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Two methods;
Opencast
Underground.
When the cost of Overburden removal to
expose the coal is economical, opencast
mining is adopted.
Technology used in underground mining
depends on geology and geometry of the
seam.
Smaller deposits can have Manual loading and intermediate
technologies with continuous miners or LHDsand SDLsBord
and Pillar method.
Large reserve and uniform deposit are mined by Longwall
mining a bulk production but capital intensive technology.
Mechanisation in Bord and pillar has limitations of gradients.
Seams steeper than 12(1 in 5 ) are not suitable -leaving little
possibility to mechanise most of the mines with these
deposits.
Existing technologies
A) TECHNOLOGIES IN OPEN CAST
1)SHOVEL-DUMPER
2)SURFACE MINER
3)DRAGLINE
4)HIGH WALL MINING
B) TECHNOLOGIES IN UNDERGROUND
1) MANUAL
2) SEMI MECHANISATION
i)SDLs
ii)LHDs
iii)CONTINUOUS MINER
3) LONGWALL MECHANIZATION : Shearer, etc.
BP
METHODS
LW
UG EQUIPMENT
INTERMEDIATE
TECHNOLOGY
MASS PROD
DRILLING
LIGHTING BLASTING
PUMPING CUTTING
UG
OPERATIONS
VENTILATION SUPPORT
HAULING
TARNSFER /
TRANSPORT
UG MINING
EQUIPMENT
COAL CUTTING
SDL COAL MATERIAL MAN
MC
CONTINUOUS
GAL ENDLESS BELT DRUM MAN RIDING
MINER
BORER
UNDERGROUND MECHANISATION STATUS (Feb11)
ROAD HEADER 2 4 6
PSLW 1 3 3 7
SHW 1 1
CONT MINER 2 2 2 6
UNDERGROUND MECHANISATION PRODUCTION
STATUS (2009-10)
EQUIPMENT ECL BCCL CCL WCL SECL MCL CIL
SDL 3.08 2.79 0.23 2.86 9.81 0.47 19.24
LHD 1.02 0.05 0.16 5.94 6.75 4.67 18.59
ROAD HEADER 0.01 0.05 0.06
CONT MINER 0.46 0.17 0.48 1.11
SHW 0.33 0.33
PSLW 0.03 0.16 0.03 0.22
CONV MECH LW 0.03 0.03
MECHANISED 4.59 3.08 0.40 8.96 17.39 2.14 36.56
MANUAL 3.64 0.82 1.07 0.66 0.44 0.06 6.69
TOTAL UG 8.23 3.90 1.47 9.62 17.83 2.20 43.25
TECHNICAL CONSIDERATIONS
Based on gradient of the seam :
Manual : In all grdients
Board
CONTINUOUS MINER package
For DEVELOPMENT & EXTRACTION
Continuous miner* - 1 no.
Shuttle cars - 2 no.
Twin/ Quad bolter* - 1 no.
Feeder breaker - 1 no.
Power pack - 1 no.
Mobile goaf edge support (Optional) -2 nos.
(* In some package both the machines are integrated into one)
LIGHTING BLASTING
PUMPING CUTTING
UG
OPERATIONS
VENTILATION SUPPORT
HAULING
TARNSFER /
TRANSPORT
Product Range Roof
Supports
Shearers
A.F.Cs
Shuttle Cars
Continuous
Miners
Continuous
Haulage
Articulated
Haulage
Flexible
Conveyor
Train
UG MINING
EQUIPMENT
COAL CUTTING
SDL COAL MATERIAL MAN
MC
CONTINUOUS
GAL ENDLESS BELT DRUM MAN RIDING
MINER
BORER
UG MINING METHODS
BORD & PILLAR Method
LONGWALL Method
ECL 161 38 - 2 1 - 2
BCCL 147 3 - 4 3 - -
CCL 19 6 - - - - -
NCL - - - - - - -
WCL 73 116 - - - - 2
Support design
Calculation of deformation
(longwall / face roadways)
SDL LHD
TECHNOLOGICAL OPTION IN UNDERGROUND MINES
MINING WITH BLASTING AT FACES
Conventional Bord and Pillar with Side Discharge Loader(SDL)/ Load Haul
Dump (LHD) m/c.
