Highwall Mining Economic & Environment Friendly Coal Extraction by a Safe World Class method Presenter: Mr. Anurag Dixit West Bokaro, Tata Steel
Tata Steel Slide 2 West Bokaro - Introduction Geological Location : Situated under : West Bokaro Coalfields, Dist. Ramgarh. Nearest National Highway : NH 33 (16 kms by road) Nearest Airport: Ranchi Nearest Railway Station: Chainpur CCL Lease Jharkhand Ramgarh Ramg Bok Bokaro Danea Railway Jhumra Hill KOTRE BASANTPUR & Station Kedla KBP Lalgarh Washery To Gomoh PACHMO To Hazaribagh Laiyo Parej Kedla To Lalpania West Bokaro Colliery West Bokaro Pundi Gose 200 km Jamshedpur Chainpur Railway Station Bok Bokaro Ramg Ramgarh To Ramgarh To Barkakhana ▪ Total lease hole area : 1740 hectare ▪ Two Mining Quarries - QAB & QSE (RC 5.1MT), Two washeries (CC 2.4MT) & Thermal Power Plant (2X10 MW) & Logistics infrastructure ▪ World class Maintenance facilities for HEMM (Caterpillar, Hitachi, Komatsu, ReCP etc.) ▪ Residential colony with facilities like schools, Banks, hospital and modern amenities including recreational facilities. ▪ Surrounding rural areas developed by TSRDS for infrastructure, livelihood, women/youth empowerment, health & hygiene.
Tata Steel Slide 3 West Bokaro Improvement Journey State of the art Mining & Maint. Facilities (SEB) - 2004 State of the art Washery – III (1993) 2018 Low density 2006 2016 of Explosives 1994 1.9 mtpa clean Introduction of First Coal washery 1982 Modernization Highwall Miner in Asia (1951) Phase III 4.9 mtpa RC throughput 5.1 mtpa RC Modernization throughput 2.5 mtpa RC 1972 Phase II throughput Becomes a division of Tata 0.6 mtpa RC Steel. throughput Modernization 1947 Phase I The year West Bokaro 0.3 mtpa RC Came into throughput being Underground Opening of Interim Quarry Opening of New Quarry with higher capacity Machineries
Tata Steel Slide 4 West Bokaro at a Glance : 5.1MT (RC), 2.4 MT (CC), 18.8 MCum (OB )
Tata Steel Slide 5 Need for New Technology ▪ A significant quantity of coal gets lost forever at mine boundaries. ▪ Non availability of encumbrance free land (LA / FC / Utilities) for Mining / Extraction of coal. ▪ Limited Coal reserves to meet the captive requirements {Increased mine life + Environment friendly method + Reduced cost + Proven technology (to meet statutes)} x Safety of Man and Machinery = Highwall Mining
Tata Steel Slide 6 Adopting the world class technology 2005 Trigger of the need • Resource estimation for potential extraction Ideas conceptualize 2010 • Sequence of Panels for HWM deployment • Collaborate with technological partners 2011 Team visits US Mining sites • Web pillar’s empirical design by Sheorey equation ( CIMFR ) 2013 Feasibility Study (Internal) • Grant of DGMS permissions Design of HWM Panels 2014 (CIMFR + Tech. Partner) • Integration of HWM and Open cast running operations (First of its kind simultaneous 2015 Integrated Planning (internal) operation) HWM Assembly at Site 2016 • Developing skills and know how HWM Operation Stabilizes 2017 FY’18 = 0.5 MT
Tata Steel Slide 7 Highwall Mining at West Bokaro Highwall Miner : ▪ Remotely operated cutter head goes underground (Near horizontal) = no underground exposure to personnel ▪ Extraction by parallel drivages (300m length) leaving coal web pillars = Provides stability to strata ▪ Ventilation / Roof support not required as no exposure to the people. = Ergonomic ease in operation ▪ No drilling or blasting hence no vibration/ noise to the people. = Friendly neighbor hood for operation ▪ Ascending operation : facilitates simultaneous in-pit overburden dumping = Compaction with Added Stability ▪ First of its kind – simultaneous operation alongside open cast = Robust Integrated Planning : Reduced Cost ▪ Automation and Digitalization = Advanced safety interventions ▪ Less Manpower = Single digit in number of people working
Tata Steel Slide 8 Highwall Miner : Components Operator Cabin ➢ Cutter head (1.5m to 4.5m x 3.5m) ➢ Push beams ➢ Push beam transfer mechanism ➢ Screw Conveyor ➢ Chain Conveyor (RAC) ➢ Operator cabin ➢ Loader / Stacker conveyor Cutter Head ➢ Jack Pad & Crawler Dimensions / Specs : ➢ Length base 16.6 m Coal Transfer ➢ Width base 8.3 m Push Beam & Mechanism ➢ Length push beam 6 m Transfer Mechanism ➢ 49 pushbeams per miner ➢ Max. force ✓ Push in: 210 t ✓ Pull out: 410 t Loader Push Beams
