souvenir - india energy forum - 6th-coal summit 2016.pdf · 07.09.2016 · g i c a l m i n i n g g...

Hotel Le Meridien, New DelhiHotel Le Meridien, New Delhi

TH6 COAL SUMMIT 2016

6th & 7th September, 20166th & 7th September, 2016

Conference & ExpoIndian Coal - Sustaining the MomentumIndian Coal - Sustaining the Momentum

SouvenirSouvenir

Indian School of MinesAlumni Association - Delhi Chapter

India Energy Forum

INSTITUTE OF INDIA

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Mining Geological & MetallurgicalInstitute of India - Delhi Chapter

HindalcoACB (India) Ltd. NTPC Ltd.(A Maharatna Company)

BEML Limited The SingareniCollieries Co. Ltd.

(A Government Company)

Essel Mining &Industries Ltd.

Associate - Sponsors

Global Coal & Mining Pvt. Ltd. Mahanadi Coalfields Ltd. A Govt of India Undertaking

Maccaferri Environmental Sol. Pvt LtdAmbey Mining Pvt. Ltd.Adani Enterprises Ltd Daniel

Vayunandana Power Ltd.National MineralDevelopment Corpn. Ltd.

Supporters :Supporters :

lR;eso t;rs

Ministry of Coal

Ministry of Power

Ministry of Mines

Organisers :

Sponsors Co-Sponsors

Northern Coalfields Ltd. NLC India Ltd.(A Navratna Enterprise)

Western Coalfields Ltd.

Coal India LimitedA Maharatna Company

South EasternCoalfields Ltd

Supporters :Supporters :

lR;eso t;rs

Ministry of Steel

Ministry of Railway

Ministry of Environment,

Forest & Climate Change

6th Coal SummitTheme : Indian Coal –Sustaining the Momentum

6-7 September, 2016

Hotel Le-Meridian, New Delhi

Contents

Sl. No. Particulars Page No.

1. Messages 3

2. About 6th Coal Summit 2016 27

- Introduction 29

- Organisers 30

- Programme 32

- Committee 37

- Glimpses of Previous Conferences 42

3. Recommendations & Coal - Global & Indian Scenario-24x7 - Power for All 45

th- 5 Roundtable Conference on Coal 2015 47

- 5th Coal Summit 2014 49

- 4th Round Table Conference on Coal 2013 52

- Coal - Global & Indian Scenario-24x7 - Power for All 54

4. Abstracts, Technical Papers 61

5. Advertisements 143

INSTITUTE OF INDIA

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Section-1

3

Messages

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6th Coal Summit 2016 6th & 7th September, 2016

vfuy Lo:ilfpo

ANIL SWARUPSECRETARY

Hkkjr ljdkjGOVERNMENT OF INDIA

dks;yk ea=ky;Ministry of Coal

'kkL=h Hkou] ubZ fnYyh&110001Shastri Bhawan, New Delhi-110001

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Rahul GuhaDirector General


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INSTITUTE OF INDIA

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It is indeed a matter of great pleasure to know that the 6th Coal summit 2016 is being

organized by the Mining, Geological and Metallurgical Institute of India (MGMI), India

Energy Forum and Indian School of Mines Alumni Association ( ISMAA) on “Indian Coal-

sustaining the Momentum” on the 6th and 7th Sept. 2016 at New Delhi.

The subject chosen for discussion during the Summit is very relevant particularly when the

supply - demand scenario in the country has taken a favourable turn. I am sure that the

Summit is going to be effectively utilized by the participants through meaningful

deliberations on various issues related to Coal industry to provide the road map for sustaining

the current momentum of Coal production and supplies to the Industry. I wish that the

presentations by the distinguished Speakers and deliberations during the Summit will also

enrich our knowledge and address ways of indicating realistic demand projection in the

coming decade.

I wish the participants of the 6th Coal summit 2016all the very best and a grand success.

A N Sahay

President, MGMI

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Message

THE MINING, GEOLOGICAL & METALLURGICAL INSTITUTE OF INDIAGN- 38/4, Salt Lake, Sector - V, Kolkata - 700 091

Tel : (+91) (33) 2357 3482 / 2357 3987, Fax : (+91) (33) 23573482

e-mail : [email protected]

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India Energy Forum

Anil RazdanPresident, India Energy Forum

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Message

The availability of adequate and affordable energy is the hallmark of a rapidly developing economy. Economic development is also related directly to the quantum of energy use per capita. Nations often display their might by trying to control global fossil fuel resources, which are not distributed uniformly across the world. Luckily, India is blessed with ample resources of coal, though we could have done much better with far greater proven reserves of oil and gas. Coal is India's energy security, besides ample sunshine. The challenge is how to use coal in a cleaner, more efficient and versatile manner. We have to work also on coal to gas, coal to liquid and coal to fertilizer.

