportunity
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