VOCATIONAL TRAINING
REPORT
Working principle of Washery
From 17th June 2022 to 15th July 2022
Submitted By: Swati
Ranjan
Roll no. 19113062
Seventh Semester
Dept. of Chemical Engineering
1|Page
Report submitted on 10th November 2022
2|Page
3|Page
ACKNOWLEDGEMENT
My indebtedness and gratitude to the many individuals who have helped
to shape this report in its present form cannot be adequately conveyed in
just a few sentences. Yet we must record our immense gratitude to those
who helped me undergo this valuable learning at CCL.
I am highly obliged to Training and Development Department for
providing me this opportunity to learn at CCL. We have further more to
thank the officers of production for sharing their knowledge about the
plant and production process. It is really a great opportunity for me by
which I have gained knowledge which is usually hard to find in
textbooks. My special thanks to
Mr Umesh Kumar Singh
(Project Officer)
Surya Bhusan Kumar (Manager E&M)
Ravi Kumar
(Assistant Manager CP)
Aman Kumar
(MT E&M)
Manish Kumar
(MT CP)
4|Page
ABSTRACT
This report is about the industrial training on the working of a Coal Washery,
Laboratory Section, Process of Washing Coal and maintenance of Plant machineries
such as pumps, Screens and other mechanical equipments under the supervision of
Mr Umesh Kumar Singh PROJECT OFFICER (KATHARA WASHERY,CCL).
This report is divided into sections that will walk you through the general
introduction about the company, the subsidiary and various sections of Kathara Coal
Washery including Raw Coal Section , Heavy Media Section, Hydro cyclone
section, Fine coal Section , RLB (Railway Loading Bunker) Section.
COAL INDIA LTD.
Coal India Limited (CIL) is an Indian central public sector undertaking under
the ownership of the Ministry of Coal, Government of India. It is headquartered
at Kolkata. It is the largest government-owned-coal-producer in the world. It is also
the seventh largest employer in India with nearly 272,000 employees.
5|Page
The psu contributes around 82% to the total coal production in India. It produced
554.14 million tonnes of raw coal in 2016–17, an increase from its earlier production of
494.24 million tonnes of coal during FY 2014–15 and earned revenues of ₹95,435
crore (US$12 billion) from sale of coal in the same financial year. In April 2011, CIL
was conferred the Maharatna status by the Government of India, making it one of the
seven with that status. As of 14 October 2015, CIL is a PSU owned by the Central
Government of India which controls its operations through the Ministry of Coal. As of
14 October 2015, CIL's market capitalisation stood at ₹2.11 lakh crore (US$26 billion)
making it India's 8th most valuable company.
CIL ranks 8th among the top 20 firms responsible for a third of all global carbon
emissions.
Operations
CIL is the largest coal producing company in the world. It produced 536.51 MT
(million tonne) coal during FY 2015–16. Coal India operates through 83 mining areas
in 8 states of India. As on 1 April 2015, it has 430 coal mines out of which 175 are
open cast, 227 are underground and 28 are mixed mines. Production from open cast
mines during FY 2014–15 was 92.91% of total production of 494.24 MT. Underground
mines contributed to 7.09% of production. CIL further operates 15 coal washeries, out
of which 12 are for coking coal and 3 are for non-coking coal with 23.30 MTY and
13.50 MTY capacities respectively. CIL's only Low Temperature Carbonisation
Plant of Dankuni Coal Complex is currently run on lease basis by its subsidiary SECL.
In addition to above, it also manages 200 other establishments like workshops,
hospitals, training institutes, mine-rescue setups, etc.
