NLC
A Navratna Company
Neyveli Lignite Corporation Limited Extends
Warm Welcome to the Distinguished Delegates & Guests
National Workshop
on
“The Technology Development & Mechanization of
Mines for enhancing Coal Production & Productivity”
20.01.2015
Address on
“Success Experience of NLC in Implementing the Highly
Mechanized Continuous Mining Technology at Neyveli”
By
Shri B. Surender Mohan,
Chairman cum Managing Director,
Neyveli Lignite Corporation Ltd.
Preamble
NLC
A Navratna Company
 The event National Workshop on “The Technology Development & Mechanization of
Mines for enhancing Coal Production & Productivity” organized by Indian National
Committee of World Mining Congress with the support of Ministry of Coal, Government of
India is a very good initiative to fulfill the “Mission 1 Billion tons”.
 For a sustainable growth , India needs energy from diversified energy sources.
 India’s energy consumption has been increasing at one of the fastest rates in the world
due to population growth and Industrial development.
 The Demand is outstripping supply.
 Energy is not easily available in the world market including India.
 As low cost energy is not just available, growing demand for clean energy coupled with
reduction of carbon foot print is ever increasing
 At this juncture I would like to state that out of 44MT of lignite produced in the country
during 2013-14, share of NLC is 26.6MT(60%). In power generation, out of 5211MW
lignite based thermal power station installed at the end of XI plan, NLC’s contribution is
2740MW (53%).
Preamble
NLC
A Navratna Company
Mining Industry & Economic Development:
For an economic development mining is a core industry which has to be
managed very well.
 Absence of due management results in mineral wastage and environment
pollution.
Mining industry is going to play a key role in meeting the ever increasing
demand of minerals and metals to sustain higher growth rate of Indian
Economy.
This amplifies the real urge of Seminars, Symposiums and Workshops like
this and I am happy over the huge response from the sponsors and great
friends like you indeed.
I would like to share some statistics on lignite mining with the eminent
personalities, on certain important issues pertaining to Mining industry.
Sources of Energy & Demand
NLC
A Navratna Company
India’s energy supply comes from different sources - Coal, Hydro, Oil & Gas, Nuclear
and various forms of non-conventional energy sources.
55% of the country's energy need is met from abundant fossil fuel Coal.
Commercial primary energy consumption in India has grown by about 700% in the
last four decades.
 The current per capita commercial primary energy consumption in India is about 350
kgoe/year (Kilo gram oil equivalent / year) which is well below that of developed
countries.
 India has the 5th largest coal reserves in the world (301.56 billion tonnes) & now
ranks third amongst the coal producing countries in the world, producing about 565
million tonnes and imports about 168 million tonnes.
Being the major fossil fuel in India till date, Coal continues to be one of the most
important sources for meeting the domestic energy needs.
Considering the limited reserve potentiality of petroleum & natural gas, eco-
conservation restriction on hydel project and geo-political perception of nuclear
power, coal will continue to occupy centre-stage of India 's energy scenario.
Coal & Lignite Reserves in India
NLC
A Navratna Company
Coal reserves:
Currently India’s estimated Coal resources stand at 301 billion tonnes of which
