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Coal India
Coal Management Speak
Coal accounts for 51% of India’s energy basket, and has assumed the proportions of a ‘burning issue’ as despite being
the backbone of the economy, reforms have largely by-passed the sector. Coal will remain the fuel of choice for key
user industries – power, steel and cement – which are executing humongous expansion plans to meet the country’s
infrastructure needs. We recently released a report on “Indian coal sector” (dated 19 April 2010) highlighting the
widening demand-supply chasm in the Indian coal industry. According to our estimates, demand is likely to grow 2.5x
by FY17 from the base of 555m tonnes in FY09 – which implies a potential coal deficit of 472m tonnes by then. This
report is another step on our part to seek clarity on the contours of the sector. We interacted with the management of
Coal India (CIL), world’s largest coal company and India’s primary source of coal supply (accounting for 82% of India’s
coal production). Our queries revolved around CIL’s preparedness to address production bottlenecks and effect
productivity improvements, coal pricing in India, progress on international acquisitions and the status of its upcoming
IPO. The management has highlighted that CIL is taking every step possible to meet supply-side expectations as also
ensure that mining is done with a ‘human face’. Even as employee productivity is on an uptrend at CIL, the company
intends to pursue an optimal mix of man and machines to maintain not only a low operating cost but also low capital
costs. Finally, CIL seems geared for international acquisitions and the upcoming IPO. Salient points of our interaction
with Coal India management are as follows.
India faces huge coal shortage. Given the pivotal role that CIL plays in India’s coal supply, what is being done to
accelerate production?
CIL’s coal production has registered a CAGR of ~6% for the last few years. The company has undertaken several measures
to ramp up production to meet the rapidly increasing demand from power generation, steel and cement sectors. Going
forward, CIL plans to invest US$7.5bn into 142 new projects having a cumulative capacity of 380m tonnes. Also, drilling
targets have been increased by 3x with the objective to accrete reserves, which will eventually translate into higher
production. CIL also plans to improve efficiency at its existing mines which has a good scope to increase production from
current levels. The company plans to invest significantly in R&D activities, training and development along with a
substantial investment into ordering of equipment which will drive productivity and augment production.
A large portion of CIL’s incremental production is likely to come from new mines, which typically face
commissioning delays. How is CIL preparing itself to address these bottlenecks?
In contrast to the 11th 5-Year Plan period (FY07-12), bulk of the targeted incremental production during the 12th Plan
period is proposed to be met through commissioning of new mines. However, commencement of these mines could be
delayed due to bureaucratic delays and other obstacles like land acquisition, forest and environmental clearances, etc.
Given that demand-supply gap has already widened to ~70m tpa and is expected to cross 80m tpa by FY12, several
initiatives have been proposed to fast-track regulatory approvals. Key among them are:
(a) The Prime Minister’s Energy Coordination Committee (ECC) – the apex policymaking body for the energy sector – is
giving shape to a proposal that envisages forestry clearance for new coal mining projects within 150 days and for renewals
in 120 days.
“For Private Circulation only” and “Important disclosures appear at the back of this report”
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(b) Environment clearance for coal mining projects would be given within 60 days while the projects that have already
received forestry clearance would be eligible for automatic environmental clearance
(c) The Ministry of Environment and Forests (MoEF), in its new notification, has stated that developers that have already
bagged environment clearance for existing projects may be exempted from the stipulated public hearings for obtaining
clearances for expansion projects.
What scope does CIL see in productivity improvement in its mines? What steps are being taken for technological
upgradation?
CIL has old legacy underground (UG) mines and ~40% of the manpower is still engaged in these. Production
contribution from these mines is a meager 8%; this has had dropped consistently from 90% at the time of coal mine
nationalization. This has led to a considerable decline in manpower productivity even as Output per Manshift (OMS) in
CIL has doubled to 4 tonnes per shift from the levels 10 years ago. Over a period of time, CIL would gradually phase out
these mines and the manpower would be redeployed for future expansion. This should lead to a considerable
improvement in manpower productivity going forward.
As regards further mechanization, the management believes that in order to stay at the lower end of the cost curve, a
business needs to aim at optimum, and not necessarily highest, labour productivity. An optimum mix of man and
machine productivity leads to low cost of operations. The current cost of CIL’s opencast operations stands at US$11.5/
tonne – already one of the lowest in the world. This clearly establishes that CIL is fairly close to the optimal mix in such
operations, which account for 90% of its total coal produced.