Subsidiaries
6|Page
Year Wise Trends in the Coal Production of CILs Subsidiaries in MTs During FY
2012–2018
CIL produces coal through seven of its wholly owned subsidiaries. These are Eastern
Coalfields Limited (ECL), Bharat Coking Coal Limited (BCCL), Central Coalfields
Limited (CCL), Western Coalfields Limited (WCL), South Eastern Coalfields
Limited (SECL), Northern Coalfield Limited (NCL), and Mahanadi Coalfields
Limited (MCL). Its 8th wholly owned subsidiary Central Mine Planning & Design
Institute Limited (CMPDIL) provides exploration, planning and technical support to all
the 7 production subsidiaries. CMPDIL also provides consulting services to third-party
market clients in the field of exploration, mining, allied engineering & testing,
management-systems, training, etc. The North Eastern Coalfields (NEC) and Dankuni
Coal Complex (DCC) are owned directly by the parent holding company of CIL.
However, DCC has been leased to SECL since 1995.
CIL also has a wholly owned subsidiary in Mozambique, Coal India Africana Limitada
(CIAL) for pursuing coal mining opportunities in that country.
The details of number of employees, revenue for FY 2012–13 and production of coal is
given in the table below:
Subsidiaries of Coal India Limited
Name of
Subsidiary
Employees
(as of 31
March
2015)
Revenue
(₹ billion
for
FY201213)
Coal Production(in million Tons)
Coking
Coal
NonCoking
Coal
Total Coal
Production
Bharat Coking
Coal Limited
(BCCL)
56,051
89.37
26.970
4.243
31.213
Central Coalfields
Limited (CCL)
45,011
92.38
16.156
31.905
48.061
7|Page
Subsidiaries of Coal India Limited
Name of
Subsidiary
Employees
(as of 31
March
2015)
Revenue
(₹ billion
for
FY201213)
Coal Production(in million Tons)
NonCoking
Coal
Coking
Coal
Total Coal
Production
Eastern Coalfields
Limited (ECL)
68,681
97.40
0.043
33.868
33.911
Mahanadi
Coalfields
Limited (MCL)
22,259
120.93
-
107.894
107.894
Northern
Coalfields
Limited (NCL)
16,226
99.86
-
70.021
70.021
South Eastern
Coalfields
Limited (SECL)
67,800
176.48
0.157
118.062
118.219
Western
Coalfields
Limited (WCL)
50,071
74.23
0.330
41.957
42.287
Central Mine
Planning and
Design Institute
(CMPDI)
3,629
6.05
-
-
-
8|Page
Subsidiaries of Coal India Limited
Name of
Subsidiary
Coal India
Africana Limitada
Employees
(as of 31
March
2015)
-
Revenue
(₹ billion
for
FY201213)
Coal Production(in million Tons)
Coking
Coal
NonCoking
Coal
-
-
-
Total Coal
Production
-
North Eastern
Coalfields
2,027
-
-
0.605
Dankuni Coal
Complex
474
-
-
-
-
CIL Headquarters
868
-
-
-
43.656
408.555
452.211
Total
333,097
13.78
770.49
0.605
Joint Ventures: CIL has two joint ventures 1. International Coal Ventures Private Limited (ICVPL) was formed in 2009
for acquisition of coking coal properties outside India. CIL
holds 2⁄7th share in paid up capital of ICVPL.
2. CIL-NTPC Urja Private Limited is a 50:50 JV between CIL and NTPC,
formed in April 2010 for acquisition of coal blocks in India and abroad.
9|Page
CENTRAL COAL FIELDS LTD.
Central Coalfields Limited (CCL) is a subsidiary of Coal India Limited (CIL), an
undertaking of the Government of India. CCL was established in 1956 as National Coal
Development Corporation Limited and is a Category-I Mini Ratna company since
October 2007. CCL manages the nationalized coal mines of the Coal Mines Authority,
Central division. CCL is headquartered at Darbhanga House, Ranchi, Jharkhand.
Infrastructure
CCL owns and operates the following:






43 operative mines (5 underground & 38 opencast)
7 operating coalfields. These coalfields are located in East Bokaro, West
Bokaro, North Karanpura, South Karanpura, Ramgarh, Giridih and Hutar.