about 125 billion tonnes or 40% are proved reserves.
Lignite reserves:
Estimated at 42 billion tonnes of which about 6 billion tonnes or 14% are proved
reserves. Efforts are required to bring more reserves to “proved category” to
increase the confidence level of the Investors.
Vast Coal & Lignite resources are at deeper depth (>200m).
Commercial Potential for development of deeper depth blocks are not amenable
to Conventional methods requires to be analyzed.
In this context it requires to look into alternate technologies to address the
environmental issues, up gradation of Gross Calorific value, exploration of deep
seated deposits etc.
NLC
A Navratna Company
GLIMPSE OF NLC’s OPERATIONS
(A ‘Navratna’ Govt. of India Enterprise)
 Incorporated on 14-11-1956 under Companies act 1956
 The biggest lignite mining company in India.
 ‘Navratna’ Scheduled ‘A’ Government of India Enterprise
 Core business : Lignite Mining 30.6 MT per annum and Power Generation 2740 MW.
Another 500 MW is under implementation.
 It has highest credit rating and net worth of Rs.14131.50 Crores (Q1 of 2014-15)
 Highest degree of safety – “AAA” (Stable) for long term barrowings by ICRA, CRISIL etc
 Over 50 Years of Service to the nation.
 Poised for many expansion & New Projects in the country.
 Out looking for venturing into clean Coal technologies viz. UCG & non-conventional
energies such as Wind Power & Solar.
 A front runner in environmental Care.
 NLC allocates not less than 2% of net profit per year as financial commitment towards
CSR activities & 50% of this amount is towards under Swatch Bharat.
 Corporate Governance:- NLC adheres to highest standards of Corporate Governance in
transparency, accountability and integrity
7
68°
70°
72°
74°
76°
78°
80°
82°
84°
86°
88°
90°
92°
94°
96°
36°
36°
JAMMU & KASHMIR
34°
NICHAHOM
SRINAGAR
Jammu & Kashmir
34°
SHALIGANGA
32°
32°
TH
A
N
SIMLA
30°
CHANDIGARH
Rajasthan
PA
K
IS
30°
Gurha
BIKANER
28°
DELHI
BIKANER LIGNITE FIELD
Bithnok,Hadla,Palana
JAIPUR
JAISALMER
26°
28°
NEP
AL
Barsinghsar
LUCKNOW
26°
NAGAUR LIGNITE FIELD
Giral
BARMER
Panandhro
Matasukh-Kasnau
KOHIMA
RAJASTHAN
PATNA
BARMER LIGNITE FIELD
IMPHAL
BANGLADESH
24°
24°
KUTCH LIGNITE FUELD
Matanomodh
GUJARAT
Rajpardi
GANDHINAGAR
22°
BHOPAL
BHARUCH & SURAT
LIGNITE FIELD
22°
KOLKATTA
Vastan
Gujarat
BHAVNAGAR LIGNITE FIELD
Tadkeshwar
20°
20°
BHUBANESHWAR
MUMBAI
18°
18°
BAY OF BENGAL
Other Lignite Projects
HYDERABAD
16°
16°
Proposed NLC Project
Existing NLC Project
PANAJI
ARABIAN SEA
14°
Tamilnadu & Pondicherry
CHENNAI
BANGALORE
SCALE
12°
CANNANORE
PONDICHERRY
BAHUR
KM 100
ALA
KER
Neyveli
TAMILNADU NEYVELI
Mine-III
JAYAMKONDAM
MANNARGUDI
Jayamkondam
Kerala
10°
14°
0
100
200
12°
300
400
500
10°
LEGEND
LIGNITE OCCURRENCES
VARKALA
8°
70°
72°
74°
76°
8°
SRI LANKA
TRIVANDRUM
78°
80°
82°
8
84°
86°
88°
90°
92°
94°
PROXIMATE ANALYSIS
Lignite
Coal
(In-situ Condition)
(In-situ condition)
Moisture %
45 – 55
2- 8
Ash %
3 – 12
20- 45
Volatile Matter %
20 – 30
20-30
Fixed Carbon %
18 – 22
25-40
Gross Calorific Value
( Kcal/Kg)
2400-2800
2400-6200
Sulphur %
0.5 – 0.75
<1
9
Four Lignite Mines of total capacity 30.6 MT
Lignite Production
capacity per annum
in MT
Over Burden
Removal per
annum in Mm3
10.5
57.75
Mine-IA
3.0
21.00
Mine-II
15.0
78.00
2.1
9.10
Mine
TPS-I Expn.
Mine-I
TPS-II Expn.
Barsingsar
Five Thermal Power Stations of capacity 3240 MW
No. & Unit size
Capacity
MW
TPS-I
6x50MW + 3x100MW
600
TPS-II
7x210MW
1470
TPS-I Expansion
2x210 MW
420
2x250MW
500
2x125MW
250