CIL plans to acquire mines abroad. Can you please give some more colour to the same?
CIL is in the process of acquiring coal resources abroad through equity stakes in various greenfield projects. Two coal
blocks with estimated reserves of 1bn tonnes have been acquired in Mozambique and production is likely to commence
in the next 2-3 years. The board has also approved to conduct due diligence for acquisition of five coal companies in
Australia, Indonesia and the US at a total cost of ~US$2bn. Over the next 10 years, CIL plans to import about 500m
tonnes of coal from these mines.
There are several problems typically associated with coal mining – including land acquisition, Rehabilitation &
Resettlement, forest cover, etc. How does CIL overcome these issues?
Land is a major input for mining of coal. CIL would require 62,000 hectares of land for future expansion. However,
unlike China or Australia, coal bearing areas in India are mostly inhabited – often by tribals and that too in forest land.
Thus, land acquisition in India involves dealing proactively with substantial social and environmental issues, if not
passionately. CIL believes in inclusive growth and pursues an effective PAP friendly Rehabilitation & Resettlement
policy aimed at making irreversible and substantial improvement in the quality of life of displaced families. The fact that
despite operating in such an environment, the company could accelerate its growth rate from less than 5.5% two years
ago to 6.8% in FY10 bears testimony to the efforts made in promoting mining with a human face. In fact, CIL has also
proposed to offer equity shares to project-affected people.
There are environment concerns and safety issues around coal mining. What is CIL’s view on this?
Mining is a highly hazardous industry and CIL has made quantum difference in the practice of safe mining. The safety
statistics have undergone marked improvement since nationalization – a case in point is that the probability of an
employee meeting with an accident today is not worse than that in the US.
Further, while conceding that coal mining is associated with environmental degradation, CIL proactively keeps a tab on
environmental parameters as the mining progresses. Technical and biological reclamation of mined-out areas is being
practiced with missionary zeal and through plantation of native species for bringing back the ecology. In this way, CIL
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has created many dense forests. CIL also introduced a satellite surveillance system for monitoring of land reclamation
and afforestation of its large opencast mines.
Average coal price increase in the last decade has lagged the rate of inflation. Do you see domestic prices being
pegged to international benchmarks in the near future?
CIL had increased coal prices in October 2009 and there are no plans to effect a further hike in FY11. The company sells
10% of its production under the e-auction route and proposes to increase the proportion to 20% in the coming years.
Even after selling coal at the notified prices, which are at a significant discount to international prices, the company has
been making 30% operating margins given its cost-competitiveness vis-à-vis the global benchmarks. However, CIL plans
to revise prices for washed coal after setting up coal washeries. It proposes to set up 20 washeries in the next few years
and increase the proportion of washed coal to 55% of total sales volumes by FY17.
CIL sells ~10% of its coal production through the e-auction route. There are indications that the same could be
increased further. What is the progress so far?
E-auction was started by CIL and its subsidiaries to sell coal in the open market with a view to provide the fossil fuel to
consumers unable to source it through the available institutional mechanisms for reasons like seasonality of coal
requirement, limited requirement of coal not warranting long-term coal linkage, etc. Under the New Distribution Policy,
CIL is allowed to sell 10% of its production under the e-auction process. The expert panel set up by the Planning
Commission has asked the coal ministry to increase the limit of 10% to 20%. This has been proposed to bridge the huge
parity between domestic and international coal prices. The proposal is yet to receive a positive response from the coal
ministry.
Coal washing and underground coal mining has to gain prominence going forward. How is CIL preparing itself
for the same?
Indian non-coking coal mostly falls in the grade between D&F, thus having very low calorific value and high ash and
moisture content. Over the medium term, coal produced is likely to be of similar, if not worse, quality – which poses
significant challenges to end users. As a result, coal washing has achieved prime importance. Post washing, ash content
in coal drops from 37-42% to ~30%. Today, coal washing accounts for <10% of CIL’s total production, which it plans to
increase to ~60% in the coming years. The company plans to set up 20 coal washeries with a total washing capacity of
111m tpa, primarily for non-coking coal, at a cost of Rs15bn. All new projects with production capacity more than 2.5m
tpa will have the beneficiation facility. CIL will also outsource coal washing to organizations with core competence on
Build-Operate-Maintain (BOM) basis for creating beneficiation facilities.