It is extremely gratifying to witness the momentum that has been built over the last year and a half, in respect of the ability to ramp up domestic production of coal. We have also accepted the challenge of a domestic production target of a billion tonne annually. The coal mining industry has to meet the challenges of productivity, quality, transportation, and competition over the coming years. The Indian coal industry could soon be at the cross road. It will have to choose a path of productivity, efficiency and versatility.

The India Energy Forum (IEF) jointly with Indian School of Mines Alumni Association, Delhi Chapter (ISMAA) and Mining, Geological and Metallurgical Institute, Delhi Chapter (MGMI) is organising this highly meaningful and constructive 6th Coal Summit & Expo 2016 on Coal. The theme is "INDIAN COAL – SUSTAINING THE MOMENTUM" on 5th, 6th & 7th September 2016 at Hotel Le Meridien, New Delhi.

I am confident all the participants will benefit from the deliberations. I wish the Conference great success.

Anil RazdanPresident, IEF

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Message

6th & 7th September, 20166th Coal Summit 2016

6th Coal Summit 2016

At the outset, I congratulate India Energy Forum, MGMI & ISMAA Delhi Chapter for jointly

organising the 6th Coal Summit & Expo, scheduled to be held on 5th to 7th September 2016.

Under the current central government, the Coal Sector is augmenting its production and

happy to note that we will now be going to Export Coal to other nations. The savings in the

Foreign Exchange will boost the economic development of our country.

Together, we can support the government in their Action Plan and I am confident issues

holding production will be discussed to throw positive solutions for its mitigation.

I wish the conference a grand success!

Place : Gurgaon

Date : 13/08/2016

Office : 953 | Sector-31 | Gurgaon | 122001 | Haryana | ( 91-124-4048286 | 2580614Res. : 17 | Sector-14 | Gurgaon | 122001 | Haryana | 91-124-2333293 | 2320416 | Fax : 91-124-4081679

E-mail : [email protected] | [email protected](

Ganesh Chandra MrigChairman: Vayunandana Power Limited

Former CMD: Bharat Coking Coal Limited (BCCL) & South Eastern Coalfields Limited (SECL) [GOI U/T)Former Promoter-MD: ACB (India) Limited

President: ISMAA Delhi Chapter | Vice President: India Energy Forum

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Section-2

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About6th Coal Summit 2016

Introduction

For a developing economy like India, assured and affordable supply of Energy is the prime pre-

requisite for achieving economic growth and desired level of human development.

In India, it is Coal which is ensuring this since it accounts for almost 55% of country's Commercial

Energy needs and more than 70% of Power Generation.

Going forward, Renewables will have a bigger role to play than what they are doing today but Coal is

projected to maintain its dominant position for almost next two decades. This also makes sound

economic sense since the country is blessed with huge Coal Resources whereas it is rather deficient in

other Fossil Fuels like Oil and Gas and development of Renewables is going to take time.

The country has an ambitious goal of ensuring ”24 x 7 supply of Power for All” and for achieving this

objective, the Coal production programme has been accelerated to 1580 million tons per annum to be

achieved by 2019-20.

It is heartening to note that the spell of stagnation which had crippled the Indian Coal Industry till

about two years back has been broken and the Industry has achieved an unprecedented growth rate of

8.4% in 2014-15. More encouragingly, the way things have progressed, it is likely to do one better in the

current year by achieving a growth rate of more than 9%.

The Industry has thus covered lot of ground but lots more remains to be done. Need of the day is to

take a look at where and how the Industry has reached where it is and chalk out the Roadmap for

sustaining the growth momentum that has been generated.

India Energy Forum (IEF), the premier think-tank of the Country on Energy issues together with

Mining, Geological and Metallurgical Institute of India (MGMI), Delhi Chapter the oldest organisation

of Earth Scientists in India and Indian School of Mines Alumni, Association (ISMAA), Delhi Chapter,

has been organising a Biennial Summit on Coal for a decade now. In view of the current situation and

on-going developments in the Industry, it has decided to devote the 6th Coal Summit due this year to

the theme of “Indian Coal - Sustaining the Momentum”. This Summit will be organised on 6th and 7th

September, 2016 at Hotel Le Meridian, New Delhi.

Challenges in Coal Sector are many and so are the obstacles which are varied in nature. The objective

of the Summit would be to identify them and take a comprehensive look there at and chalk out

strategies to meet them. The entire gamut of Coal Mining activities starting from Exploration and

including Mining technologies, improvement in Infrastructural facilities, upgrading of Mining

Equipment and facilitation of clearance processes particularly those related to Environment and Forest

and Land Acquisition and R&R and most importantly Mine safety will have to be addressed.

Relevant issues to be dwelt upon have been identified as under:

1. Modernising Coal Exploration Technology;

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6th & 7th September, 2016

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2. Expediting statutory clearances like those related Forest and Environment;

3. Enlisting proactive cooperation of the State Govts. in matters of Land Acquisition and R&R;

4. Improvement in Infrastructural facilities particularly Rail connectivity for un-developed/ under

developed coalfields;

5. Upgradation of Mining Equipment;

6. Improvement in Underground production with modernisation of Technologies;

7. Impact of volatility in International Coal Prices on Domestic Coal;

8. Development of Captive Coal Blocks;

9. Improving availability of Indigenous Coking Coal;

10. Making Coal Mining and Coal Utilisation more environment friendly with particular emphasis on

Coal Beneficiation.