7 washeries
o 4 operational coking coal washeries
at Rajrappa, Kedla, Kathara and Sawang
o 1 operational non-coking coal washery at Piparwar
o 2 non operational non-coking coal washeries at Gidi and Kargali
1 central workshop at Barkakana
2 regional workshops at Giridih and Bhurkunda
3 repair workshops at Jarangdih, Tapin North and Dakra
KATHARA WASHERY
Kathara Area is one of the operational areas of the Central Coalfields Limited located
mainly in the Bokaro district in the state of Jharkhand, India.
The projects of the Kathara Area are: Kathara open cast, Jarangdih open cast, Jarangdih
underground, Sawang open cast/ underground, Govindpur underground, Kathara
Washery, Swang Washery. The area office is at Kathara, PO Kathara 829116.
10 | P a g e
1. BACKGROUND
CCL intends to set up a coking coal washery with raw coal linkage from Govindpur
Ph II and Kathara Colliery on Build-Own-Operate (BOO) concept. The assured raw coal
throughput of the washery will be 3.0 Mtpa on ‘arb’ (as received basis). The expected
monthly average ash content of Raw Coal is around 30.5% on ‘adb’ (air dried basis) and
likely to vary within the range of 24.9 to 33.6% on ‘adb’. The average total moisture
content is 2.8%.
The washery will be designed to produce three products viz. washed/ clean coal,
washed coal (power) & rejects.
2. LOCATION
The proposed washery will be located in the premises of existing Kathara Washery
of CCL in East Bokaro Coalfield, Kathara Area, District- Bokaro, State Jharkhand. The
land for the proposed washery is in possession of CCL.
3. COMMUNICATION
The proposed New Kathara Coking Coal Washery is located in premises of existing
Kathara Washery which is easily approachable by road and rail. The plant is connected by
road from Bokaro Steel City, Dhanbad, Giridih etc. Bokaro Thermal Railway station and
Gomia Railway station are located approximately 4 kms. and 8 kms. respectively from
New Kathara washery.
The nearest Airport connected by daily commercial flights
is
at
Ranchi
approximately at a distance of 120 kms.
4. DRAINAGE
The Washery is located on the left bank of Damodar river.
5. CLIMATE
The climate of the area is tropical. The temperature varies from maximum of 45 oC to
minimum of 8oC in winter. The maximum temperature rises during April to June and
minimum is recorder during December to February. The monsoon period lasts from July
11 | P a g e
to September when maximum rainfall takes place. The average
annual rainfall is of the
order of 1250 mm and the average monthly rainfall varies between 215 mm to 315 mm.
The annual rainfall was 1351.38 mm (2014); 990.34 mm (2015); 829.05 mm (2016) and
1124.17 mm (2017 up to Nov. 2017).
6. LAND REQUIREMENT
An area of about 11.33 Ha has been identified by CCL, within existing Kathara washery
premises.
7. OBJECTIVE
New Kathara Coking Coal washery of 3.0 MTY capacity will supply washed coal with
30.5+0.5% ash to thermal power stations.
8. RAW COAL LINKAGE TO THE PROPOSED WASHERY
Raw coal linkage to the proposed New Kathara Coking Coal Washery is from Govindpur
Phase-II and Kathara Colliery. The minewise and seamwise mineable reserves as on
01.04.2017 of these mines are given belowMineable Reserves
Mine
Govindpur Phase-II
Kathara Colliery
Total
Mt
44
24
68
9. UNIT OPERATIONS-

Coal Washing Methods
12 | P a g e
The various procedures are broadly classified as the ‘Wet’ ‘and Dry’ processes. The
dry process doesn’t involve the use of water, where as in the wet process, the water is
the main medium for washing and jigging. The washery will be operated on wet
process. The different processes involved in the washery are given below;
Crushing
Purpose of the crushing is to reduce the Run of Mine (ROM) coal to a size suitable for
washing and, size reduction involving various principles such as compression, impact,
shearing, splitting and attrition.
