1. The document discusses the future challenges facing SCCL including depleting opencast reserves and the need to mine deeper underground reserves. 2. Longwall mining is presented as a technology that can enable bulk underground coal production safely and with higher recovery rates compared to other methods. 3. Key advantages of longwall mining discussed include proven success in thin and thick seams, improved safety, and potential for ongoing technological developments and automation.

1. State of Art of
Mechanisation
of
Underground Mines in SCCL
MD. Suresh Kumar
Addl.Mgr. Proj.Plng
The Singareni Collieries Company Limited

2. World Coal Scenario
World Coal Production: 6186 MT
Major Producers of Coal in 2010 include:
PR China 3162 Mt
USA 932 Mt
India 538 Mt
Australia 353 Mt
South Africa 255 Mt
Russia 248 Mt
Indonesia 173 Mt
Kazakhstan 105 Mt
Poland 77 Mt
Colombia 74 Mt
SOURCE – International Energy Agency, 2010.

3. Coal in World Energy Market
SOURCE – IEA- 2010.

4. Coal Mining in India Brief Review
• Geological reserves: The total geo-
reserves are estimated as 250.09BT of
non-coking and 33.47BT coking coal (As
per MoC report as on 1.4.2011)
• Extractable reserves: 172.1 BT non-
coking (85% in total) and 29.8 BT coking
coa.
• Singareni has 22.016 Bt total reserves
including 9.436 Bt proved (as on
31.03.2010).
• Coal deposits spread over 27 major
coalfields, and are mainly confined to
eastern and south central parts of the
country.
• The lignite reserves stand at a level
around 38.93 Billion tonnes, of which
about 82% occur in the states of
Tamilnadu & Puduchery.

5. Coal Demand Report of Various Agencies
Source : Working Group on coal & lignite

6. Coal Production in India
- Demand for Coal is high and there is always a shortage.
- Shortage is to be bridged by imports.
2007-08 2008-09 2009-10 2010-11
Production 457.082 492.94 531.617 572.37
(MT) (anticipated)
Imports (MT) 49.794 59.000 54.000* 81.34
(anticipated)
Source – MoC
* Coal insights

7. SCCL- at a glance
Singareni at a Glance
Mines Under Ground - 36 : Opencast - 14
Manpower (as on 30-09-2011) 67,104
Targetted Production(2011-12) 53.4 Million tonnes
Targetted Production(2010-11) 51.3 Million tonnes
Actual Production(2010-11) 51.33 Million tonnes
Output per manshift(Mines+Depts)(2010-11) 2.90 Tonnes
Major consumers Power,Cement and others
2004-
YEAR 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11
05
COAL 50.43
35.30 36.14 37.71 40.60 44.54 51.33
(MT)
OB
101.65 114.99 139.86 140.73 184.64 247.05 215.65
(MCum

8. Future challenges for SCCL
1. Depleting Opencast Reserves
• The present trend of coal production is 90:10 towards opencast.
• The mechanised Longwall faces produces hardly 4 % of total
underground coal production in 2009-10.
• In future the reserves beyond 300m have to be exploited through
underground methods.
• For getting bulk production, we need to take up mining in deep
seated reserves either by Longwall or Continuous miner
technology.
• With higher Stripping Ratio, the cost of production is also
increasing in opencast mining.
• Land Acquisition becomes critical and invoking R&R problems.
• Forest Clearance from MoEF and Land diversion also becoming
critical and time taking.

9. Status of existing mines and depletion of OC property
1. Depleting
Opencast
Reserves…
Maximum number of
existing OC mines are
closing between 14th
five yr plan period.
The closing OC
projects are:
• RG OC-1
• MOCP. RG-I
• KTK OC sector-1
• GK OC. KGM
• JVROC-1exp (SB-1)
• Koyagudem OC-2
• JK-5 OC. YLD
• BHBL OC-II Ext
Source:
Road Map-2011 Proj.
Plng. Dept. SCCL

10. Future challenges for SCCL
2. Working of deep mines
• Depth of operation of our mines has already crossed 300m depth line.
• New UG projects such as ADRIYALA, KLP were planned upto 600m and are
under implementation.
• Future projects such as SHANTHIKHANI, KK6&7 are being planned beyond
650m.
• SCCL is facing strata control issues at VK-7, PVK, Adriyala where working have
crossed 400m dpth.
Cross gradient
3. Working of steep mines in coal roof
• Seam gradient of KTK, SRP mines, RKP mines are
ranging from 1 in 2.8 to 1 in 3.8.
• New Projects are to be planned in steep gradients at
Shanthikhani, Sharavanapally- I&II, KK 6&7 etc.,
• Intermediate technologies such SDL and LHD are not
suitable in steep gradients.
• Movement Shuttle cars/Ram cars restricted by steep
gradient in CM faces.
• Cross gradient problem hinders smooth working of Road
headers Continuous miners.