11. Coal Demand Side Management.

Successful organisation of an Event of this nature and magnitude will require the active support of all

the stakeholders in Coal Sector like Coal Producers, Coal Consumers, Regulatory Authorities in

general and that of Ministry of Coal, Ministry of Power, Ministry of Environment and Forests, Ministry

of Steel, Indian Railways, concerned State Governments in particular. This support has already been

sought and assured.

The Forum is a unique NGO, which promotes energy sector as a whole.

Most major players in Power, Oil & Gas, Coal and Renewable are its

members. These include NTPC, NHPC, Power Grid Corpn., Power Finance

Corpn., PTC, Tata Power, ALSTOM, ONGC, IOCL, CIL, Neyveli Lignite Corporation, Vestas RRB, JP

Group, Bhilwara Group and about 90 eminent energy experts. In addition, it has MOUs with leading

regional chambers and specialized organizations including Bombay Chamber, Bengal Chamber,

Bangalore Chamber, Madras Chamber, PHD Chamber, Observer Research Foundation, IRADE,

INWEA, MGMI-DC, ISMAA-DC, Petrotech, Petrofed and work closely with them.

MGMI is one of the oldest professional Institutes of its kind in Asia having being

founded in 1906. It has been organizing conferences and seminars on issues

impacting the mineral sciences. MGMI is a unique, independent, non-profit

organization and represents professionals of the mineral sector as a whole. It is

manned by highly qualified and experienced mining engineers, geologists and

metallurgists and energy experts.

ORGANISERS

India Energy Forum

The Mining Geological & Metallurgical Institute of India (MGMI), Delhi Chapter


DELHI CHAPTER

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Indian School of Mines Alumni Association (ISMAA)-Delhi Chapter

The ISM Alumni Association continues to provide yeoman service to the mineral

industry in India as well as abroad with complete dedication and commitment to

the mineral industry. In appreciation of the fact that the prime pre-requisite for

industrialisation in India will be a sound Mineral Sector, Govt of India way back in

1926 set-up a world class Mining Institution at Dhanbad which was named Indian

School of Mines and Applied Geology. This was formally inaugurated by his

Excellency Lord Erwin the then Viceroy on 9th December 1926. Now named as

Indian School of Mines, it has become a full -fledged University and the Captains of Indian mineral

Industry take pride in calling themselves the Alumni of this world class Institution. ISM Alumni

Association works as a think tank for Mineral Industry in India and coordinates with ISM Alumni

abroad for updating and upgrading mineral science in the country.

The Summit provides an ideal forum for miners, planners and policy makers to discuss the

various issues affecting the coal, mining and allied industries across the globe.

The Summit will be an unique platform for Entrepreneurs, Decision Makers, Senior

Government Officials, Investors, Industry Members, Traders, Equipment Buyers &

Suppliers, Academia, Miners, Engineers and Trade Delegations to congregate, brainstorm,

showcase and forge meaningful partnerships for business development.

Concurrent with the 6th Coal Summit Conference 2016, an International Expo - Coal Summit Expo

(CSE) 2016 is being organized by TAFCON under the aegis of IEF, MGMI (DC) & ISMAA (DC) at Hall

No 15, Pragati Maidan, New Delhi.

The Expo provides an excellent business opportunity for coal, mining and allied industries to

showcase their new initiatives, technologies, products and services to the global audience.

SUMMIT AND EXPO


TAFCON

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PROGRAMME

THDAY I - MONDAY, 5 SEPTEMBER 2016

THDAY II - TUESDAY, 6 SEPTEMBER 2016

Venue : Hall -15, Pragati Maidan, New Delhi

4.00M : Registration

5.30pm : Inauguration of Exhibition by

Shri Balvinder Kumar, Secretary, Ministry of Mines

6.00 pm : Cocktail Reception

• A Room will be arranged for seating the VIPs who arrive for the Inauguration.

• Arrangement will be provided at the Entrance to the Exhibition Venue for a small meeting to be addressed by

the Chief Guest before the Inauguration.

