NATIONAL WORKSHOP ON COAL
PRODUCTION & PRODUCTIVITY
20th January 2015
New Delhi
UNDERGROUND MINING - WITH WAYS
AND MEANS TO MAKE IT SUCCEED
T K LAHIRY
CHAIRMAN/Mg. DIRECTOR
BHARAT COKING COAL LIMITED
1
BCCL- Brief Profile

A MINI RATNA COMPANY

Mines are spread over :
 Jharia Coalfield located in Jharkhand -273 km²
 Raniganj Coalfield located in Jharkhand (19 km²)and West Bengal (14 km²) 33km²





As per UNFC classification the total Resource and Reserve is 12.976 Bt
(1.4.2013)
Operating Mines are 53 consisting of
 Underground- 19
 Opencast14
 Mixed –
20
MANPOWER
: 57010 (AS ON 31.12.2014)
The Company also runs 6 coking coal washeries, 2 non- coking/ NLW coal
washeries.
Construction of 6 new washeries of 18.6 Mty capacity and 2 Nos. Rapid
Loading system of 5Mty capacity taken up.
2
Why technology up gradation is needed
Need
Solution
Coal reserves are available in the By introducing global high capacity
country up to 1200M.
UG technology exploitation of these
At present mostly, mining is limited reserve will be successfully done
up to 200 to 300M except a few UG with increase in production.
mine.
Availability of Land & EC capacity is
Vast reserve is available for taken care by existing mining
exploitation from 300M to 1200M.
operation.
Most of the land over these reserve This increase in production can full
are available or in the process of fill the existing gap between demand
acquisition for mining operation.
and supply.
EMP for the mine is also available.
3
Inherited Legacy
•
•
•
•
•
•
•
BCCL incorporated in Jan 1972.
Inherited large nos. of small loss making UG Mines.
Occurrence of multi-seam and adverse geo – mining condition.
Occurrence of Fire, gas, subsidence and water logged workings.
Zero Environmental clearance of the mines.
Prevalence of Manual age old technology prevailing in Mines.
Incurring loss to tune of Rs.2000 Cr. from this UG operation.
4
Post 2008 scenario
 BCCL adopted strategic plan for long term and short term production.
 It was decided to work up to combined seam by Open cast method within
the available Land.
 The shallow depth UG Mines were converted to Open cast Mines and
opencast activities increased thereby increasing production.
 Introduction of high capacity UG Mines in place of existing small UG Mines
and in seams below the existing opencast operation.
 16 Nos. of shallow depth UG Mines were converted to Opencast
mines because of which financial health of company improved
considerably with a profit of Rs. 1714.35 Cr. In 2013-14 compare to
a huge loss of Rs 1380.47 Crores loss in 2008-09.
5
Future scenario
 Conceptually 6 UG mines were identified and tender
floated for introduction of mass production technology.
 Tenders for these six mines have been finalized and they
will contribute with high productivity, 8.0 MT of coal to
the production of BCCL.
 Apart from the above, another six underground mines
whose tenders are in pipeline are envisaged for capacity
addition of about 6 Million Tonne per annum of prime
coking coal.
 The above initiative will not only improve the growth in
underground production and contribute profit to the
company but also facilitate absorption and adaption of
state of the art technologies.
6
UG Production
9.00
7.00
Actual
4.50
2019-20
2018-19
2017-18
3.50
2016-17
2015-16
2014-15
2.70 2.80 2.85
2013-2014
2012-13
2011-12
2010-11
2009-10
2008-09
4.46 4.13
3.90 3.70
3.48 3.15
2007-08
10.00
9.00
8.00
7.00
6.00
5.00
4.00
3.00
2.00
1.00
0.00
Projection
7
UG Production
10.00
9.00
Production growth due to
introduction
of
new
technology
7.00
9.00
8.00
7.00
6.00
5.00
4.00
3.00
2.00
1.00
4.46
4.50
4.13 3.90
3.70 3.48
3.15
3.50
2.85
2.70 2.80
Decreasing trend of
production if existing mines
were continued
2.50 2.30 2.27 2.23
2.20
0.00
8
STEPS TAKEN BY BCCL
 BCCL took the strategic initiative for exploitation
of deeper deposits by underground methods and
invited global bids for development and
operation of high capacity underground mine by
latest global technology.
Conditions:
Bid evaluation is done on the basis of Long range
marginal cost (LRMC) using discounted cash flow
technique calculated for each bid but it has to be
lower than notified selling price.
9
STEPS TAKEN BY BCCL
Contd…
Bonus and Penalty Clause
Actual Production between 90% -100% : No Penalty.
From 70% to 90%:
@ 10% of Per tonne rate charged on the
difference of actual production from 90% of the
annual guaranteed production.