11. Continuous Miners
World status
• CM technology becomes
core & integral part of UG
mining world wide.
• Being deployed for gate
roads preparation for
Longwall mining
• Deployed for Room & pillar
mining (dev & extraction)
• There are 1400+200 CM and
MB are available.
• Avg of 1.5 MTPA is being
achieved per Continuous
miner
• World coal mines demand
160 CMs / year
• Machine survives 3 rebuilds
or 10yrs.
Courtesy: Golabal CM/BM sensus. RWTH. Aachen.Germany

12. Continuous Miners
Indian status
• The first CM was introduced at Chirimiri Anjana Hill Mine, (SECL)
supplied by Joy in May 2002
• The complete system, supplied by Joy Mining Machinery Ltd,
included a 12CM15 continuous miner, two shuttle cars, a feeder
breaker, a mobile roof bolting machine and electrical distribution
system.
• Coal production in Chirimiri recorded as highest of average of more
than 50000 TPM
• This is proved and successful mechanised de-pillaring in India.
• In the present technological transformation, with considerable
awareness and training it is possible to produce 4 to 6 LTPA in Indian
mining condition.
Present 1. Anjana Hill Mine, Chirimiri (SECL) in May, 2002.
2. Tansi Mine (WCL) in June, 2003.
Continuous
3. VK No: 7 Incline, Kothagudem (SCCL) in Aug, 2006.
miner Projects 4. Jhanjra Under ground Mine (ECL) in June, 2007.
in India 5. GDK 11A Incline (SCCL) in Dec, 2008.

13. Continuous Miners
Limitations
Can not work in steep seams.
Workability in deeper deposits yet to be
proved.
Can work in 2- 4.5m thick seams only.
Reserves lost in bord & pillar extraction
with CM.
Cavability of roof rock heavily affects
performance of CM in caving panels.
Strata control issues are not fully
satisfactory.

14. Longwall Mining Brief Review
• India as a general rule
followed the world trend of
mechanisation in coal mining
during 1970s.
• In 1975. ‘Project Black
Diamond’ envisaged
introduction of 130 Powered
Supports Longwall (PSLW)
faces by the year 2000.
• The first fully mechanized
self- advancing PSLW face
was ntroduced in Moonidih
mine in Jharia Coalfield in
1978.
• Subsequently more mines
were planned with PSLW in
80s, namely, East Katras • First long wall in SCCL was introduced
(BCCL), Seetalpur, Dhemo-
Main, Jhanjra, khottadih (all at GDK-7 incline in 1983.
in ECL ),Patharkhera (WCL) • In the process about 30 PSLW sets had
and Churcha (SECL). been imported from different sources in
different countries like, UK, Poland,
Russia, Germany, France and China.

15. Why Longwall Mining ?
Emerging requirement of SCCL is:
Bulk production from UG
Safe mining operations
Conservation of coal
Environmental protection
Reduction of drudgery on workmen,
supervisors and officers.
Longwall mining is a method, which
can fulfill all the above conditions in
underground mining.

16. Supremacy of Longwall Technology
1. Suitable for thin seams
Thin seams in Mandamari Shaft
4.5m Blocks
• Power Support Longwall with
coal plough can work in 0.6m
seams.
• Longwall from 0.6m thick 1.7m
seams are producing 0.6m LW face in West Virginia. USA
1.5MTPA in West Virginia,
USA. 2.0m

17. Supremacy of Longwall Technology
2. Proven Technology for thick seams
• Seams around 6m are being worked
with Longwall technology.
• 6m Longwall faces are extensively
being operated in China.

18. Supremacy of Longwall Technology
2. Proven Technology for thick seams2 : LTCC
• Australia and China have started
LTCC for thick seam mining.
• Basically involves an additional
AFC to transport top coal falls
behind the Shields.
• When compared to other thick
seam mining techniques it
ensures a high recovery rate and
productivity.
• The Chinese industry had
reported averages of 15,000 to
20,000 TPD from an LTCC face.
• 9m thick seams using a 3m
operating height Longwall and A new semi-automated 300m long LTCC
with 5 MTPA face production. face was installed at the Xing long zhuang
• Presently around 70 LTCC faces Colliery of the Yankuang Group, in
are operating in China. Shandong Province, (started in August, 2001) is
producing around 7MTPA.

19. Supremacy of Longwall Technology
3. Safest UG mining method
• Power Shields are fail-
safe supports for men
and machineries in LW
face.
• Gate roads (Main gate&
Tail gate) are well
supports by 30/40T
Hydraulic props upto
abutment zone.
• Men are not exposed to
bad roof conditions and
goaf edges.
• Strata control issues are
more scientifically dealt
with.
• No ventilation problems in Only 3 avoidable fatal accidents
LW faces. reported so far in 30 years of LW
experience in SCCL.