With a significant cash balance on the books, is CIL looking to diversify into other areas like power generation?
CIL has signed an agreement to form a 50:50 JV with NTPC to set up two 2,000MW coal-based power plants in
Jharkhand. The JV will set up the power projects at the Brahmini and Chichro Patsimla coal mines at a total investment
of Rs160bn. In addition, CIL plans to set up a 1,000MW power plant with NTPC near the North Karanpura coal fields.
CIL is also considering power projects with utilities such as Orissa Power Generation Corporation, Chhattisgarh State
Electricity Board and Neyveli Lignite Corporation.
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150 100
Indian coal reserves concentrated in eastern parts… …with majority of reserves within 300mtr of depth
Proved Indicated Inferred (Depth MT) Proved Indicated Inferred
80 180
6.3
13.8
60 135
13.8
30.9
65.8
40 4.4
31.5 90
5.7 18.1
29.2 5.1
20 39.5 2.6 10.0
11.6 45 82.8 46
10.3
19.9
10.9 11.7 15.8 6.1
8.0
0 21.4 11.7
Jharkahand Orrisa Chhatisgarh West Bengal Madhy a Others 0 1.7
Pradesh 0-300 300-600 600-1200
Distribution of coking (metallurgical) coal reserves Bulk of India’s non-coking coal reserves are low grade
21 45
14 30
7 5.3 15 12.5
9.6
1.7 4.3
- 1.2
0
Prime coking Medium coking Semi-coking A B C D E,F&G
Source: Ministry of Coal
Increasing share of captive mining in total supplies Indian imports of coking and non-coking coal
40 Captive (m tonnes - LHS) Captive as % of total (RHS) (m tonnes) Non-coking Coking
10.0 40
8.0
7.5 11.0
30 6.8 7.5 30
8.2
% 6.0
5.1 8.2
20 27.5 32.2 36.9 5.0 20 6.7
20.8 23.0
6.9
17.4 7.0 25.9
24.0
10 2.5 10 19.3
13.9 16.3
10.4
-
0 0.0
FY03 FY04 FY05 FY06 FY07 FY08 FY03 FY04 FY05 FY06 FY07 FY08
Source: \Ministry of Coal, Crisil Research
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ECL Ra niganj, RajMahal West Bengal 30.5 46 27.10% • Total command area of 1,620 sq.kms
& Mugma Salanpur and Jharkhand • Operates 83 u/g mines, 21 o/c mines
and 6 mixed mines
• Total reserves of 40.6bn tonnes
BCCL Jharia & Ranigaunj West Bengal 24.2 30 20.20% • Total command area of 1,620 sq.kms
and Jharkhand • Operates 83 u/g mines, 21 o/c mines
and 6 mixed mines
• Total reserves of 40.6bn tonnes
CCL North & South Bihar & 41.3 78 4.70% • Total command area of 2,600 sq.kms
Karanpura, East & Jharkhand • Operates 26 u/g mines & 39 o/c mines
West Bokaro,
• Total reserves of 33.5bn tonnes
Ramgarh & Giridih
NCL Singrauli Madhya 52.2 70 - • Total command area of 2,202 sq.kms
Pradesh • Operates 10 o/c mines
WCL Wardha, Umrer, Madhya 43.2 45 22.90% • Operates 84 mines grouped into 10
Patharkhera & Pradesh & operationa l areas
Kamptee Maharashtra • Total reserves of 13.1bn tonnes
SECL Korba & Raigarh Chhattisgarh & 88.5 111 18.30% • Total command area of 974 sq.kms
Madhya • Operates 72 u/g mines, 12 o/c mines
Pradesh and 1 mixed mine
• Total reserves of 46.5bn tonnes
MCL IB Valley & Talcher Orissa 80 137 2.50% • Operates 3 o/c mines and 5 major
coalfields
• Total reserves of 63.3bn tonnes
Source: Coal Ministry, Coal India, IDFC Securities Research (ECL—Eastern Coalfields Ltd, BCCL—Bharat Coking Coal Ltd, CCL—Central Coalfields Ltd, NCL—North
Coalfields, WCL—Western coalfields Ltd, SECL—South Eastern Coalfields Ltd, MCL—Mahanadi Coalfields Ltd)
260
130
CIL
-
81.4%
2004 2006 2008
Source: Ministry of Coal (Note:- SCCL stands for Singareni Collieries Ltd
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