Highwall Mining Economic & Environment Friendly Coal Extraction - - PowerPoint PPT Presentation

Highwall Mining

Economic & Environment Friendly Coal Extraction by a Safe World Class method

Presenter:

• Mr. Anurag Dixit

West Bokaro, Tata Steel

Slide Tata Steel

West Bokaro - Introduction

▪ 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.

Jharkhand

Jamshedpur West Bokaro

200 km

Kedla

Laiyo

West Bokaro Colliery

Chainpur Railway Station

Danea Railway Station

KBP

Jhumra Hill

To Hazaribagh To Lalpania To Ramgarh Kedla Washery

Ramg Ramgarh Bok Bokaro

To Gomoh To Barkakhana

KOTRE BASANTPUR & PACHMO

Ramg Ramgarh Bok Bokaro

Lalgarh

Parej Pundi Gose

CCL Lease

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

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Slide Tata Steel

West Bokaro Improvement Journey

1947 The year West Bokaro Came into being 1972 Becomes a division of Tata Steel. Modernization Phase I 1982 Modernization Phase II 1994 Modernization Phase III 2006 1.9 mtpa clean

Underground Opening of Interim Quarry Opening of New Quarry with higher capacity Machineries 0.3 mtpa RC throughput 0.6 mtpa RC throughput 2.5 mtpa RC throughput 4.9 mtpa RC throughput

2016 Introduction of Highwall Miner

5.1 mtpa RC throughput

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First Coal washery in Asia (1951) State of the art Washery – III (1993) State of the art Mining & Maint. Facilities (SEB) - 2004

2018 Low density

• f Explosives

Slide Tata Steel

West Bokaro at a Glance : 5.1MT (RC), 2.4 MT (CC), 18.8 MCum (OB )

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Slide Tata Steel

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

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Slide Tata Steel

Adopting the world class technology

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2010 2011 2013 2014 2016 2017 Ideas conceptualize Team visits US Mining sites Feasibility Study (Internal) Design of HWM Panels (CIMFR + Tech. Partner) HWM Assembly at Site HWM Operation Stabilizes 2005 Trigger of the need

FY’18 = 0.5 MT

• Resource estimation for potential extraction
• Sequence of Panels for HWM deployment
• Collaborate with technological partners
• Web pillar’s empirical design by Sheorey

equation ( CIMFR )

• Grant of DGMS permissions
• Integration of HWM and Open cast running
• perations (First of its kind simultaneous
• peration)
• Developing skills and know how

2015 Integrated Planning (internal)

Slide Tata Steel

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

• verburden 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

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Slide Tata Steel

➢ 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 ➢ Jack Pad & Crawler

Dimensions / Specs :

➢ Length base 16.6 m ➢ Width base 8.3 m ➢ Length push beam 6 m ➢ 49 pushbeams per miner ➢

• Max. force

✓ Push in: 210 t ✓ Pull out: 410 t

Push Beams

Highwall Miner : Components

Operator Cabin Cutter Head Push Beam & Transfer Mechanism Coal Transfer Mechanism Loader

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Slide Tata Steel

Highwall Component :

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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

Slide Tata Steel

Highwall Miner – Operating principle

➢ Seam is penetrated by a continuous miner propelled by a hydraulic push beam transfer mechanism. ➢ Cycle includes pushing forward, raising and lowering of the cutter head boom to cut entire length of coal ➢ Push beams of 6 m are placed in between cutter head and power head as depth of penetration increases ➢ Using video imaging and gamma detector, the cutter head moves inside the seam and cut only coal ➢ All functioning is controlled from a touchscreen panel located in

• perator cabin.

➢ Small crew operates the whole system.