Less than 70%:
Over & above the deduction made above in (b),
further @ 20% of per tonne charged on the
difference of production from 70% of annual
guaranteed production.
100% TO 110% :
No bonus is payable.
>110%:
@8% of per tonne rate payable for that production
year on incremental production above 110% of
Annual guaranteed production in that production
year provided that the maximum price per tonne
inclusive of bonus remains less that the notified
price of the coal produced.
10
STEPS TAKEN BY BCCL
Contd…
The mines whose tenders have been finalized
are:
•
•
•
•
•
•
Moonidih XVI seamMuraidih Underground Kapuria UndergroundMoonidih XV seamLohapatti Block-II Underground-
0.70 Mty
2.00 Mty
2.00 Mty
2.50 Mty
0.35 Mty
0.45 Mty
11
Moonidih XVI Top project
Conceived and tendered
:
Capacity
Sanctioned Capital
Expenditure till 31 Mar 14
Anticipated Expenditure in 2014-15
:
:
:
:
Tender floated in 07 Mar’ 11.
the proposal approve in 287th BCCL
board meeting in July 2012
0.70 MTY
Rs. 201.53 Crores
Rs. 6.44 Crores
Rs. 155.60 Crores
Year
2015-16
2016-17
2017-18
2018-19
2019-20
Production (MTY)
0.637
0.700
0.700
0.700
0.700
Present Status: Incline drivage & shaft sinking started.
12
Moonidih XVI Top project
Contd..
Proposed Technology:
 Production will be done with powered
support long wall system.
Face is already installed
Production is expected to start from this
month.
Guaranteed production will come in 2015-16.
13
Moonidih XV Seam UG Turnkey Project
Conceived and tendered
Capacity
Sanctioned Capital
Expenditure till 31 Mar 14
Anticipated Expenditure in 2014-15
Profit (In Rs. Per Tonne)
: Tender floated in 06 April’ 10.
the proposal approve in 279th BCCL
board meeting in July 2011
:
2.50 MTY
:
Rs.1230.274 Crores
:
0.0
:
Rs. 46.07 Crores
:
Rs. 585.61
Year
2015-16
2016-17
2017-18
2018-19
2019-20
Production (MTY)
0.00
0.00
0.10
0.543
1.50
Present Status: Incline drivage & shaft sinking started.
14
Moonidih XV Seam UG Turnkey Project
Contd..
Proposed Technology:





It has been proposed to drive 2 drifts from surface up to XV seam
(400ms Depth) by Road Headers associated with conveyor (for coal
evacuation) and monorail for man and material transportation.
Mechanised technology with self advancing powered support long wall
system is proposed. Bolter Miners are proposed to be engaged for all
road headings etc.
Road headers for drift drivage
Face length : 1440 m- 2760 m, and widths of 250 meters.
It is proposed to produce 2.5 MTPA from the mine using 800 T capacity
two legged shield supports commencing at the end of fifth year.
15
Muraidih U/G turnkey project
Conceived and tendered
Capacity
Sanctioned Capital
Expenditure till 31 Mar 14
Anticipated Expenditure in 2014-15
Profit (In Rs. Per Tonne)
: Tender floated in 26 Mar’ 10.
the proposal approve in 265th CIL
board meeting in Feb 2011
:
2.00 MTY
:
Rs. 339.875 Crores
:
Rs. 0.0 Crores
:
Rs. 10.0 Crores
:
Rs. 259.47
Year
2015-16
2016-17
2017-18
2018-19
2019-20
Production (MTY)
0.250
0.450
0.832
1.832
2.000
Present Status: Incline drivage started & shaft sinking to be done.
16
Muraidih U/G turnkey project
Contd…
Proposed Technology:
•
•
•
•
It is proposed to extract of coal by “longwall technology” with powered support in
conjunction with gate road development by “Bolter Mine / Low Capacity Continuous
Miner”.
PSLW Longwall with single lift
Face Length :- 200M
Averege seam thickness
– Seam-iii 4.5m (PSLW set with max. Cutting height of 4.8m and max. Support height of 5.0m
will be used)
– Seam-i 2.5m (seam-iii PSLW equipment will be modified to make it suitable to work in
seam-i by modifying the supports and replacing the shearer.
•
Average Panel Length
– SEAM-III – SEAM-I -
•
•
•
1468M (RANGE 660M TO 2150M)
2037M (RANGE 920M TO 2060M)
Gate Road Development Will Be Done With Sandvik Miner Bolter / Low Cost
Continuous Miner
The production is scheduled to commence in the 3rd year and total guaranteed
production is envisaged to be 20.43 million tonne.
