Workshop on “The Technology Development &
Mechanisation of Mines for enhancing
Coal Production & Productivity ”
20th January, 2015
Presentation by
Western Coalfields Limited
WCL operates 80 Mines (41 UG, 39 OC) in 10 Areas (7 in Maharashtra & 3 in Madhya Pradesh)
WCL contributes more than 7% of the total National Coal Production from its 3.26% of the total National Geological Coal Reserves
2
Western Coalfields Limited
Coal ReservesCoalfield
Resources
Reserves Total
Maharashtra
Wardha Valley 2.90 0.82 3.72Umrer Nand Bander 0.36 0.21 0.57
Kamptee 0.87 0.21 1.08Madhya Pradesh
Pench Kanhan 1.07 0.20 1.27Pathakhera 0.22 0.07 0.29
Total 5.42 1.51 6.93
(in Billion Tonnes)
(As on 01.04.2013) 3
Western Coalfields Western Coalfields LimitedLimited
Unique Feature of WCL • Adverse geo - mining condition• Deep seated Reserve• High stripping ratio• Presence of Black Cotton Soil & Silt• Lower grade Coal• Smaller Capacity Opencast Projects• Very old and extensive UG Mines• Heavy Water seepage (Kamptee Series)
8.7 8.39 8.2 7.73 7.9
34
.95
34
.72
34
.09
32
.00
36
.10
0
10
20
30
40
50
2010-11 2011-12 2012-13 2013-14 2014-15BEUnderground Opencast
43.65 43.11 42.29
Performance at a Glance : Coal Performance at a Glance : Coal ProductionProduction
44.0039.73
Figures in Million Tonnes 5
Growth: 10.7%
Mill
ion
Tonn
es
53
.42
58
.93
52
.54
60
.78
68
.00
62
.40
63
.56
61
.15
59
.30
62
.00
0
20
40
60
80
100
120
140
2010-11 2011-12 2012-13 2013-14 2014-15BE
Hired Departmental
122.49115.82
PerformancePerformance at a Glance : OB Removal at a Glance : OB Removal
113.69130.00120.08
Figures in Million CuM 6
Mill
ion
Cum
Growth: 8.3%
14
4.0
15
0.3
14
1.0
14
5.7
15
8.4
0
20
40
60
80
100
120
140
160
180
2010-11 2011-12 2012-13 2013-14 2014-15BE
Performance at a Glance : Composite ProductionPerformance at a Glance : Composite Production
7
Mill
ion
Cum
Growth: 8.7%
FY 2013-14 CCL BCCL ECL WCL MCLComposite Production (Mcum) 92.57 107.16 109.78 145.7 169.65
17.5
4
18.0
4
21.1
3
22.1
7
22.0
0
20.5
4
18.8
0
15.6
9
13.8
0
18.7
04.48 5.13 4.73 3.98
4.30
0
5
10
15
20
25
30
35
40
45
50
2010-11 2011-12 2012-13 2013-14 2014-15BE
Rail Road Other Means
42.56 41.97
Performance at a Glance : Coal OfftakePerformance at a Glance : Coal Offtake
41.55 39.95 45.00Growth 12.65%
Figures in Million Tonnes 8
Impact of NCWA-IX
Mill
ion
Tonn
es
Crore Rs.
9
Trend Of Coal Production, Offtake & Operating Trend Of Coal Production, Offtake & Operating Profit/ LossProfit/ Loss
Strategy adopted for Enhancement of ProductionStrategy adopted for Enhancement of ProductionCoal Production (MT) 15-16 16-17 17-18 18-19 19-20
BAU 41.85 39.45 33.36 32.75 32.28
Internal efforts : Five projects 1.60 4.60 6.50 9.30 12.50
BG Relaxation : Six projects 0.50 0.80 1.40 1.80 2.37
Revision of CMPDIL norms : Nine projects 1.05 3.15 8.74 11.15 12.85
Total Production 45.00 48.00 50.00 55.00 60.00
10
Year Name of Project Area State Capacity (Mty) Opening Date
2014-15(7.00 MT)
1 Makardhokra-I OC Umrer MAH 2.00 28-Nov-142 Bhanegaon OC Nagpur MAH 1.00 25-Jan-153 Penganga OC Wani MAH 4.00 25-Mar-15
2015-16(15.58 MT)
4 Gokul OC Umrer MAH 1.50 25-May-155 Sharda UG Kanhan MP 0.32 25-Jun-156 Dinesh OC Umrer MAH 4.00 25-Jul-157 Dhau North UG Kanhan MP 0.36 25-Aug-158 New Majri UG to OC Majri MAH 0.80 25-Sep-159 Amalgamated Yekona-I & II OC Majri MAH 2.50 25-Oct-15
10 Singhori OC Nagpur MAH 0.80 25-Nov-1511 Amalgamated Pauni-II & III OC Ballarpur MAH 2.50 25-Jan-1612 Tawa -III UG Pathakera MP 1.00 25- Feb-1613 Chincholi OC Ballarpur MAH 0.30 25-Mar-1614 Kamptee Deep OC Nagpur MAH 1.50 25-Mar-16