Bord and Pillar with SDL/LHD & Universal Drill Machine (UDM)
Cable Bolting method with Remote SDL/LHD
Blasting gallery Method of Mining
However, hike in wages cost and quantum jump in coal demand now
necessitates search for suitable technological option.
SDL LHD
MINING WITH BLASTING AT FACES
Bord and Pillar with SDL/LHD & Universal Drill Machine (UDM).
UDMs have been introduced for coal face and roof drilling in several
mines with following advantages:
SDL LHD
MINING WITH BLASTING AT FACES
Cable Bolting method with Remote SDL/LHD in Bord & Pillar layout.
SDL LHD
MINING WITH BLASTING AT FACES
BARRIER
Step 6
seams
(6-8 m) BARRIER
SDL LHD
BLASTING FREE MINING
M.P. Dikshit
Chairman-cum Managing Director
South Eastern Coalfields Limited
SHORTWALL MINING AT
BALRAMPUR MINE, BISHRAMPUR
AREA, SECL
B A R R I E R
GOAF
FACE
RETREATING
P I L L A R S
PANEL LENGTH = 540M
110
INTRODUCTION
The Shortwall technology for extraction of developed
bord & pillar property.
PSLW with associated equipment.
Implemented at Balrampur Mine in CIC.
SHORTWALL MINING
Shortwall Mining - an evolutionary variation of L/W
mining for extraction of developed B&P workings.
Geometric simplicity (Shorter face length : 84m/104m)
EQUIPMEN Shearer
T
Bridge Stage Loader & Crusher
Power Pack & Communication
System(Ck2), Electricals
POWERED SUPPORTS
3.62 m
Canopy
Back Shield
Leg
1.4-2.7m
Lemniscates linkage
Base
2.14 m
POWERED SUPPORTS-
TECHNICAL FEATURE
Type of Support 4 Leg Chock Shied
Height 1.4- 2.7m
Canopy Length 3.62m
Width 1.5m
Support Density 116 Te/m 2 (min.span)
100 Te/m2 (max.span)
Setting Pressure 30MPa
Yield Pressure 41MPa
Capacity 650 Te.
Operation Mode Adjacent Control
Weight 16.13 Te.
SHEARER
TECHNICAL FEATURES
Coal Seam
Cutting Height 1.5 3.1 m
Inclination <= 35
Coal Hardness Medium to Hard
DESCRIPTION OF SHEARER
Drum Diameter : 1600mm
Centre dis. of Drum : 8432mm
Web Depth : 600mm
(Maximum)
b) Chain 0.92m/second
Speed
c) Motor 150 kW Tail
(Tail and and Drive end
Drive) at 1.1 KV.
d) Line Pan 1500mmX
Size 764mm X
275mm
e) Chain Size 26 X 92 mm
BRIDGE STAGE LOADER (B.S.L.)
Make CME, I&E, PR-China
Type SZZ-764/132
Effective overlap 12m
Line Pan Size 1500mmX764mmX222m
m
Chain Configuration 2 In-board
Chain Dimension 26mm X 92mm
Chain Speed (m/Sec) 1.2 m/Sec.
Distance bet. flight (mm): 736mm
Conveying Capacity 900 TPH
Drive Motor 132 KW / 1.1 KV
POWER PACK
DESCRIPTION VALUE
A) Nominal Pressure 31.5 MPa
B) Nominal Flow 200 LPM
C) Motor Power 125 kW / 1100 V
D) Water emulsion oil 95 : 5
ratio
E) Emulsion Tank
i) Model R X 1600
ii) Capacity 2 X 1000 Ltrs.
iii) Fluid medium Emulsion (95% clean &
neutral water with 5%
POWER TRAIN / ENERGY TRAIN
Electricals for Shortwall operation installed at main gate
in Energy/ Power Train (on 14 trolleys).