Tata Steel Slide 9 Highwall Component : Features Specifications / Details Cutter Head Cutting height 1.5m to 4.5m Gathering System Two Gathering arms to collect coal Horizontal Control Up and Down controlled by lower shear return point Cable reeling drum Armored protection of power cable, hoses, pipes Navigation & Steering Fibre Optic Gyro Compass in Cutter head, PLC operated steering arms Electric Controls Electrical switchgears operated on Electrical Control Module Continuous Video Monitoring For real time feedback and control Hydraulic Control Provided with explosion proof solenoids Water Spray Interlock Cutting stops when water pressure is below required pressure Failsafe Methane Monitor Interlocking of methane sensor, If exceeds 1.25%, Power to cut off
Tata Steel Slide 10 West Bokaro HWM : Highwall Miner – Operating principle ➢ Penetration up to 300 meters ➢ Seam is penetrated by a continuous miner propelled by a ➢ Seams of 0.8 m to 4.5m, typical 1m to 3m hydraulic push beam transfer mechanism. ➢ Cycle includes pushing forward, raising and lowering of the cutter ➢ Gradient of up to -8 degrees and +15 head boom to cut entire length of coal degrees ➢ Push beams of 6 m are placed in between cutter head and power head as depth of penetration increases ➢ Highest Monthly production – 75KT ➢ Using video imaging and gamma detector, the cutter head moves ➢ Operates with 6 man crew inside the seam and cut only coal ➢ All functioning is controlled from a touchscreen panel located in ➢ Coal Recovery : 30% – 65% operator cabin. ➢ Simultaneous in pit OB dumping ➢ Small crew operates the whole system.
Tata Steel Slide 11 Continuous Strata monitoring using Radar Safety Management at Highwall Slope Stability Radar: Slope stability Radar for real time slope monitoring (Digital) o ▪ Continuously measures mine wall Methane detector for real time methane emission o movements with sub-millimetric accuracy Bench monitoring using total station o ▪ Provides reliable early warning for Subsidence and slope monitoring at the pit edge / surface o progressive slope movement Bore hole extensometer monitoring to know movement if any o ▪ All weather conditions A protective bund to arrest small boulder’s accidental fall ▪ Map the long term evolution of slow o moving slopes Regular dressing down of loose boulders to a height of 5-10m o ▪ Eagle vision assists to High Placement of Machine 15 m from the high wall resolution images o ▪ Triggers automated SMS alerts to Access control / Temporary fencing to prevent entry o concerned. Acceptable limit of Hole deviation is within 0.2% o On board cameras and sensors working during the extraction o PLC based Steering Arms o Gyro sensors o Water spraying interlock o
Tata Steel Slide 12 Highwall Mining Performance at West Bokaro Apr’16 Jan’18 KPI Figs in KT Run Hour Per day 7.5 9.6 80 67 73 66 Monthly HW Coal Production 52 51 40 37 60 45 44 OMS 20 56 43 40 36 27 26 15 8 40 15 24 Productivity TPH 136 163 13 15 20 MTTR 25 10 - MTBF 51 28 Aug-16 Sep-16 Oct-16 Nov-16 Dec-16 Jan-17 Feb-17 Mar-17 Apr-17 May-17 Jun-17 Jul-17 Aug-17 Sep-17 Oct-17 Nov-17 Dec-17 Jan-18 Feb-18 Mar-18 Sp Power 3.6 2.2 3,190 Run Hour Challenges Actions taken +36% 2,344 450 • 344 Frequent Timely replacement of Belly chain, Torque shaft, 305 303 273 272 243 220 144 106 breakdowns Hydraulic pipe • Optimization of Sumping rate FY FY Apr May Jun Jul Aug Sep Oct Nov Dec Jan 17 18E • Face preparation Advanced Face Planning 3,752 • Marching delays Advanced Backfilling to avoid to and fro marching B/D Hours -21% 2,965 • Power issues Dedicated power supply 400 368 352 355 294 185 131 180 157 51 • Blasting delays Maintain time & Provision of blasting shelter FY FY Apr May Jun Jul Aug Sep Oct Nov Dec Jan 17 18E
Tata Steel Slide 13 Economic : Environmental : ➢ Additional coal from ultimate pit ➢ Silent mining with minimum impact. limits and from constraint area ➢ Continuous Monitoring of methane. ➢ Less operational cost. ➢ Dust suppression system ➢ Lessen the burden of imports . ➢ Interlock of methane sensor (PLC) ➢ No sizing cost for processing ➢ Utilization of scarce natural resources. ➢ Homogeneous feed to plant Benefits Safety : Social : ➢ Low man machine interface. ➢ Reduces impact of vibration, Dust, noise pollution in nearby areas. ➢ Elevated cabins with cameras. ➢ Extraction of coal from sensitive ➢ Blast free technology. areas. ➢ No underground exposure. ➢ Reduces indirect struggles to get clearances for land. ➢ Digitalized monitoring
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