Venue : Hotel Le-Meridian, New Delhi

8:30 - 9:30 a.m. : Registration

9:30 - 10:30 a.m. :

Welcome Address by : Shri Anil Razdan, President, India Energy Forum

Address by : Shri A N Sahay, President, MGMI

: Shri G C Mrig, President, ISMAA

Introduction of : Shri S Bhattacharya, Chairman, Organising Committee &

theme by CMD, Coal India Ltd

Inaugural Address by : Shri Anil Swarup, Secretary, Ministry of Coal

Vote of Thanks by : Shri N N Gautam, Convenor, Organising Committee

10:30 - 10:45 a.m. : Tea

10:45 - 12:00 p.m. :

Chairperson : Shri C Balakrishnan, Former Secretary, Ministry of Coal

Co-Chairperson : Shri N Sridhar, CMD, SCCL

Session Coordinator : Shri Ashok Mehta, Former CMD, WCL

Topics : Coal Production and Marketing Policy Perspective

Shri D N Prasad, Advisor (Projects), MoC

: Future of Bulk Production from U/G Mine in India

Dr MK Mukopadhyay, Sh Amit Kumar - Mecon

INAUGURAL SESSION

TECHNICAL SESSION-I

POLICY Perspective


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: Coal Pricing

Shri Sunjoy Joshi, Director, ORF

: Australian Experience in Coal Sector

Mr Richard Dewhirst, General Manager, Resources - South Asia &

Middle East

12.00 - 1.00 p.m. :

Chairperson : Shri P S Bhattacharyya, Former CMD, Coal India Ltd

Co-Chairperson : Shri D N Prasad, Advisor (Projects), Ministry of Coal

Session Coordinator : Dr M M Seam, Former Advisor, Essar Minerals

Topics : Modernisation of Coal Exploration Technology & Reserve Assessment System -

Indian Scenario

Shri B N Shukla, Director (Operations), CMPDI

: Modernisation of Opencast Mining Technology for higher production and higher

productivity - Human as well as Capital

Shri T K Nag, CMD, NCL

: Underground Coal Production and Mine Construction

Shri B N Pan, Former CMD, BCCL

1:00 - 1.45 p.m. : Lunch

1:45 - 2.45 p.m. :

Chairperson : Shri Gurdeep Singh, CMD, NTPC

Co-Chairperson : Shri B R Reddy, CMD, SECL

Session Coordinator : Shri A K Tooley, Former Director, WCL

Topics : Coal for Power Sector

Shri Arun Srivastava, Chief-Regulations & Advocacy, Tata Power

: Importance of Coal for Cement Sector

Shri N A Viswanathan, SG, Cement Manufacturer Assn

: Import of Coal and Price Volatility

Shri Kalyan Maity, Director (Raw materials), SAIL

: Solar based Power Generation

Shri Amit Kumar, Tata Power Solar

2.45 pm - 3.00 pm : Tea

TECHNICAL SESSION - II

TECHNICAL SESSION - III

Coal Exploration and Production

Coal Utilisation


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3.00 - 4.00 p.m. :

Chairperson : Shri Alok Perti, Former Secretary, Ministry of Coal

Co-Chairperson : Shri S C Khera, Former CMD, CCL

Session Coordinator : Shri S K Grover, Former GM - Fuel Mgnt., NTPC

Topics : Coal Utilisation technologies for reducing Carbon foot print

Shri D K Jain, Former Director (Tech), NTPC

: Importance of Coal-based Power Generation

Shri RP Singh, Former CMD, Power Grid Corporation of India Ltd.

: Overland transportation of coal traversing difficult terrains

Shri S K Nayak, LNV Technologies and Shri S K Grover, Former GM - Fuel Mgnt., NTPC

4.30 - 7.00 pm : Visit to Exhibition

7.00 p.m. : Dinner at Exhibition Venue

• For facilitating visit to the Exhibition, a Mini Van will be available throughout the Session. Its movement will be co-ordinated by a person nominated for this purpose.

• At 4.00 pm, an AC bus will be available at the Summit Venue for taking Delegates to the Exhibition Ground.

Venue : Hotel Le-Meridian, New Delhi

9:00 - 10:15 a.m. :

Chairperson : Shri S K Chowdhary, Former CMD, Coal India Ltd

Co-Chairperson : Shri Gopal Singh, CMD, Central Coalfields Ltd.

Session Coordinator : Shri Umashankar, Sr Vice President, Adani Enterprises Ltd.

Topics : Applications of IT in Coal Mining

Shri Deep Krishna, MD, DKG Labs

: Tendency of Washery Industry and Dry Beneficiation

Shri Dongpimg Wang, Dadi Engg. Development (Group) Co. Ltd., China.

: Safety in Indian Coal Mines

Shri B P Singh, DGMS

: Improvement in Underground production with Strata monitoring and management

Dr S K Singh, Chief Scientist and Head of Research Group, Mining Methods and Design Simulations, CSIR-Central Institute of Mining & Fuel Research (CIMFR)

TECHNICAL SESSION - IV

TECHNICAL SESSION - V

Infrastructure

Technology

THDAY III - WEDNESDAY, 7 SEPTEMBER 2016


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10.15 - 11.45 a.m. :