AFC
Bunker
BSL +
Crusher
Gate Belt At Surface
Conveyor Trunk Belts
LAYOUT OF EQUIPMENT AND STRATA
MONITORING INSTRUMENTS AT THE
SHORTWALL PANEL
ClickMe.exe
Continuous miner in operation (Animation)
5-entry_R&P.exe
Coal Indias plan for enhancing UG coal
production Projections
Production (Mt)
Company 2006-07 Increase
2011-12
(Actual) over 06-07
ECL 8.27 16.73 8.46
BCCL 4.90 6.00 1.10
CCL 1.96 3.30 1.34
WCL 9.92 11.92 2.00
SECL 16.20 23.78 7.58
MCL 1.97 4.40 2.43
NEC 0.11 0.40 0.29
Total 43.32 66.53 23.21
Coal Indias plan for enhancing UG coal production
Equipment requirement (XI Plan)
PSLW (Existing) 3 1 0 0 1 0 5
Additional 1 2 0 2 1 0 6
2. Mining Technology of China
Coal-mining Method
Coal-mining method
others
Single Single Top-slicing
LWM LWM Full seam mining system of
on the on the Inclined slicing sublevel caving
strick dip On the strike
Flexible shield Overhand mining
mining in the Oblique slicing
false dip Shrinkage stoping, and so on
2. Mining Technology of China
Coal-mining Method
Yield support
Full-mechanized
workface
Back flight
conveyor
Coal wining
machine
Auxiliary transport
Auxiliary transport personnel,
materials and facilities, and so on.
Underground auxiliary transport: mine
locomotive, trackless transport,
overhead rope monorail, road railer,
endless-rope haulage.
Underground mine locomotive
Mine locomotive
Track transport
Trackless transport conveying yield support
Trackless transport conveying
people
Battery
engine
Overhead
monorail
Diesel engine
Diesel engine road wailer running on oriented
track, driven by diesel engine.
Road wailer
Diesel engine
Underground Overhead
System sketch
Conveyor for People
Capabality:100~3000t/h
Power:100~2000kW
Pan width:0.4~1.2m
Double straps in the
middle, side unloading
3. Manufacture& Equipment of CCI
Support strength:
10000kN
Support height:
1.8~4.0m
3. Manufacture& Equipment of CCI
High Mining Height Hydraulic Support
Belt conveyor
Belt strength:250~6300N/mm
Belt width:0.6~2.0m
Conveyor capability:
150~5000t/h
3. Manufacture& Equipment of CCI
Road-heading machinery
Producing tunneling machine,
continuous miner, driving anchor
machine, driving& boring
machine.
Power:50200kW
Section area:1025m2
Tunneling machine
Mine
ventilation
Production capacity
designed: 15.0Mt/a
( largest mine being put
into operation currently)
Drift tunnelingbelt
conveyor length reaches
7km
Full-mechanized top-coal
caving workface ,
10.0Mt/a
high efficiency
Trackless transport
Introduction to some selection projects--Huojitu
Output10.0Mt/a
Drift tunneling
Large cutting height face, mining height 5.5m
270workers, average efficiency: 74t/worker
Introduction to some selection projects--Tunliu
Auxiliary
vertical shaft
4
North
airshaft
Coalface of north-
1 mining area
Main vertical Central airshaft
shaft
Coalface of south-1
mining area Tunneling face
Ground
Hoisting
Belt conveyor
Underground
Belt conveyor
Belt conveyor
4. Selection Projects Designed by BHEC
Inclined shaft, large cutting height face in whole seam, output of face is
3
Vertical shaft
tunneling
Roadway tunneling and support
1-roadheader2-transfermachine3-telescopic4-slideway
5-dedusting fan;6-scalable;7-jackleg drill
SUITABILITY
ADVANTAGES
METHODOLOGY
PARTIAL METHODS OF EXTRACTION
Limitations:
LONGWALL MINING
Operational Experience:
Operational Constraints:
Strata Management
Difficulties due to shallow depth of cover
Intrusion of hard sand stone
Warranty failures of major hydraulic components
Thinning of coal seams
Spares management
MASS PRODUCTION TECHNOLOGY
Limitations:
Operations:
Limitations:
Applicable to developed B & P workings.