West Bokaro HWM : ➢ Penetration up to 300 meters ➢ Seams of 0.8 m to 4.5m, typical 1m to 3m ➢ Gradient of up to -8 degrees and +15 degrees ➢ Highest Monthly production – 75KT ➢ Operates with 6 man crew ➢ Coal Recovery : 30% – 65% ➢ Simultaneous in pit OB dumping

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Slide Tata Steel

Safety Management at Highwall

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• Slope stability Radar for real time slope monitoring (Digital)
• Methane detector for real time methane emission
• Bench monitoring using total station
• Subsidence and slope monitoring at the pit edge / surface
• Bore hole extensometer monitoring to know movement if any
• A protective bund to arrest small boulder’s accidental fall
• Regular dressing down of loose boulders to a height of 5-10m
• Placement of Machine 15 m from the high wall
• Access control / Temporary fencing to prevent entry
• Acceptable limit of Hole deviation is within 0.2%
• On board cameras and sensors working during the extraction
• PLC based Steering Arms
• Gyro sensors
• Water spraying interlock

Slope Stability Radar: ▪ Continuously measures mine wall movements with sub-millimetric accuracy ▪ Provides reliable early warning for progressive slope movement ▪ All weather conditions ▪ Map the long term evolution of slow moving slopes ▪ Eagle vision assists to High resolution images ▪ Triggers automated SMS alerts to concerned.

Continuous Strata monitoring using Radar

Slide Tata Steel

Highwall Mining Performance at West Bokaro

15 24 40 13 15 43 27 67 45 44 26 15 8 36 51 40 37 73 52 66

• 20

40 60 80 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

Monthly HW Coal Production Figs in KT

+36% Jan 450 Dec 243 Nov 272 Oct 344 Sep 273 Aug 106 Jul 144 Jun 220 May 303 Apr 305 FY 18E 3,190 FY 17 2,344 Run Hour

KPI Apr’16 Jan’18 Run Hour Per day 7.5 9.6 OMS 20 56 Productivity TPH 136 163 MTTR 25 10 MTBF 51 28 Sp Power 3.6 2.2

355 352 400 368 294

FY 17 3,752

• 21%

Jan

157

Dec Nov

180

Oct

51

Sep Aug Jul Jun 131 May

185

Apr FY 18E 2,965 B/D Hours

Challenges Actions taken Frequent breakdowns

• Timely replacement of Belly chain, Torque shaft,

Hydraulic pipe

• Optimization of Sumping rate

Face preparation

• Advanced Face Planning

Marching delays

• Advanced Backfilling to avoid to and fro marching

Power issues

• Dedicated power supply

Blasting delays

• Maintain time & Provision of blasting shelter

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Slide Tata Steel

Economic :

➢ Additional coal from ultimate pit limits and from constraint area ➢ Less operational cost. ➢ Lessen the burden of imports. ➢ No sizing cost for processing ➢ Homogeneous feed to plant

Social :

➢ Reduces impact of vibration, Dust, noise pollution in nearby areas. ➢ Extraction of coal from sensitive areas. ➢ Reduces indirect struggles to get clearances for land.

Environmental : ➢ Silent mining with minimum impact. ➢ Continuous Monitoring of methane. ➢ Dust suppression system ➢ Interlock of methane sensor (PLC) ➢ Utilization of scarce natural resources. Safety :

➢ Low man machine interface. ➢ Elevated cabins with cameras. ➢ Blast free technology. ➢ No underground exposure. ➢ Digitalized monitoring

Benefits

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Slide Tata Steel

Way Forward / Recommendations

▪ New technology in India ▪ Most promising technology as many open cast mines in India will reach to its ultimate pit slope in next 10-15 years

I ➢ Proven technology to extract blocked resources from its boundaries. ➢ Planned to extract 1 MT coal from the highwall of West Bokaro - differential cost benefit. ➢ Recoveries can further increase from 35% to 50% by backfilling. ➢ Technology suppliers of Highwall miner to enhance knowledge & skill of manpower (workers and executives). ➢ Maintenance support on spares availability and troubleshooting etc. from technology suppliers. ➢ Corporate initiatives to study and understand the benefits of this technology for mining practitioners. ➢ Policy makers to incentivize the introduction of Greener and safer technology to increase the available resource. ➢ Technology suppliers, policy makers & corporates to come together to improve sustainability of mining industry. Its matter of time and we will see usage of better technologies

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Slide Tata Steel 15

Hope have added some value !