Year wise Opening of ProjectsYear wise Opening of Projects
11Replacement Project
Year Name of Project Area State Capacity (Mty)
Opening Date
2016-17 (9.20 MT)
15 Mungoli Nirguda Deep OC Wani MAH 4.00 25-Apr-1616 Hindustan Lalpeth Expn. OC Chandrapur MAH 1.00 25-May-1617 Dhuptala Extn. (Sasti UG to OC) * Ballarpur MAH 1.70 25-Jul-1618 Padmapur Deep OC Chandrapur MAH 2.50 25-Jan-17
2017-18(3.14 MT)
19 Niljai Expansion (Deep) OC Wani MAH 3.00 25-Apr-1720 Harrradol UG Kanhan MP 0.14 25-May-17
Grand Total 34.92 (Mah -33.1MP -1.82)
Contribution from above 20 Projects by 2019-20 27.72BAU Production by 2019-20 due to depletion of reserves 32.28
Total Production by 2019-20 60.00
Year wise Opening of ProjectsYear wise Opening of Projects
12Replacement Project
39.7342.00
45.0048.00
51.0055.00
60.0057.78
68.98 69.08 69.28 70.08 70.58 70.58
30354045505560657075
13-14 14-15 15-16 16-17 17-18 18-19 19-20
Production (Now Projected)
Demand
Coal Demand Vis-à-vis ProductionCoal Demand Vis-à-vis ProductionM
ILLI
ON
TO
NN
ES
YEAR
13
Group-wise Future Production ScenarioGroup-wise Future Production Scenario
Existing & Completed Projects
Ongoing Projects
Total Production
Future Projects
Mill
ion
Tonn
es
Year 14
Share of UG and OC production Share of UG and OC production
7.73 7.90 8.00 8.22 8.31 8.77 9.17
32.0036.10 37.00 39.78 41.69
46.2350.8339.73
44.00 45.0048.00 50.00
55.0060.00
0
10
20
30
40
50
60
70
13-14 14-15 15-16 16-17 17-18 18-19 19-20
UG
OC
Total Production
Mill
ion
Tonn
es
Year15
OC Composite Production : Departmental & Outsourcing
178.87
253.56290.69
311.72335.23
Figures in Million CuM 16
17
Opencast : Existing &
Required Equipment
Existing HEMM PopulationEquipment
ModelCapacity Population
Dragline 3
Shovels, Electric Rope
5 Cu.mt 39
Shovels, Hydraulic
More than 2.5 Cu.mt
67
Shovels, Hydraulic
Less than 2.5 Cu.mt
29
Dumpers 35 Ton 55
Dumpers 50 Ton 225
Dumpers 60 Ton 174
Equipment Model
Capacity Population
Dozer Crawler 410 HP 6
Dozer Crawler 320 hp 139
Wheel Dozer 460 HP 12
RBH Drill 250 mm 21
RBH Drill 160 mm 82
Graders 280 HP 24
Cranes 30 -40 Ton 11
TOTAL 887
18
Status of existing major Equipment & their Performance
SN Equipment Capacity Supplier
(No) Performance
1 Dragline 24Cum /96 m
20 Cum /90 m
9Cu Yds /70 Yds
Bucyrus (1)
Uralmash(1)
Marion (1)
• Age – 23 Yrs
• Age – 22 Yrs
• Age - 45 Yrs
2 Electrical Rope Shovel
5 Cum HEC (39) • Delayed supply of spare parts• Inferior quality of spares
19
Status of existing major Equipment & their Performance
SN Equipment Capacity Supplier (No) Performance
3 Hyd. Excavator
4.5/5.5 Cum BEML (28) • Swing pump life –failing at an average life of 7000 Working Hour , against desired life of 20,000 WH
• Power-Take Off–failing at an average life of 8000 WH, against desired life of 20,000 WH
TATA Hitachi(15) • High cost of sub assemblies.
4 Dumper 60/50 T BEML(248 ) • Poor Supply of spare parts• Less Transmission Life
Caterpillar (151 ) • High cost of spares20
HEMM to be procured against replacement
Equipment Model Capacity
Shovel Hydraulic 4.3 / 5.5 Cu.mt
Shovel Hydraulic Less than 2.5 Cu.mt
Dumper 60 Ton
Dozer, Crawler 410 HP
Dozer, Crawler 320 HP
Wheel Dozer 460 HP
RBH Drill 250 mm
RBH Drill 160 mm
Grader 280 HP
Crane 30 - 40 Ton21
Equipment Model Capacity
Shovel Hydraulic 5 - 6 Cu.mt
Shovel Hydraulic 4.3 / 5.5 Cu.mt
Dumper 60 Ton
Dozer 410 HP
Dozer 320 HP
RBH Drill 160 mm
HEMM required for new projects (Dept.)