HIGH WALL MINING
Suitability:
Enables recovery of coal from surface pits -
that have reached final high wall position due to
uneconomic stripping ratio or
where coal has become sterilized due to surface
constraints.
Limitations:
stability of web-pillars & sustainability of roof have to be
established by scientific investigations.
Advantages:
Minimises safety risks as persons are not required at active
working faces.
Coal is recovered from very difficult situations, other wise it
could have been forfeited for good.
MINING WITH SDL / LHD COMBINATIONS
MINING WITH SDL / LHD COMBINATIONS
Limitations:
This method is not yet proved for seam thickness
more than 7m.
Not suitable for higher degree of gassiness.
Not suitable under poor roof condition.
Not suitable shorter incubation period.
MINING WITH SDL / LHD COMBINATIONS
LONGWALL
BORD & PILLAR
MANUAL
CONTINUOUS MINER
UNDERGROUND MINING TECHNOLOGY IN INDIA AND ABROAD:
- Shuttle Car Gathering Arm Loader Combination.
- Slusher/Coal Scrapper
- Bord and Pillar Technology with SDL/LHD as loading and suitable
compatible conveying equipment.
- Sub-level caving.
- Limited Span Mining
- Wide Stall Mining
- Longwall with Single ended Ranging Arm Drum Shearer and hydraulic/friction
props.
- Mechanised Longwall with Powered Support equipment & DERD Shearer.
- Continuous Miner and Shuttle Car Combination.
- Road Header/Alpine Miner for faster heading development in coal seams.
- Blasting gallery technique of extraction in moderately thick coal seams
with remotely operated SDL/ LHD .
(c) Strategic underground mining technology in SECL:
Mechanisation culture and adoption of new technology is continued in SECL since long.
Some of the new technologies as planned for implementation in SECL mines are :-
(v) A small quantum of coal production from conventional manual districts in the
underground mines of SECL is also planned for conversion to mechanized operation within a
short spell of time.
SDL & LHD
CONTINUOUS MINER
LONGWALL
INDIVIDUAL PROPS
SOLID BLASTING
SHEARER
PLOUGH
AUGER MINING
PUNCH LONGWALL
HYDRAULIC MINING
HIGH WALL MINING
HIGH WALL MINER
AUGER MINING
PUNCH LONGWAll
HYDRAULIC MINING
COAL PRODUCTION PROGRAMME
OC/UG BREAK-UP
COM- OC/ ACTUAL TARGET, Mt (%)
PANY UG (Mt)(%)
06-07 07-08 11-12 16-17 21-22 26-27
ECL OC 22.2 (72.86) 23.18 (69.38) 32.84 (71.39) 34.86 (72.63) 32.20 (71.97) 32.20 (72.18)
UG 8.27 (27.14) 10.23 (30.62) 13.16 (28.61) 13.14 (27.38) 12.54 (28.03) 12.41 (27.82)
BCCL OC 19.30 (79.76) 20.62 (81.83) 24.72 (82.40) 28.75 (82.14) 31.39 (74.74) 31.70 (76.18)
UG 4.90 (20.24) 4.58 (18.17) 5.28 (17.60) 6.25 (17.86) 10.61 (25.26) 9.91 (23.82)
CCL OC 39.36 (95.26) 42.00 (95.45) 75.60 (96.92) 112.60(97.91) 114.29(97.25) 115.87(97.30)
UG 1.96 (4.74) 2.00 (4.55) 2.40 (3.08) 2.40 (2.09) 3.23 (2.75) 3.21 (2.70)
WCL OC 33.30 (77.07) 32.39 (76.39) 34.38 (76.40) 34.21 (76.02) 26.65 (67.28) 22.36 (60.66)
UG 9.92 (22.93) 10.01 (23.61) 10.62 (23.60) 10.79 (23.98) 12.96 (32.72) 14.50 (39.34)
