The Barmer Lignite Mining Company Ltd (BLMCL) was established with a single mission: to supply lignite at minus 100 mm to the power plants of JSW Energy (Barmer) Ltd. Since 2011, BLMCL has operated the Kapurdi open cast lignite mine, 4km to the north of the power plant. A second mine at Jalipa, located at 2km from the plant, is now being developed to augment the supply of lignite. This included construction of a crushing and conveying system to size and transport lignite to the power plant. A conveyor system was the preferred option in order to limit operating costs and reduce environmental impacts. 

We had previously constructed the conveyor system for the Kapurdi mine on an EPC basis. After a competitive bidding process, BLMCL again awarded us the contract to provide the solution for Jalipa. The EPC contract was awarded in November 2018 for a 6 million tpa system. 

Scope of supply included:

  • Two Abon® sizers
  • Two apron feeders
  • A 2.2 km pipe conveyor with a single 104 degree horizontal curve
  • Three belt conveyors
  • An ECS/ControlCenter™ process control system 

We chose FLSmidth based on their proven track record in material sizing and handling systems, including at our Kapurdi mine. Their ability to provide all of the critical equipment in-house assured us of the quality of products being delivered, while their long-term service solutions guarantee trouble-free operation and supply of spare parts. We had no doubt that they would successfully execute this project.

Amrendra KumarVice President - Operations, BLMCL

A flexible solution for lignite sizing and transport 

We designed a flexible crushing system with two semi-mobile crushing stations (Abon sizer + apron feeder) feeding into the pipe conveyor. The relocatable crushing stations ensure that truck haulage from the operating face is kept to a minimum.

 

 

From the Jalipa mine, the pipe conveyor runs along the ground for 1.6km, including two 35° curves, supported by sleepers and standard modular frames. For the remaining 0.5km, the pipe conveyor is supported by galleries and trestles along a horizontal plan curve of 104°. Through this elevated curved section, gantries were supplied at a standard length and constructed using hollow square sections.

 

 

A further challenge came when routing the pipe conveyor near the power plant site. With existing structures to work around, as well as overburden soil dumps and private land, installation of the new tower for the pipe conveyor was far from a simple exercise.  

Expert execution brings tangible benefits

 

 

Installation of the new system on an EPC basis – which weighed in at about 1000 tonnes – was carried out on site over a period of six months. Commissioning and performance guarantee testing are scheduled for mid-2020. In addition to the handling system, we also installed the ECS/ControlCenter V8 process control system – ensuring the mine is digital ready!

Building on the success of the Kapurdi conveyor installation, we again proved ourselves to BLMCL as an expert one-source supplier for their Jalipa material handling needs. Although the project team encountered extreme weather conditions, the unseasonably heavy rains did not deter us from delivering the project.

Kamlesh MishraProject Manager, FLSmidth

By eliminating the need to transport lignite via truck, BLMCL has lowered both its operating costs and environmental footprint. Truck maintenance and diesel costs are eliminated, for example, while the conveyor can operate in all conditions. Even in extreme weather that would keep trucks parked up. Limiting the number of trucks onsite also reduces the risk of accidents, improving safety conditions.


On the environmental side, CO2, SOX and NOX emissions are reduced, while there are zero emissions of dust from the pipe conveyor. Finally, the production of fines is also reduced by the use of sizers to crush and size the lignite. This has the dual benefit of again limiting dust emissions and ensuring a greater proportion of the lignite mined reaches the plant as usable fuel.  

About Barmer Lignite Mining Company Ltd

  • Began commercial mining at Kapurdi in 2011 
  • Joint venture between Rajasthan State Mines & Minerals and JSW Energy (Barmer) Ltd 
  • Holds an exclusive 30-year fuel supply agreement to supply JSW Energy (Barmer) Ltd 
  • JSW Energy (Barmer) Ltd generating capacity is 1080 MW with 650 MW expansion under consideration

 Read more about the company.

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