TPS
TPS-II Expansion
Barsingsar
*
*
Project under implementation & under stabilization process
10
The soft strata of sedimentary formation and the existence of powerful system of confined aquifer
rules out the possibility of under ground mining method.
In NLC mines, Specialized Mining Equipments (SME) are used for mining both overburden and
lignite. The SME includes equipments such as Bucket Wheel Excavators (BWE), Mobile
Transfer Conveyors (MTC), Conveyor system, Tripper and Spreader etc.
11
OVERALL VIEW OF BENCHES
12
BLASTING IN MINES
BRIDGE TYPE 1400 LITRE BWE IN OPERATION
14
700 LITRE BWE OPERATION IN LIGNITE BENCH
15
DUMPING OPERATION OF 20,000 TPH SPREADER
16
SWC PUMPING
In Lakh Tons
266
270
262
256
260
246
250
248
240
240
230
220
2011-12
2012-13
Target
Actual
2013-14
In Million Units
19989
19902
20000
18576
18789
18600
18929
18000
16000
2011-12
2012-13
Target
Actual
2013-14
Sr.No
NAME OF PROJECT
CAPACITY
PROJECT COST
Rs.IN CRORES
500 MW
(2 X 250 MW)
3,477.22
From 13.5 to 15.0
MTPA
1,458.17
Project Under Implementation:
a.
Thermal Power Station II
Expansion at Neyveli (under
stabilization)
b.
Restructuring of Mine-I & IA
c.
New Thermal Power Project at
Neyveli
d.
Wind Power
e.
Solar P.V Project at Neyveli
1000 MW
(2 X 500 MW)
5,907.11
51 MW
332.52
(34x1.5 MW)
Total
10 MW
77.89
1.5 MTPA/
1561 MW
11,252.91
20
Sl
No
NAME OF PROJECT
CAPACITY
PROJECT COST Rs IN
CRORES
1
Bithnok Lignite Mine in Rajasthan
2.25 MT/A
504.21
2
Bithnok Thermal Power Project in
Rajasthan
250 MW (1 X 250 MW)
2146.89
3
Hadla Lignite Mine in Rajasthan
1.9 MT/A
519.51
4
Barsingsar TPS Extension
250 MW (1 X 250 MW)
2094.31
5
Lignite Mine III at Neyveli
9.0 MT/A
8333.00
6
Thermal Power Station II – 2nd Expn at
Neyveli
1000 MW (2 X 500 MW)
6000.00
7
Coal based Sirkali Thermal Power project
(4000 MW – Phase-I:1980 MW)
1980 MW
14482.00
8
Pachwara South coal Mine
Jharkhand
10.0 MT/A
750.00
9
Solar Power
At Barsingsar, Rajasthan
10 MW
87.76
3490 MW/23.15 MTPA
34917.68
10
Total addition
21
Sr.No
PROJECTS
I.
Projects Under implementation:
a.
Coal based Tuticorin Thermal
PowerStation
Sub Total (I)
II.
Projects under Formulation:
a.
Coal Based Thermal Power project in
Uttar Pradesh
b.
Jilga-Barpali UG Coal Mine
Chattisgarh
Sub Total (II)
CAPACITY
1000 MW (2 X 500 MW)
1000 MW
PROJECT
COST Rs. IN
CRORES
6602.74
6602.74
1980 MW
14,375.40
6.0 MT/A
Yet to be estimated
1980 MW/6.00 MT/A
14,375.40
22
Sr.No PROJECTS
CAPACITY
PROJECT
COST RS. IN
CRORES
1
NLC’s Projects under
Implementation
1561 MW/
1.5 MTPA
11,252.91
2
NLC’s Projects under
Formulation
3490 MW/
23.15 MTPA
34,917.68
3
NLC Joint Venture
Projects under
Implementation
1000 MW
6602.74
NLC Joint Venture
Projects under
Formulation
1980 MW/6.00 MT/A
14,375.40
8031 MW/ 30.65 MTPA
67,148.73
4
TOTAL
23
Marching towards Brighter Future
NLC
A Navratna Company
Clean Coal Technologies (CCTs like CBM,CMM,UCG,etc) are of paramount
important to fulfill the energy demand of the Nation.
Few foreign countries proclaim that they have successfully implemented Clean Coal
Technologies for exploration of deep seated deposits, up-gradation of Gross
Calorific value of low rank Coals/Lignite, minimize CO2 emission etc.
However, the above technologies require to be tested for Indian condition.
NLC is contemplating to exploit the deep seated Lignite deposits of Ramnad in
Tamilnadu by Underground Gasification Technology.
NLC has developed a Bio-fertilizer namely ‘Humic acid’ as a by-product from Lignite
and obtained Patent rights in the year 2006. NLC is initiating steps to commercialize