SECL OC 72.30 (81.69) 74.04 (80.92) 91.30 (82.25) 119.00(85.00) 109.11(81.57) 107.05(86.01)
UG 16.20 (18.31) 17.46 (19.08) 19.70 (17.75) 21.00 (15.00) 24.66 (18.43) 17.41 (13.99)
NCL OC 52.16 (100) 58.00 (100) 70.00 (100) 80.50 (100) 81.50 (100) 81.50 (100)
UG - - - - - -
520.50
500
384.51
400360.91
606.42 574.14 557.68
300 465.94
200 337.53
317.59
100
46.98 54.56 57.58 67.92 61.03
0 43.32
2006-07 2007-08 2011-12 2016-17 2021-22 2026-27
(Actual)
Year
50 48.00
Coal Production Target, Mt
20 23.18
22.20
10
10.23 13.16 13.14 12.54 12.41
8.27
0
2006-07 2007-08 2011-12 2016-17 2021-22 2026-27
(Actual)
Year
35
30 30.00
25.20 31.39
25 24.21 31.70
20 28.75
24.72
15 20.62
19.30
10
5 10.61 9.91
4.58 5.28 6.25
0 4.90
2006-07 2007-08 2011-12 2016-17 2021-22 2026-27
(Actual)
Year
100
80 78.00
20 42.00
39.36
40 36.86
35
30
32.39 34.38 34.21 26.65
25 33.30 22.36
20
15
10
12.96 14.50
5 10.01 10.62 10.79
9.92
0
2006-07 2007-08 2011-12 2016-17 2021-22 2026-27
(Actual)
Year
120 111.00
10088.50 91.50
80 119.00 109.11
107.05
60 91.30
72.30 74.04
40
20
17.46 19.70 21.00 24.66 17.41
0 16.20
2006-07 2007-08 2011-12 2016-17 2021-22 2026-27
(Actual)
Year
70
60 58.00
52.16
50
40 80.50 81.50 81.50
70.00
30 58.00
52.16
20
10
0
2006-07 2007-08 2011-12 2016-17 2021-22 2026-27
(Actual)
Year
Opencast Total
COAL PRODUCTION PROGRAMME
MCL
250
197.00
Coal Production Target, Mt
200 182.92
170.59
150 137.00
3
2.00
2 3.10 3.10
2
1.05 1.70
1
1 0.94
0.30 0.40 0.40
0 0.11
2006-07 (Actual) 2007-08 2011-12 2016-17
Year
INTRODUCTION
- The gap between production and demand of coal
in future can not be totally met by the depleting
Opencast mines. Hence immediate and urgent
attention is required to plan and execute large
underground coal mining projects.
- For bulk production of coal at a faster rate from
underground mining, particularly at depth, the
proven technology world over is Longwall.
INDIAN LONGWALL
- PAST EXPERIENCE:
- Introduction of advanced technology system in
Indian coal mining industry marked a major step
with the installation of first mechanized Longwall
Powered support face at Moonidih in August 1978.
- In 25 years about 20 mechanised longwall sets from
- U.K, Russia, China, France have been tried in
various locales, mostly funded by GOI.
Mechanised Longwall mining was introduced
in India about 25 years back with much
fanfare but could not fully meet the
expectations of the mining industry for various
reasons, while China starting at the same time
was quite successful and even exported their
Longwall packages to India.
PAST EXPERIENCE
- In early nineties, higher capacity of Longwall
powered supports were introduced.
- These faces were mostly succesful except the
collapse of Churcha and Kotadih.
- With the perspective of history of Longwall of China,
US etc and the need of understanding the
technology these should be treated as experiences
rather than failures.
REASONS FOR THE UNSUCCESSFUL
ATTEMPTS TO INTRODUCE
LONGWALL TECHNOLOGY IN INDIA