Chairperson : Dr M P Narayanan, Former Chairman, Coal India Ltd

Co-Chairperson : Shri Vinay Prakash, CEO, Adani Enterprises Ltd

Session Coordinator : Shri P R Mandal, Advisor, Essel Mining

Topics : Cutting Edge Technologies in Coal-based Power Generation

Mr R Sonde, Thermax

: Rail Infrastructure in Indian Coalfields

Shri Devinder Singh, ED (TP), Railway Board

: Indian Coal-Environmental Impact

Dr Manoranjan Hota, Advisor/Scientist G, MoE,F&CC

: Presentation by

Mr. Vikramjiet Roy, Mg Director, Maccaferri India

11:45 - 12:00 Noon : TEA

12:00 - 1.30 p.m. :

Chairperson : Shri S K Acharya, CMD, NLC

Co-Chairperson : Shri M N Jha, Former CMD, CMPDI/ SECL

Session Coordinator : Shri Peeyush Kumar, Director (Tech), Ministry of Coal

Topics : CBM in India- Prospects and Present Status

Shri Sudhir Vasudeva, Former CMD, ONGC

: Coal to Liquid- Clean Coal Technology Corporation

Shri Amlendu Sinha, Former Director, CIMFR

: Higher Capacity Mining Equipment - Make in India

Shri D K Hota, CMD, BEML

: Surface and Underground Coal Gasification

Dr. Rabindra Nath Maiti, DGM, (R&D), EIL

: Coal Mine Methane - Current Status & Future Prospectus

Shri V K Sinha, Director - Technical, CMPDI/ Rajiw Lochan

1:30 - 2:15 p.m. : Lunch

TECHNICAL SESSION - VI

TECHNICAL SESSION - VII

Environment

CBM & CMM


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2:15 - 3:45 p.m. :

Chairperson : Shri Anil Razdan, Former Secretary, Ministry of Power

Co-Chairperson : Capt R S Sindhu, CMD, ACB India Ltd

Session Coordinator : Shri V K Sehgal, MD, Global Coal & Minings

Topics : Review of Proven Coal Preparation Technologies Treating Indian Coal

Shri Gurudas Mustafi, CEO, Mbe Coal & Mineral Technology India

: Dry Beneficiation of Indian Coal

Dr G V Ramana, Ardee Hi-Tech Pvt Ltd

: Recent advances in Coal Beneficiation Technologies

Shri Sunil Yadav, Vice President, Metso

: Advanced Design & Process Technology for India Coal

Shri Robert Hollis, Vice President, The Daniels Company

3.45 - 4.00 p.m. : Tea

4.00 - 5.00 p.m. :

Chief Guest : Shri Ajay N Jha - IAS, Secretary, Min of Environment, Forest and Climate

Change

Panelists : Shri K A Sinha, Former Director (Tech), CIL

: Shri U Kumar, Former CMD, SECL

: Shri P S Bami, President Emeritus, IEF

Presentation of Draft : Dr M M Seam

Recommendations

Announcement of Result of Best Expo Stall Competition

Presentation of Award for Best Expo Stall

5.00 pm : Vote of Thanks by

Shri Amarjit Singh, SG, IEF

: Visit to Exhibition

TECHNICAL SESSION - VIII

VALEDICTORY SESSION

Coal Beneficiation


Ms. Aruna SundararajanSecretary, Ministry of Steel

New Delhi

Mr Balvinder KumarSecretary, Ministry of Mines

New Delhi

Mr. Ajay Narayan JhaSecretary, Ministry of Environment,

Forest & Climate Change, New Delhi

Shri Mohd JamshedMember (Traffic)

Railway Board, New Delhi

Dr AK DubeySpecial Secretary

Ministry of Coal, New Delhi

Shri BP PandeyAdditional Secretary

Ministry of Power, New Delhi

Shri Rahul GuhaDG, DGMS,

Dhanbad

Shri DN PrasadAdvisor (Projects)

Ministry of Coal, New Delhi

Shri Gurdeep SinghCMD, NTPC Ltd

New Delhi

Shri N Sridhar, IASCMD, Singareni Collieries Co. Ltd,

Hyderabad

Shri TK ChandCMD

NALCO

Dr DC PanigrahiDirector,

Indian School of Mines, Dhanabd

Dr MP Narayanan,Former Chairman,

Coal India Ltd, New Delhi

Shri SK Chowdhary,Former CMD, CIL & Executive President, Indian Coal Forum,

New Delhi

Shri P S BamiPresident Emeritus, India Energy Forum

Shri G C MrigChairman,

Vayunandna Power Ltd, Gurgaon

Shri NM BorahFormer CMD,

OIL

Shri D BhattacharjeeCMD,

HINDALCO

Shri Tuhin MukherjeeMD, Essel Mining & Industries Ltd,

Mumbai

Shri Sanjay Sagar,Jt Managing Director

JSW Energy Ltd, Mumbai

Shri Vinay Prakash,CEO, Adani Enterprises,

New Delhi

Capt RS Sindhu,CMD, ACB (India) Ltd,

Gurgaon

Shri Sunjoy Joshi,Director,

ORF

Shri Arun Srivastava,Vice President,

Regulatory and Advocacy, Tata Steel

Shri NN Gautam,SG, ISMAA-DC &

Chairman, Coal Group, IEF, New Delhi

Shri Amarjit Singh, MBESecretary General, IEF,

New Delhi

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Chairman

Patrons

Chairman Co-Chairmen

Convenor Co-Convenors

Shri Anil SwarupSecretary, Ministry of Coal

Mr Anil Razdan Shri C. Balakrishnan Shri Alok PertiFormer Secretary, Ministry of Power Former Secretary, Ministry of Coal Former Secretary, Ministry of Coal

