highwall mining economic and environment friendly mining...highwall mining performance at west...
TRANSCRIPT
Highwall Mining
Economic & Environment
Friendly Coal Extraction by a Safe
World Class method
Presenter:Mr. Anurag Dixit
West Bokaro, Tata Steel
SlideTata 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 BokaroColliery
Chainpur Railway Station
Danea Railway Station
KBP
Jhumra Hill
To Hazaribagh
To Lalpania
To Ramgarh
Kedla Washery
Ramgarh Bokaro
To Gomoh
To Barkakhana
KOTRE BASANTPUR & PACHMO
Ramgarh Bokaro
Lalgarh
Parej
PundiGose
CCL Lease
Geological Location :Situated under : West Bokaro Coalfields, Dist. Ramgarh.Nearest National Highway : NH 33 (16 kms by road) Nearest Airport: RanchiNearest Railway Station: Chainpur
2
SlideTata 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
3
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
of Explosives
SlideTata Steel
West Bokaro at a Glance : 5.1MT (RC), 2.4 MT (CC), 18.8 MCum (OB )
4
SlideTata 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
5
SlideTata Steel
Adopting the world class technology
6
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
operations (First of its kind simultaneous
operation)
• Developing skills and know how
2015 Integrated Planning (internal)
SlideTata 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
overburden 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
7
SlideTata 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 tPush Beams
Highwall Miner : Components
Operator Cabin
Cutter Head
Push Beam &
Transfer Mechanism
Coal Transfer
Mechanism
Loader
8
SlideTata Steel
Highwall Component :
9
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
SlideTata 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
operator 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
10
SlideTata Steel
Safety Management at Highwall
11
o Slope stability Radar for real time slope monitoring (Digital)
o Methane detector for real time methane emission
o Bench monitoring using total station
o Subsidence and slope monitoring at the pit edge / surface
o Bore hole extensometer monitoring to know movement if any
o A protective bund to arrest small boulder’s accidental fall
o Regular dressing down of loose boulders to a height of 5-10m
o Placement of Machine 15 m from the high wall
o Access control / Temporary fencing to prevent entry
o Acceptable limit of Hole deviation is within 0.2%
o On board cameras and sensors working during the extraction
o PLC based Steering Arms
o Gyro sensors
o 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
SlideTata 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
Au
g-1
6
Sep
-16
Oct
-16
No
v-1
6
Dec
-16
Jan
-17
Feb
-17
Mar
-17
Ap
r-1
7
May
-17
Jun
-17
Jul-
17
Au
g-1
7
Sep
-17
Oct
-17
No
v-1
7
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
355352400368294
FY
17
3,752
-21%
Jan
157
DecNov
180
Oct
51
SepAugJulJun
131
May
185
AprFY
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
12
SlideTata 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
13
SlideTata 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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SlideTata Steel 15
Hope have added some value !