Opencast Mining Technology Higher Production and Productivity Modernisation of Opencast Mining Technology For Higher Production and Productivity T.K.Nag CMD NCL

STRATEGIC IMPORTANCE OF INDIAN COAL SECTOR Around 77 % of coal consumed met through indigenous source CIL produces 81.73% of India’s current coal production Coal – India’s Primary Source of Energy * Others 9.4 % SCCL 8.9% CIL 81.7% Coal Production : Company -wise Share Sector-wise Supply Share from CIL Sources * Others include captive producer ,TATA STEEL, Meghalaya & Other PSUs ** Others include cement, sponge iron, fertilizer. Bricks etc 2 Source : Coal Controller

Open Cast Mining in Coal India Limited Spread over in Eight States ~ Jharkhand, WB, Orissa, CG, MP, UP, Maharashtra & Assam Operates 430 Mines through 82 Areas OC Mines-175 Contribution of OC has crossed 93 %.

Existing Scenario – Opencast Mining Dragline Shovel-Dumper Combination Surface Miner In-Pit Crushing & Conveying

Existing Size & Population of Equipment- CIL Mines OC Mines: Draglines ( 5 m3 to 30 m3) : 36 Nos Excavators (1.2 m3 to 42 m3) : 704 Nos Dumpers (35 T to 240 T) : 2829 Nos Crawler Dozer (320 HP to 850 HP) : 916 Nos Drill (100 mm to 350 mm) : 676 Nos Source : CMPDI

*One Bt Production: Projection for Next 5 Years Mt * 908 Mt identified; Further identification underway

OB Removal Projection (MM3) - CIL Present Striping Ratio: 1.8; In 19-20, Striping Ratio – 2.75

Largest Volume Handling in CIL 100% Coal Production in NCL by Departmental means

Future Options of Technology & Mechanization – Perspective of CIL

POTENTIAL AREAS FOR IMPROVEMENT IN OPENCAST MINING TECHNOLOGY NCL Equipment selection : Incorporate high performance equipment and avoid mismatch Maintenance Management : Switching to CMMS system using EAM and ERP Software Electrical Power Supply re-organsiation Improvisation in Blasting Techniques : To minimise public annoyance, mitigate environment and Ground Vibration issues Water Management Mine Illumination and Haul road maintenance Monitoring the safety of OB dumps Use of IT for checking pilferage of coal

TECHNOLOGICAL UPGRADATION NCL Higher capacity Draglines, Shovels, Dumpers for better health monitoring, reliability, productivity & safety 24/96 Draglines in place of 10/70 Draglines , 20 Cum Shovels & 200T or Equivalent Dumpers Procurement of Draglines & Shovels with AC drive systems 24/88 Draglines & 20 cum shovels with AC Digital drives in future procurement GPS based machines for monitoring location and working on real time basis from anywhere. GPS option is included in 200 T or equivalent dumpers, 20 cum shovels & draglines. Replacement of Some ER Shovels with Sate of the art Hydraulic Shovels

TECHNOLOGICAL UPGRADATION NCL Mandatory air-conditioned operator cabin to increase productivity Improvement in Haul Road design so as to reduce wear and tear of tyres. Simulator Training for Dumper, Shovel and Dragline Operators Creation of NDT facility at Central Work Shops for ensuring structural stability of HEMMs Auto lubrication system in all HEMMs

TECHNOLOGICAL UPGRADATION Pay load monitoring system Vehicle health monitoring system   Proximity working device to detect objects in close proximity of the equipment and generation of alerts in case of presence of any object Tail gate protection/ Anti collision device to provide additional protection to the Operator Extensive use of condition monitoring & NDT NCL

Long term contract with OEM for maintaining DEPOT of all Major HEMMs Way forward NCL Reliability improvement by technology upgradation for existing equipment with help of OEMs Procurement of only proven and performing equipment based on life cycle cost Insurance coverage for fire prone equipment like hydraulic shovels Long term contract with OEM for maintaining DEPOT of all Major HEMMs

Human Capital – Skill Development NCL OEMs may be asked to deploy their service personnel at mine premises for long period Comprehensive training(class room & on job) by OEM for maintenance & operation personnel Pool of manpower(skilled & Unskilled) for deployment from a man power resource centre formed for the purpose to fulfill the manpower requirements.

Technology Up-gradation – OC Mines Particulars Present Level of Technology Future Perspective OB Removal & Coal Production Use of Surface Miners More use of Surface Miners - wherever feasible - for the purpose of selective mining, maintaining quality of coal etc. Haul Road maintenance by motor-grader Extensive use of high capacity motor – graders & vibratory road rollers, ripper dozer to establish & maintain haul roads, Use of RCC in Haul roads

Technology Up-gradation – OC Mines Particulars Present Level of Technology Future Perspective Transport of Coal from Mine to loading point Coal loading through front end loader with dumpers, CHP & Silo arrangement with conveyors Installation of more CHP & Silos for faster loading Increased use of ‘In-Pit Crushing & Conveying System’ Use of Angle conveyors including high angle conveyors, Skip conveyors, Tube Conveyors, Flexible Conveyors Coal Transportation through rail, road, MGR, conveyors & aerial ropeways To continue with the existing modes with capacity enhancement of rail transportation.

Technology Up-gradation – OC Mines Particulars Present Level of Technology Future Perspective Maintenance Management Break –down maintenance, preventive maintenance Up-gradation of workshops with modern facilities, On-line machine health check up, Routine condition monitoring Mining steeply dipping seams Conventional Mining Redesign open cut mines to reduce haul distances and elevations & dump schedules.

Training of Manpower : Skill Development Particulars Present Level of Technology Future Perspective Training of workforce Conventional Training Modules Simulation training for workforce of OC Extensive use of simulation training for all OC machines

Technology Up-gradation – Mine Safety Particulars Present Level of Technology Future Perspective Mine Plan Maintenance Conventional & Digitization of Mine Plan 3D Simulation of Mine Plan Blasting Technology Conventional Technology Advanced technology, e.g. Computer Aided Blast Design, Borehole Tracking system, use of E-Dets

Technology Up-gradation – Information Technology Particulars Present Level of Technology Future Perspective Use of IT Limited use of IT - OITDS, GPS/GPRS, Inventory Management & in office set up More use of IT in equipment monitoring for example, Vehicle tracking system using GPS/GPRS, Monitoring Dump Stability by using 3-D Laser Scanners RFID Integrated Weighbridge Safety management Office set-up ERP Solutions Coalnet developed by IIT is in use Migration to latest ERP solution

Other System Improvements E procurement of equipment & spares Reverse Tendering of Work & Services Establishment of connectivity

Environment Management

Land Reclamation

Ground cover after one year Eco-restoration work through FRI, Dehradun at Nigahi And Krishanshila on 10 Hact OB dump Ground cover after one year