Shri S. Bhattacharya Shri A N SahayCMD, CIL President, MGMI & CMD, MCL

Shri P.R. Mandal Shri V.K. Sehgal Former Advisor, Ministry of Coal & MD, Chairman, MGMI - Delhi Chapter Global Coal & Mining Pvt. Ltd.

Shri SK AcharyaCMD, NLC

Shri SK GroverEx GM-NTPC

National Advisory Board

Members

Committee


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Chairman

Co-Chairmen

Convenor

Co-Convenors

Shri S BhattacharyaChairman, CIL

Shri G C Mrig Shri U Kumar Shri N KumarChairman, ISMAA, Delhi Chapter Advisor, Essel Minerals Director (Tech), Coal India Ltd &

CMD, BCCL

Shri N N GautamChairman, Coal Group, IEF & SG, ISMAA, Delhi Chapter

Dr. M M Seam Shri Prabhakar Chowky Shri Uma ShankarFormer Advisor, Essar Minerals GM, CIL & SG, MGMI DC , Adani GroupVice President

Organising Committee

Shri R G GuptaAddl Secretary, Ministry of Coal,

New Delhi

Shri Anil Kumar JainJoint Secretary (Thermal),

Ministry of Power, New Delhi

Shri Devender SinghExecutive Director (Traffic Railway)

Railway Board, New Delhi

Shri N K SinghJt Secretary

Ministry of Mines

Shri S N PrasadDirector (Marketing),

CIL, Kolkata

Shri Gopal SinghCMD, CCL Ranchi,

Jharkhand

Shri R R MishraCMD, WCL,

Nagpur, Maharastra

Shri T K NagCMD,NCL

Shri Shekhar Sharan

CMD, CMPDI,Ranchi, Jharkhand

Shri B.R. Reddy CMD, SECL

Shri CK DeyCMD, ECL, Sanctoria,West Bengal, D(F), CIL

Shri Anjani Kumar, Coal Controller

Shri Peeyush Kumar Director (Tech),Ministry of Coal

Shri N K NandaDirector (T), NMDC Hyderbad,

Andhra Pradesh

Shri Subir DasDirector,

NLC

Shri B Ramesh KumarDirector,

SCCL

Shri. P S BhattacharyyaFormer Chairman,

Coal India Ltd

Shri K.A. SinhaChairman,

Min Mec Consultancy

Shri S.C. KheraFormer CMD, CCL &

Vice Chairman, ISMAA, DC

Shri Ashok MehtaFormer CMD, WCL, New Delhi

Prof. BB DharFormer Director,

CMRI

Shri VK JainFormer Director,

NMDC

Shri PR MandalPresident

MGMI-DC

Shri RK SharmaSecretary GeneralFIMI New Delhi

Shri A.K. TooleyFormer Director

Emta Group, New Delhi

Shri B P SinghMember,

DERC, New Delhi

Mr P S UpadhyayFormer Director,

NMDC

Shri MN JhaJaypee Group

Shri Prashant RoyHon Secy,

MGMI, Kolkatta

Members


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Working Committee

Chairman

Shri B R Reddy

CMD, SECL

Former CMD, SECL

Shri NK Sharma Shri B Akla Shri Ashok Mehta

Former Chairman, Coal India Ltd Former CMD, CMPDI Former CMD, WCL

Shri Abdul Kalam Shri N N Gautam Shri P R Mandal Shri S K Grover

Former CMD, SG, ISMAA-DC & President Ex GM-

BCCL Chairman - Coal Group, IEF, New Delhi MGMI-DC NTPC

Co-Chairman

Members

Shri V K Seghal

Technical Committee

Chairman

Co-chairman

Members

Shri R R Mishra

CMD, Western Coalfields Ltd

Shri S J Sibal Shri S C Khera Shri M N Jha

Former DG, DGMS Former CMD, CCL Former CMD, CMPDI

Shri M S Nagar Shri A.R. Sharma

Former CMD, IREL Former CMD, WCL

Dr. M.M. Seam

Former Advisor, Essar


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Souvenir Committee

Chairman

Co-Chairman

Members

Shri Gurdip Singh

Chairman, NTPC

Shri SK Grover

Ex-GM, NTPC

Shri Ashok Mehta Shri AK Tooley Shri SP Singh

Ex CMD, WCL Ex Director (T), WCL Ex D(T), MCL

Shri Prabhakar Chauki Shri Umashankar

GM, CIL, New Delhi Adani Group

Resource Committee

Chairman

Co-Chairman

Convenor

Members

Shri AK Jha

CMD, MCL

Shri K Biswal

DCF, NTPC

Shri NN Gautam

Former Advisor (Projects)

Shri Uma Shankar ShriSubir Das Shri P R Mandal

Adani Enterprises Director (Tech), NLC Essel Mining & Industries Ltd

Shri Sanjay Sagar Shri Prabhakar Chouki

Jt Managing Director, JSW Steels GM , Coal India Ltd.

