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

2. 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

3. 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 %.

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

5. 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

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

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

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

9. Future Options of Technology & Mechanization – Perspective of CIL

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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.

16. 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

17. 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.

18. 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.

19. 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

20. 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

21. 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

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

23. Environment Management

24. Land Reclamation

25. 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