20. Supremacy of Longwall Technology
4. Scientific approach in Strata management
2.CPR-continuous
pressure measurement in 3.RCI- Remote
1.Leg Pressure Gauge to Supports Convergence Indicators
measure Load on Supports for measuring
convergence remotely

21. Supremacy of Longwall Technology
4. Scientific approach in Strata management- Gate Roads measurements
Vibrating Wire Load cell Stress cells Read-out unit
Tell Tale Extensometer Mechanical Load cell

22. Supremacy of Longwall Technology
5. Scope for sustaining developments
• Countries like US, Australia involved in
continuous R&D works and technological
development in the field of Longwall mining.
• As a result:
• Face Length is increased from 100m to 400m.
• Panel Length is increased from 1 KM to 3 KM.
• Single Gate road development modified to triple
entries.
• Production levels are enhanced to 7MTPA per
face.
• Support capacity has been increased from
300T to 2000T. Advancement in Eqpmt capacities
• Entire operations of LW faces are automated.
• Men transport becomes speedy using FSVs.
• Equipment shifting from one face to other
becomes sofisticated and mechanised.
• Equipment capacity is increased to multifold.
• Power of Shearer, AFC, BSL and Belts
tremendously increased.
• Operating voltage increased to 1.1 KV to 3.3KV
• It gives scope for further technological
developments.

23. Supremacy of Longwall Technology
6. Scope for continuous Research and Development ( R&D)
2 Leg/ 4 Leg Frames 6 Legs Chock Shield-675T
4 Leg IFS Chock Shield-800T 2 Leg IFS Shield-1100T

24. Supremacy of Longwall Technology
7. Advantages of 2-Leg Shield supports
Anti topple
Face frogs
• Support Resistance : 110-120T/m2
• Support capacity : 1000-1150T
• Base width : 1.7 or 1.8m
• Advancing Ram : 60T capacity. Base
lifting ram
• Face frogs
• Anti skid + Anti topple
• Base lifting rams.
• Resultant force is closure to face.
Anti skid
Base 1.7/1.8m

25. Supremacy of Longwall Technology
8. Advantages of 2-Leg Shield supports
Roof Bolting Practice in underground mines-needs ‘ Review & Policy’
Workshop on Strata Control- Planning issues

26. Supremacy of Longwall Technology
9. New Generation Longwalls: LW Automation
• Highly sophisticated
Longwall faces are being
operated in US and
Australia.
• Operations of Shearer
and Supports are
automated with radio
active control.
• It works with much more
higher efficiency than
human efficiency.
• Batch control is possible.
• Assured positive setting pressure.
• Speed of support advance is compatible with shearer speed.

27. Supremacy of Longwall Technology
10. Face Automation Power Support Automation-Sensor units
involves:
Mining Engineering
Electrical Engineering.
Electronics Engineering.
Communication
Engineering.
Software Engineering.

28. Supremacy of Longwall Technology
11. World Longwall
Production
High productive mines:
1. Oaky North (NSW) - 8MTPA
2. Newland North - 7MTPA.
3. Kestrel&Moranbah North - 5MTPA

29. Potential GR Blocks for future Mechanisation
Expecte
Geo. Ext. TOTA Fores
Proposed Annual d year of Depth
Life in Reser Reser L t Land
Name of Mine Technolog Capacity coal Range
Years ves ves AREA Reqm
y (MT) Producti (m)
(MT) (MT) (Ha) t (Ha)
on
KK-7 INC LW 1.5 27 2026-27 55.1 32.64 489.48 49.22 92-606
KTK 3 inc LW 1.5 12 2016-17 31.63 13.73 377.95 18.44 56-590
SRAVANAPALLI (dip side) LW 2.0 29 2028-29 120 48 630 315 350-600
550.7
RKP SB-I UG LW 2.0 16 2022-23 97.56 39.84 588.67 129-573
5
517.5
RKP SB-II& NW EXTN UG LW 2.0 17 2025-26 141.03 42.24 657.16 222-623
3
LAXMIDEVIPET UG LW 1.5 22 2027-28 60.76 28.91 925.8 135 35-368
87.37
Mallayyapalli block LW 3.0 32 2019-20 291.25 1350 83.25 160-650
5
Jallaram UG CM 1.7 36 2015-16 157.61 58.57 549 157.4 155-603
KK-6Inc(MM SB sec-C,D) CM 1.2 21 2026-27 69.93 19 357.76 88.25 176-544
RKNT SB (dipside) CM 1.5 16 2027-28 40 16 400 400 300-600
RAMPUR SHAFT
CM 1.0 32 2016-17 122.27 32.2 900 640 337-585
PROJECT
KOYAGUDEM 2 INCLINE CM 1.0 16 34.98 10.5 306.33 134.6 140-220
Source: Road Map-2011 Proj. Plng. Dept. SCCL

30. Conclusion..
• Future of above ground lies below ground.
• Opencast reserves are depleting and cost of production increasing.
• Cost of production of existing UG mines is Rs. 2537(2010-11) and OC is
Rs.1142.
• The above figures likely to increase still when our depth operation increases.
• Mechanisation plays vital role to get bulk production and to make UG projects
viable.
• Bulk production from UG mines is possible only by introducing Continuous
miners and Longwall faces in more numbers.
• The future projects of SCCL are being planned beyond 400m and it exceeds
650m where seams are thin, geologically disturbed, highly complicated.
• Performance of Continuous Miners are yet proved in such conditions.
• Longwall is a proven technology world wide for all types of complicated seams.
• It is safe, perfectly engineered technology and it gives scope for further
technological developments and adventures.
• Hence SCCL is planning for Longwall technology in deeper deposits at various
capacities.