41


Reception Committee

Chairman

Co-Chairman

Members

Shri N SridharCMD SCCL

Shri P R MandalFormer Advisor, MoC

Shri Subir Chandra Shri Abdul Kalam Shri VK JainDirector (P&P), CCL Former CMD, BCCL Former Director, NMDC

Shri Ramesh Khanna Shri Vaibhav Gupta Shri Ashok Kumar Shri VK TalwarFormer CGM, Coal India Ltd ICICI Bank ICICI Bank Cement Manufacturers Association

Exhibition Committee

Chairman

Co-Chairman

Members

Shri T K NagCMD, NCL

Shri AK Tooley Shri IP WadhwaEx-Dir (T), WCL Mg Worker, Tafcon

ShriAmit KumarAGM, Tafcon

Shri Chanakya Choudhry, Shri P S Upadhya Shri R K KhoslaGroup Director, CC & Former-Director, Former General Manager

Regulatory Affairs, Tata Steel NMDC BEML

Shri A L Thakor Shri Arun Tripathi, Shri V B SahayGeneral Manager (I/C), Managing Director V P - Washeries,

GMDC Tass Technical Pvt ltd ACB India Ltd

Shri Lokesh Roy Mr P R Mandal Mr U KumarFormer Director

Joy Mining Services Pvt ltd

Convenor

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Glimpses of Previous Conferences


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Glimpses of Previous Conferences


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Recommendations

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Coal - Global & Indian Scenario-24x7 - Power for All

th5 ROUNDTABLE CONFERENCE ON COALTheme : Energising Coal Sector - The Eco-Friendly Way

30th October 2015Hotel Le Meridien, New Delhi

Future Projections of Coal requirement in India show that even going forward, Coal will continue to

occupy the dominant position in Energy Security scenario of the country. This will also be borne out

from the fact that a very ambitious Coal projection target of 1580 mtpa to be achieved by 2020 has been

fixed by the Govt.

Various issues connected with Coal were deliberated upon at the 5th Round Table Conference held at

Hotel Le-Meridian, New Delhi on 30.10.15.

Following recommendations are made based on the results of the deliberations:

1. Exploration : Exploration for Coal has got to be intensified further for ensuring that adequate

Proved Reserves are available for meeting the ever increasing requirement of the country. For

this purpose, the problem caused by the restriction of drilling only, 3 Boreholes per sq km in

Forest Land has to be resolved so that atleast 10 Bore Holes per sq km are permitted. This is

necessary since Proved Reserves cannot be established on the strength of 3 Bore Holes per sq km

and investment decision cannot be taken unless adequate Proved reserves are established.

2. Mine Planning : Eco-friendly measures have to be integrated in all spheres of Mine Planning as

well as Mine operation and post- mine- closure activities. Effective monitoring system has to be

put in place for ensuring that the eco-friendly provisions in the Mining Plan/ Mine Closure Plan

are conscientiously implemented.

3. Land Acquisition and Reclamation : It was felt that Leasing of land should be made a Parallel

Route for meeting the land requirement for mining projects. Reclaimed land should be returned

to the erst while owners and this aspect should be kept in mind while deciding on the

compensation to be paid to the land owners for acquisition/ leasing of their land.

4. Coal Beneficiation : Considering the heavy polluting effect of Coal burning and the fact that

larger and larger quantities of Coal will be utilised going forward, It is recommended that all

Coal except that used for Power generation at pithead should be beneficiated and the current

mandate for use of Coal having less than 34% Ash in Power Stations located more than 750 kms

from the Mine and those located in critically polluted and environmentally sensitive areas

should be rigidly implemented.

5. R&D : Following R&D activities pertaining to Coal should be given due attention:

i. Coal Gassification

ii. Coal Bed Methane: CBM Cells should be created in CMPDI and in subsidiaries of CIL and

CBM activities in the area should be treated as independent projects.

RECOMMENDATIONS

47


48

iii. Coal to Liquid

iv. Coal utilisation by switching to Super Critical and Ultra Super Critical Technologies for

Power Generation

v. Gainful utilisation of Fly Ash and Washery Rejects

vi. Wider application of FBC Technology for utilisation of Inferior Grade Coal/Washery

Rejects

vii. Carbon Sequestration Technology

viii. Slurry Transportation

ix. Use of Non-Coking Coal for Steel Making

6. Mining Equipment : The projection prepared by Coal India Ltd for future equipment

requirement should be made available to Equipment manufacturers in the country and they

should take steps for manufacturing these Equipment so that import dependence can be

reduced.