Primary crusher(s) are generally designed to receive ROM coal and reduce it to a top
size of 2” to 8’’
Secondary crushers are generally designed to reduce the size (to a top size of 1 ¾”) of
the middling fraction from jigs or the middling fraction from heavy – medium trough
separators, and, in turn these fractions would be rewashed. Crushing of as received coal
sample (rom coal size) down to -13mm size is proposed.
 Screening
Sizing is the separation of a heterogeneous mixture of particle sizes into groups wherein
all particles range between a maximum and minimum size.
Screens Used in Coal Preparation:
1. Scalping screen – for separating refuse and fines prior to size reduction
2. Raw coal sizing screen- for separating the raw coal into coarse and fine size
for further processing.
13 | P a g e
3. Pre-wet screen- to remove fines prior to the mechanical cleaning
4. Heavy media recovery screens- for recovery and reuse of magnetite
5. Desliming screens-to remove extreme fines; and
6. Dewatering screens-to remove water.
 Jigs
Jigs operate by differences in specific gravity and rely on stratification in a bed of coal
when the carrying water is pulsed. The shale tends to sink, and the cleaner coal rises.
The basic jig is suitable for larger feed sizes. Although the Baum jig can clean a wide
range of coal sizes, it is most effective at 10-35 mm. A modification of the Baum jig is
the Batac jig, which is used for cleaning fine coals. The coal is stratified by bubbling
air directly through the coal-water-refuse mixture in this cleaning unit.
14 | P a g e
For intermediate sizes the same principles are applied, although the pulsing may be
from the side or from under the bed. In addition, a bed or hard dense mineral is used to
enhance the stratification and prevent remixing. The mineral is usually feldspar,
consisting of lumps of silicates of about 60mm size.
Jigs offer cost effective technology with a clean coal yield of 75-85% at about 34% ash
content. The jigs are used more frequently than dense-medium vessels because of their
larger capacities and cheaper costs.
Baum Jig and Fledspar Jig
15 | P a g e
 Dense Media Seperator
Dense-medium vessels also operate by specific gravity difference; however rather than
using water as the separation medium, a suspension of magnetite and water is used.
This suspension has a specific gravity between that of coal and the refuse and a better
separation can be obtained. The slurry of fine magnetite in water can achieve relative
densities up to about 1.8. Different types of vessels are used for dense- medium
separators such as baths, cyclones and cylindrical centrifugal separators. For larger
particle sizes, various kinds of baths are used, but these require a substantial quantity
of dense- medium, and therefore of magnetite. For smaller sizes, cyclones are used
where the residence time is short and throughput relatively high. Cylindrical centrifugal
separators are used for coarse and intermediate coal.
Dense-medium cyclones clean coal by accelerating the dense-medium, coal and refuse
by centrifugal force. The coal exits the cyclones from the top and the refuse from the
bottom. Better separation of smaller-sized coals can be achieved by this method.
Key factors in the operation of any dense-medium system based on magnetite are the
control equipment and the efficiency of magnetic recovery for recycle.
16 | P a g e
Dense Media Seperator
 Froth Flotation
Froth flotation is the most widely used method for cleaning fines. Froth flotation cells
utilize the difference in surface characteristics of coal and refuse to clean ultra fine coal.
The coal-water mixture is conditioned with chemical reagents so that air bubbles will
adhere only to the coal and float it to the top, while the refuse particles sink. Air is
bubble dup through the slurry in the cell and clean coal is collected in the froth that
forms the top.
Froth Flotation

Transportation of rejects to Temporary Reject Storage Site by belt conveyor.

Provision of closed water circuit with zero effluent discharge has been envisaged.
10. BALANCE OF PRODUCTS
Washed coal / clean coal is having yield% of 60.6 with ash% of 18.0. Washed coal (power)
is having yield% of 6.8 with ash% of 34.0. Rejects is having yield% of 32.6 with ash% of
52.2.