the product through National Research Development organization (NRD).
NLC has executed an R&D project Utilizing Bottom ash of Thermal Power Plants for
Construction Activities as substitute of Fine Aggregates (Sand) in collaboration with
Vellore Institute of Technology (VIT) at a cost of Rs. 45.46 Lakhs. An experimental
building of 920 SFT has been constructed by Utilizing Bottom ash as substitute of
Fine Aggregates (sand).
NLC Forerunner in Mining with Special Mining Equipments
NLC
A Navratna Company
NLC is the first company having the expertise both in mining of lignite and power
generation. It plays a major role in meeting the energy demands of several states of
South India.
The lignite seam was first exposed in August 1961 in NLC and regular mining of lignite
commenced in May 1962.
German excavation technology in open cast mining, using Bucket Wheel Excavators,
Conveyors and Spreaders (SME Technology) were used for the first time in the country
in Neyveli Mine-I.
It is worth to mention here that the Hambach, the largest Lignite opencast Mine in
Germany (located in North Rhine-Westphalia) is fore-runner of the state of art of Bucket
wheel Excavator technology. The first BWE was commissioned in 1933 in this mine.
At present it is claimed that Hambach mine is deploying the world’s biggest Excavator
capable of extracting 2.4 LT of lignite/day or 2.4 LCM of OB per day by deploying 5
nos. of BWEs of capacity 2.4 LCM/day, 2 nos. of BWEs of capacity 2.0 LCM/day and
1 no. of BWE of capacity 1.1 LCM/day. The overburden strata in this mine is loose and
it does not require any blasting.
SMEs deployed in NLC
NLC
A Navratna Company
SMEs deployed in NLC Mines viz. Mine-I, Mine-IA and Mine-II at Neyveli:
• 1400 L BWEs
: 13 Nos
• 700 L BWEs
: 16 Nos
• 20000 TPH Spreader
: 4 Nos
• 11000 TPH Spreader
: 7 Nos.
• 5000 TPH Spreader
: 4 Nos
• 2400 mm Conveyor
: 27.34 Km
• 2000 mm Conveyor
: 61.80 Km
• 2400 mm Conveyor
: 27.34 Km
• 1500/1600/1800 mm Conveyor
: 34.08 Km
SMEs deployed in NLC
cont…
NLC
A Navratna Company
The configuration of SME equipments deployed in Mine-II of 15.0 MTPA capacity with an
Overburden removal capacity of 78.0 Mm3/A is depicted with equivalent CME equipments
required for your better understanding.
SYSTEM
New Surface Bench
Capacity
# 21.15 Mm3/A
Surface Bench
Capacity
# 21.15 Mm3/A
Top Bench Capacity
# 19.575 Mm3/A
Middle Bench
Capacity
9.0 Mm3/A
Bottom Bench
Capacity
# 7.125 Mm3/A
Overburden
Total capacity
Lignite System
Capacity
15.0 MTPA
Bench
Height
25 m
25 m
25 m
25 m
18 m
SME EQUIPMENTS
2* 1400L Bridge Type BWEs
2400mm Conveyor (11.58 Km)
1* 20,000 TPH Spreader.
2* 1400 L Bridge Type BWEs,
2400 mm Conveyor (9.64 Km),
1* 20,000 TPH Spreader.
2* 1400 L BWE,
2000 mm Conveyor (7.49 Km),
1* 20,000 TPH Spreader.
1* 1400 L BWE,
2000 mm Conveyor (7.46 Km),
1* 11,000 TPH Spreader.
2* 700 L BWEs,
2000 mm Conveyor (7.64 Km),
1* 11,000 TPH Spreader.
Equivalent CME equipments
reqd.
26 Numbers shovels of
10 to 12 M3 size with
combination of 230 nos. of
100 T Dump Trucks are
required for removal of
78.0 Mm3 over burden.
78.0 Mm3/A
18 m
4* 700 L BWEs,
2000 mm conveyor (9.50 Km).
5 Nos. shovels of 10 to 12
M3 with combination of 40
nos. of 100 T Dump Trucks
Remarks
# Capacity of one 1400 L
BWE is 9.0Mm3 for 4000
working hours. By deploying
additional
BWE
during
overhaul, working hours of
system is increased to 4700
hours and thereby getting
increased capacity.
Challenges In Lignite Mining
NLC
A Navratna Company
The Twin Challenges are:

Handling of OB more than 1:6 Stripping ratio (6 Cu. M per tonne of Lignite) and

Pumping to the tune of 8 to 10 Cu. M of water/ tonne of lignite.
The lignite is underlined by powerful artisan aquifer. Depressurization of aquifer is
being done to control the upward pressure for safe mining of lignite.

The above challenges are aptly handled by adopting SME technology and
optimizing the Ground water pumping pattern.
Challenges In Deploying SME in Neyveli
NLC
A Navratna Company
 SME technology is well suited for mining conditions prevailed at Germany.
 Major teething problems encountered at Neyveli Mines was made possible by adopting
suitable modifications in the design of the buckets, teeth and structural parts to tackle the
hard and abrasive nature of the Neyveli Overburden strata.
Modification in the Teeth & Bucket :
Tungsten Carbide tips with hard-faced sides on the teeth are provided
 Modifications on the structural side reduced the strain on the machine.
The sticky nature of soil reduces the bucket volume and the problem was overcome by
fixing chain mate on the backside of all the buckets.
Blasting:
To improve the productivity and to reduce the strain on BWE blasting is inevitable.
Presently around 70% Site Mixed Emulsion explosives are used for advantages like:
 Superior bore hole coupling , Highly safe as it is Non explosive,
 Eliminates manual loading & unloading and threat of pilferage.
 Latest systems available in the market like Electronic Detonators and Gas bags
are being regularly used in the sensitive areas.
 Around 7,300 tons of Explosive/annum is consumed in Neyveli.
New Initiatives implemented In Lignite Mining at Neyveli
NLC
A Navratna Company
Implementation of Variable Voltage & Variable Frequency (VVVF) Drives:
The fully digital VVVF drives are based on pulse encoder feedback
technology for individual motors.
 It increases the power factor - saving substantial energy.
 Drives facilitate smooth starting - resulting in lesser downtime of the machine.
 VVVF drives are also introduced in conveyor drive heads.
PLC Based Automation System for Lignite Bunker
 For smooth dispatch of lignite, PLC based automation control including
retrofitting of relay logic with PLC networking, centralized control system,
operation and monitoring with two way industrial paging system and CCTV
system was implemented during 2006.
 The SMEs with PLC and other advance controls increased the working hours
to nearly 6000 hours per year.
New Initiatives implemented in Lignite Mining at Neyveli
cont…
NLC
A Navratna Company
Wireless Based Centralized Monitoring Operation and Control System :
In Mine-IA is very helpful for operation as well as maintenance without much wastage of
productive time involving:
 One 700 L. BWE, one 4420 cubic meter/hour of MTC,
Five 1600 mm Conveyor of total length 5000 meters (approximately) and
One 4420 cubic meter/hour spreader including networking of existing programmable
logical control stations for centralized monitoring, operation and control.
Mining equipment maintenance management system (MEMMS) (SAP based):
 This system reduces the Breakdown, plan preventive maintenance, the stoppage duration
and also reduces the inventory.
 Equipment details, maintenance task details, manpower, spare parts are computerized.
 For the work either planned or Breakdown, work order will be generated with all the
required information and tools to complete the work.
New Initiatives implemented in Lignite Mining at Neyveli
cont…
NLC
A Navratna Company
Condition Monitoring for SME Equipment:
Accepted as an effective method:
 To assess the requirements of maintenance
 Increase the operating life of installed plant and machines.
 Many parameters can be monitored for an effective health condition of the equipment.
Using the technique of “Vibration Analysis and Diagnostic Studies” are applied to pinpoint
the health condition of the SME equipment.
Water Management in Neyveli Mines

NLC
A Navratna Company
Ground water management:
As a part of the ground water management Ground water levels and quality are
regularly monitored in and around Neyveli.

Through continuous study and implementation of new methods, the quantity of
water pumped out has been reduced considerably.