22
Equipment Model Capacity
Shovel Hydraulic
3.1 Cum
4 Cum
10 Cum
Dumper
18.7 Cum
19.5 Cum
100T
Surface Miner
Proposed HEMM required for new projects (Outsourcing)
23
24
Underground : Existing
& Required Equipment
24
Underground : Existing Major Equipment
25
SN Equipment Population
1 Continuous Miner Package 1
2 SDL ( 1.0 Cum) 72
3 LHD (1.5 Cum) 113
4 UDM 45
5 Man Riding System 09
SN Equipment Supplier (No) Performance1 Continuous
MinerJoy Global (1) • Inadequate performance of Quad Bolter
2 SDL ( 1.0 Cum)
Eimco(57)BEML (14) • Design flaws in the machine
• Delayed supply of spares• Inadequate Service support
Simplex (1)
3 LHD( 1.5 Cum)
Eimco (101)Simplex (12) • Delayed supply of spares
• Inadequate service support
4 UDMEimco (36)Simplex (9) • Delayed supply of spares
• Inadequate service support
Status of existing major Equipment & their Performance
26
Replacement Equipment To Maintain Existing Production
Machine Capacity
SDL 1.0 Cum
LHD 1.5 Cum
UDM
27
Underground: New Projects
• Introduction of Continuous Miner Package on hiring basis
• Mass Production Technology package @ 1 MTY of coal production on Turnkey basis (MDO Route)
• Manriding system28
Continuous Miner Package on Hiring Basis
S.No. NAME OF MINE Potential Production (MTPA)
Estimated Year of Production
1. Tawa-II Expn. 0.36 2016-17
2. Waghoda 0.39 2016-17
3. Tawa-I 0.70 2016-17
4. Naheriya 0.34 2017-18
5. Dhau North 0.36 2017-18
6. Sharda 0.315 2018-19
29
Turnkey Projects through MDO Route
S. No. Name Of Mine Proposed Technology
Potential Production
(MTPA)
Estimated Year of
Production
1. Tawa-III Mass Production technology(LW/CCT) 1.00 2018-19
30
Installation of Manriding Systems in UG Mines
15-16 16-17 17-18 18-19 19-20
Nandgaon Rajur Mahakali Saoner III AB Incline
Adasa Naheriya HLC-1 Mathani Patansaongi
Saoner II Vishnupuri II Ghorawari
Silewara (Winder)
Ambara
2 2 3 3+1(Winder) 4
31
32
Coal Evacuation &
CHP Required
32
Coal Evacuation Year-wise, Mode-wise
2015-16 2016-17 2017-18 2018-19 2019-20
Production 45.0 48.0 50.0 55.0 60.0
Rail 23.29 25.29 26.79 32.06 35.61Road 17.03 17.11 17.60 18.31 19.26MGR 1.10 1.10 1.10 1.10 1.10Despatch 3.60 4.50 4.52 3.53 4.03Offtake 45.0 48.0 50.0 55.0 60.0Rakes/day 16.3 17.8 18.8 22.6 25.0
Fig. in MT
CoalCoal Evacuation of 60 MT by 2019-20 Evacuation of 60 MT by 2019-20
• Presently WCL is maintaining evacuation arrangement for 45 MT through 19 no. of Railway sidings
• Additional 7 MT will be evacuated by utilizing spare capacity of existing sidings
• Silo arrangement for 2 OC projects (8 MT) & Rail Connectivity (15 Km) up to silos by 2019-20
34
CHP : Existing Crushing Equipment
35
SN Equipment Population
1 Feeder Breaker/Crusher (-200mm) 42
2 Crusher(-100mm) 4
CHPs : Plan for 2015-16
Machine Capacity
Secondary Crushers-100mm output
Feeder Breaker/ Crusher-100mm output
36
Major area of concern
• Availability of experienced Contractors• Availability of required Excavators,
Dumpers/Hauling Trucks and matching support equipment in a span of four years for existing and new projects.
• Trained Manpower for both Departmental & Outsourced equipment
Dept HOE TotalExcv 71 114 185
Dumpers 282 467 749
37
Suggestions• Workshop for Outsourcing Agencies with
participation of all Subsidiaries.• Year-wise schedule may also be drawn by
Suppliers/Manufacturers• Skill Development Centers at Subsidiary level to
tap in-house as well as external (PAPs) potential.
38
ThankYou
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