11. ENVIRONMENTAL POLLUTION MITIGATION MEASURES
17 | P a g e
The project related activities may have some impact on environment in study area in
order to take care of the same, appropriate mitigation measures are recommended below.
Mitigation Measures for Air Quality
i) Coal crushing
This is a source of dust generation it is proposed to cover the crusher with enclosure.
A dust extraction system would be provided to collect all dust generated during the
crushing operation. The dust should be collected in bags. Subsequently these collected
bags would be disposed off appropriately.
ii) Road Transport
Coal transportation by road is likely to be a major source for generation of particulate
matter. In order to mitigate the impact of this, following recommendations are given:
a. Blacktopping - The transport road is to be blacktopped. This measure would lead
to low generation of dust from road.
b. Wet transportation by Tippers- Raw coal will be transported by tippers in wet
condition. This will facilitate in minimizing dust generation and spillage.
18 | P a g e
c. Green Belt along Road- Project will plant three rows of plants on both sides of the
road. This will serve as wind shelter that will help in minimizing the generation of
dust from road.
iii) Coal Handling Plant (CHP)
a) Raw Coal storage- A ground bunker would be provided in raw coal yard for
storage of raw coal before crushing. A Water Sprinking system would be installed
for wetting the coal stock on ground. This will
exposed coal mass.
minimize
dust
generation from the
b) Belt Conveyor
1) the belt will be covered on top and both sides by sheet cladding. These
arrangements will protect the coal mass moving on belt from blowing wind. In
this way the dust generation wiould be minimized.
19 | P a g e
2) Water Sprinkling system on all transfer points will be provided in CHP.
Water Pollution Control Measures
(A) Effluent Source
The sources of effluent generation in washery plant complex are-.

Industrial Effluent
The proposed washery will have zero discharge, however , during heavy
storms, storm water may be contaminated

Municipal Effluent
The washery will have some service buildings including office, canteen, rest
shelter etc. these will house facilities for drinking Water and wash rooms.
Municipal effluents will be generated from these facilities.
(B)
Mitigation Measures
In order to treat above effluents, following arrangements are recommended.
(a) Industrial effluent
Storm water drains will be provided will carry storm water into ponds in
series . One set of ponds will be for treatment of effluent, second set for
drying and third set for cleaning.
In addition, there will be one pond to store treated Water. Treated Water
will be recycled for use as process water.
(b) Municipal Effluent
Keeping in view that volume of municipal effluent is low, it is proposed to
provide septic tank and soak pit for its treatment.
Noise Pollution Control Measures
The following measures shall be taken:
20 | P a g e
 Proper designing of plant & machinery by providing in-built mechanisms like
silencers, mufflers and enclosures for noise generating parts and shock
absorbing pads at the foundation of vibrating equipment.
 Routine maintenance of equipment.
 Rational deployment of noise generating plant and machinery.
 Greenbelts around the infrastructure sites and service building area besides
avenue plantation on both sides of the roads
 Personal protective devices to all the persons working in high noise areas.
 Regular monitoring of noise levels at various points.
12. ENVIRONMENTAL MONITORING PRORAMME
(A) Parameters to be Monitored
Following parameters will be monitored
►
Ambient Air Quality
(i)
GSR-742 E dated 25.09.2000 on work zone.
(ii)
For other: GSR-826 E dated 16.11.09 (NAA QS)
● Respirable Particulate Matter (RPM)
● Suspended Particulate Matter (SPM)
● Sulphur Dioxide (SO2)
● Oxides of Nitrogen (NoX)
►
Waste Water
Waste water will be monitored as per parameters given in MoEF standards for
Effluents. The coal washery will maintain the close circuit operation with zero
effluent discharge. In case of periodic cleaning heavy rainfall etc., GSR 7, dated
27.12.1998, shall be complied.
►
Ground Water
Ground water will be tested for parameters covered under BIS 10500: (1991).