The water is gainfully utilized in captive Thermal Power stations.

Storm Water Management:
The clear water from sedimentation sumps of Mine-I is pumped to a modern
Water Treatment Plant of 8,000 GPM capacity.

The treated water is supplied to township dwellings.

Similar treatment plant of 15,000 GPM to treat the storm water from Mine-II, for
use in the Thermal Power Station-II & Expansion has been constructed.

Utilizing the storm water has resulted in conserving valuable ground water.

Further, the clear storm water from Mines is supplied to surrounding villages for
agricultural activities helps in raising crops three times in a year.
Adaptation of CME Technology in NLC:
NLC
A Navratna Company
CME equipments were mostly used for:
 Initial development of mines,
 Ramp formation, road formation, second seam mining etc.
 In the year 2006, CME outsourcing was introduced to tackle high ratio
areas, exploiting the left out areas
 Based on the experience gained, CME technology with outsourcing
option was adopted for both OB & Lignite production to have better
cost effectiveness in Barsingsar mine.
 For the projects under formulation like Bithnok and Hadla in
Rajasthan, it is proposed to adopt the CME technology with
outsourcing option to tackle the multi seams apart from having cost
effectiveness.
NLC
Assessment of SME technology:
A Navratna Company
 SME technology is very much suitable for soft strata
 To improve the productivity after analyzing the experience gained during the
operation of SME over 5 decades, the imported technology was indigenously
modified periodically to suit the conditions prevailing at Neyveli Mines.
 This made the SME technology a perfect match for the Geo- mining condition
at Neyveli where lignite is associated with unconsolidated
sandstones and
clays when compared with the sand stone, silt stone and shale in coal deposits.
 For production of Overburden of about 156 Mm3 per annum at the Mines at
Neyveli, within the available range of CME equipments, the capital cost involved
and operating cost including carpeting the working benches for CME technology
balances with the capital intensive SME technology.
SME Technology Vs CME Technology
NLC
A Navratna Company
 NLC initially preferred for combination of SME and CME for its Barsingsar Mine.
But the annual Overburden removal capacity of 9.0 Mm3 per annum after offsetting OB
removal at the bottom most slice over lignite with CME option due to steep gradient
and splits in the lignite formation, only lower capacity SMEs was proposed.
 This resulted in 63% of OB handling by SME and the balance 37% by CME for
Barsingsar project.
The economics for departmental operation favored for the combined technology for
SME & CME against complete operation by CME.
 When compared with outsourcing, CME technology was mainly preferred on account
of reduction of transfer price.
As there is no suitable player for Outsourcing of SME technology, a point to point
comparison of both the technologies with the outsourcing of CME technology could not
be made. However, a theoretical evaluation could always be possible.
SME Technology Vs CME Technology Cont…
NLC
A Navratna Company
 With the changed Global scenario, a techno commercial evaluation on built
own operate transfer (BOOT) basis for various combination of technologies
could be evaluated for different geo technical and various capacities of
mines.
 NLC for its proposed Mine-III (9.0 MTPA) at Neyveli, with 60 to 70 Mm3 of
OB removal/ annum and for the Jayamkondam project (5.5 MTPA to 13.5
MTPA), actively considers looking for techno economically viable option for
either combination of SME & CME or completely SME or CME deployment
for attaining the above requirements.
Adaptation of NLC’s experience in other Opencast mines
NLC
A Navratna Company
In pursuance of NLC’s high level of success in adopting an imported technology
of SME, I would like to suggest consideration of this technology in large opencast
mines on the following counts.
Superior in environment friendliness as this technology fully use electrical power
Higher annual production of OB:
For Soft strata associated with trafficability difficulties in deploying CME equipments
it is suggested to carry out a techno-commercial evaluation of CME and SME technology
prior to freezing the technology.
Combination of Technology:
Presently coal mines are adopting combination of CME & Dragline, CME & Surface
Miners very advantageously.
 In line with the above, an attempt can be made for combination of SME with any of
the above technologies wherever the strata condition is amenable for BWEs.
Besides, SCCL is adopting In-pit Crusher, Conveyor and Spreader with CME
technology for which NLC has provided consultancy services.
NLC
A Navratna Company
THANK YOU