17
Kapuria U/G Turnkey Project
Conceived and tendered
Capacity
Sanctioned Capital
Expenditure till 31 Mar 14
Anticipated Expenditure in 2014-15
Profit (In Rs. Per Tonne)
:Tender floated in 27 April’ 10.
the proposal approve in 279th BCCL
board meeting in July 2011 &
consequently by CIL Board.
:
2.00 MTY
:
Rs.988.354 Crores
:
Rs. 0.0 Crores
:
Rs. 41.90 Crores
:
Rs. 846.54
Year
2015-16
2016-17
2017-18
2018-19
2019-20
Production (MTY)
0.00
0.00
0.20
0.90
1.50
Present Status: Preparatory work for shaft sinking is started & incline drivage
to be done.
18
Kapuria U/G Turnkey Project
Contd…
Proposed Technology:
• It is proposed to drive two reverse drifts to intersect
seam XVIIIA & XVIB for coal evacuation and man- riding
and for material transportation. One shaft (6.5m dia.
upto a depth of 520m.) will be sunk for providing main
return air way.
• The seam development and coal winning is proposed to
be accomplished with the engagement of bolter miner
and Powered support Longwall (retreating) technology
with power support with capacity of 90-100 T/m² for
extraction of coal and Bolter Miner for development of
gate roads.
19
Block-II Continuous Miner U/G
Turnkey Project
Conceived and tendered
Capacity
Sanctioned Capital
Expenditure till 31 Mar 14
Anticipated Expenditure in 2014-15
Profit (In Rs. Per Tonne)
:Tender floated in 25 Mar’ 10.
the proposal approve in 265th CIL
board meeting in Feb 2011
:
0.45 MTY
:
Rs.113.37 Crores
:
Rs. 0.0 Crores
:
Rs. 5.0 Crores
:
Rs. 107.82
Year
2015-16
2016-17
2017-18
2018-19
2019-20
Production (MTY)
0.00
0.15
0.30
0.45
0.45
Present Status: Agreement is likely to be signed soon after
discussion on clarifications sought by M/s. Minop.
20
Block-II Continuous Miner U/G Turnkey Project
Contd…
Proposed Technology:
•
The project report for introduction of Continuous Miner for
exploitation of I/II seam (0.45 MTY), Block-II Area was
approved by CIL Board on cost plus basis. In the proposed
area for underground mine, upper seam i.e. V/VI/VII seams
is being worked by opencast method and shall be kept
sufficiently ahead of proposed underground workings.
• It is proposed to drive two Nos. of reverse incline from
surface up to seam I/II which shall be utilised as intake and
a pit from surface to serve as return. The property is
proposed to be worked by Board & Pillar method and
followed by depillaring with caving using Continuous Miner.
21
Lohapatti UG Project
Conceived and tendered
Capacity
Sanctioned Capital
Expenditure till 31 Mar 14
Anticipated Expenditure in 2014-15
Year
Production (MTY)
:
:
:
:
:
Tender floated in 05 April ’ 11.
0.35 MTY
Rs.167.243 Crores
Rs. 0.0 Crores
Rs. 0.0 Crores
2015-16
2016-17
2017-18
2018-19
2019-20
0.00
0.00
0.10
0.35
0.35
Present Status: Approved by BCCL Board. To be implemented soon.
22
Lohapatti UG Project
Contd…
Proposed Technology:
• It is proposed to extract coal by board & pillar method
with continuous miner whereas shuttle cars shall be used
for face conveying and conveyor belt for final transport.
• First set of low height continuous miner will be engage in
upper seam with a annual production target of 0.35 Mty
up to the 11th Year.
• From 12th Year Production district will be shifted to lower
seams and normal height continuous miner package will
be introduced reproduced @ 0.45 Mty upto 22nd Year.
23
Benefits
 Infrastructure created for these high capacity UG Mines will be utilized
for the exploitation of balance reserve of the mines for next 30 year.
 Operation of these High capacity UG mines generate confidence among
us and train our workforce.
 During the operation of these high capacity UG mines will develop
indigenous capacity for required spares and equipments.
 These technology development for UG mines will be similar to
indigenization of Opencast technology which took place in last two
decade.
 With indigenization the success rate of Long wall technology will
improve where delay in supply of spares were major reason for failure
as continuity long wall operation is very significant for its success.
 These global UG technology is being adopted in different mines having
different geo mining condition which may help in adopting the
technology in large nos. of mines in future with varying geo mining
condition.
24
CONCLUSION
The
above
strategy
of
underground
augmentation developed and successfully
implemented by BCCL will no doubt bring about
landmark success in long term growth.
If adopted by all subsidiaries of CIL in their
mines
and
developing
high
capacity
underground mines will make the entire energy
sector sustainable.
25
THANK YOU
26