►
Surface Water
Surface water will be monitored for parameters as per BIS 2296:1982
►
Noise Level
21 | P a g e
Ambient noise level will be monitored in db(A) limit in accordance with MoEF,
GOI notification dated 26.12.1989, vide GSR 1063 (E) the ambient noise level
standard for different categories.
13. The proposed budget for environmental management is given below
A. CAPITAL ESTIMATE
Air Pollution Control
(i)
Dust Control Equipments in Coal Crusher House
Rs.
20.00 Lakh
Rs.
10.00 Lakh
Rs.
5.00 Lakh
(iv) Water Sprinklers
Rs.
40.00 Lakh
(v)
Rs.
15.00 Lakh
Rs.
50.00 Lakh
Rs.
140.00 Lakh
(ii)
Dust Controls Measures for ground raw coal storage /
Water sprinkling, Enclosures etc.
(iii) Dust Control Measures for CHP
Green Belt
(vi) Road Widening & Black Topping
Sub-Total
Water Pollution Control
(i)
Washery effluent Treatment Facility
Rs.
25.00 Lakh
(ii)
Municipal effluent treatment plant
Rs.
5.00 Lakh
Sub-Total
Rs.
30.00 Lakh
Grand Total
Rs.
170.00 Lakh
B. REVENUE BUDGET ESTIMATE
(i)
(ii)
(iii)
Repair & Maintenance cost of Environment Rs.
Mitigation equipments.
Operational Cost of Environment Mitigation Rs.
equipments.
10.00 Lakh
Env. Monitoring Cost
Rs.
10.00 Lakh
Total
Rs.
50.00 Lakh
30.00 Lakh
22 | P a g e
SUMMARISED DATA
1.
2.
Capacity & Operating conditions
a)
Annual
:
3.0 Mty
b)
Daily
:
11000 t
:
Govindpur Phase-II and
Raw coal linkage
Kathara Colliery
3.
Construction period
4.
Quality of raw coal feed (average)
a)
5.
Ash%
Balance of Products
18 months
:
30.5
:
Product
6.
:
Yield%
Ash%
Washed/Clean Coal
60.6
18.0
Washed Coal (power)
6.8
34.0
Rejects
32.6
52.2
Total
100.0
30.5
Broad initial capital investment (Rs. in Crores)
7.
Construction period including trial run, PGT & commissioning
8.
Other details
a)
270.00
18 months
-
Washery site
An area of about 11.33 Ha has been identified by CCL,
within existing Kathara washery premises. In the given
11.33 Ha, abandoned structure to be demolished.
b)
Water
Source of water required for construction and operation
of the washery will be from mine water or existing Kathara
washery source.
c)
Railway
siding
for
Dispatch of washed/ clean coal and washed Coal (power)
23 | P a g e
loading & dispatch ofwashed coal
d)
Reject
disposal/ utilisation
24 | P a g e
will be done by existing Railway siding of Kathara Washery which is adjacent to the
proposed washery site.
The rejects produced from the plant shall be transported & temporarily stacked/dumped
separately at the identified reject storage site. Further, sale/ disposal of rejects will be
done as per CIL policy.
25 | P a g e
26 | P a g e
CONCLUSION
In conclusion, the training that we had already gone through is very interesting, instructive and
somehow challenging. It gave us lots of benefit and positive changes that enable us to enter
the environment of a washery. Through this training we were able to gain new insights and
more comprehensive understanding about the working condition and the global challenges
around washing of coal. The training has provided us the opportunities to develop and
improve our creative and practical skills. All of this valuable experience knowledge that we
have gained were not only acquired through the direct involvement in task given but also
through other aspect of the training such as assignments and submissions of the given work.
From what we have undergone, we hundred per cent agree that the our training program have
achieve its primary objective. It is the platform to prepare for the students to face to real
working life. As a result of the program, we are more confident to enter the working world
and build our future career.
--- THE END ---
27 | P a g e