7. Manpower Requirement : Manpower requirement in the Industry as a whole keeping in view,

its future growth should be assessed and a comprehensive policy together with infrastructure

should be created for “skilling” for meeting this requirement.

8. Rationalisation of Coal Linkage : The steps initiated by Govt in this direction were appreciated

and it was recommended that the entire linkage structure should be re-examined so that use of

imported Coal in Industries located inland is totally stopped. While imported Coal should be

used in coast-based Industries, indigenous Coal linked to these Industries should go to Inland

Industries .


49

th5 COAL SUMMIT

Theme : Coal – A Relook on The Way Forward

23th & 24th September, 2014

Hotel The Ashok, New Delhi

In view of the Government programme for ensuring 24x7 supply of power, Coal requirement of the

country which had been projected as 710 mill tonnes by 2016-17 will now increase to 980 mill tonnes in

2016-17 and 1373 mill tonnes by 2021 – 22.

Following recommendations are made based on the views expressed at Coal Summit held on

23rd/24th September 2014 at Hotel Ashok , New Delhi.

1. Demarcation of Coal Blocks

The existing demarcation of Coal Blocks had been made taking Captive Mining into account

which in its very nature was restrictive in matters of production level from a Mine . Now that

Coal Sector has been opened to Merchant Mining it will be possible to plan bigger mines with

higher production capacities and the Blocks which are not to be offered for Captive Mining

should therefore be demarcated afresh so that large capacity mines can be planned.

2. Exploration

a) For converting Indicated/ Inferred Resources into Reserves present rate of drilling which is

about 7 lakhs mtr per annum should be increased to 30 lakhs mtr p.a.

b) Further, the provision for seeking Forestry Clearances for Coal Exploration in Forest areas

should be relaxed.

3. Equipment Productivity

There is urgent need for improving the Equipment Productivity in India to bring it to

international levels. For achieving this skill development for both operation & maintenance

personnel should be made a focus area .

4. Land

a) LA & R&R Act 2013 has made Land Acquisition for Industrial Development in general and

Mining in particular extremely difficult. The Act should be amended to make it industry

friendly.

b) Instead of out-right purchase/ Acquisition of Land ,Mining Industry should go for taking

Land on Lease, reclaiming the Land after Mining operations are over and returning the

land back to the erstwhile owners. During the lease period, lease rent linked to the

agricultural produce from the Land should be paid to the Land Owners.

RECOMMENDATIONS


50

c) A new model for Land compensation should be designed without the condition for

provision of employment to the Land Users.

d) Forest Land and Govt. Land should be handed over to the Projects free from encumbrance.

5. Nodal Officer

For ensuring better coordination between the Central and the State Govts., Nodal Officers should

be appointed by the State Govt. for each Mining Project.

6. MDO Route

a) For Mines to be operated through MDO Route getting land and all statutory clearances

should be the responsibility of the Mine Owner.

b) Provision should be kept for periodic review of the Terms of the Agreement between the

Owner and the MDO.

c) The MDO Model should be re-designed to attract reputed International Contract Mining

Companies.

7. Underground Production

a) Modern Mass Production Technologies should be deployed for improving U/G

production and productivity.

b) U/G Equipment manufacturers should be incentivized to avail themselves of “Make in

India” opportunity.

8. Infrastructure

a) Rail connectivity for Coalfield areas should be improved by laying more Rail Lines.

b) The Rail Projects under execution in North Karanpura (Tori-Shivpuri), Mand-Raigarh, IB

Valley and Talcher Coalfields should be executed on Mission Mode.

c) Rapid Load Out System should be made mandatory for all Coal Projects Planned for

production level of more than 5 mtpa.

9. Coal Utilisation

a) Use of Beneficiated Coal should be made mandatory for all Coal -based power stations

except those located at Pit-head.

b) Once Demand-Supply gap is bridged the Concept of Coal linkage should be done away

with and the consumer should be given the freedom to select his source of Coal supply.

c) Efficient use of Coal by adoption of super–critical, ultra super-critical and IGCC

Technologies should be Incentivized.


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10. Foreign Participation

a) International Mining Companies should be incentivized to take up exploration on

chargeable basis.

b) When the Block is auctioned based on the data generated by such exploration, the

concerned company should be given the first right of refusal.

11. Clearances

a) Cluster approach to be adopted for grant of Environment Clearance.

b) Need for Public hearing to be dispensed with for Expansion projects.

c) Environment cadre to be created in Coal Companies.

d) Forestry Clearance except in Protected / National Reserve forest areas should be granted

more as routine than as exception.

e) Provision of non-forest land for Compensatory Afforestation should not be insisted upon

till all the de-graded forest land is afforested.

12. Coal Regulator

A strong Regulator with adequate authority, to be appointed which will oversee quality of

exploration, Coal Price Fixation, Compliance with Mining Plan and EMP Clearance conditions

and Dispute resolutions.


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th4 ROUNDTABLE CONFERENCE ON COAL

Theme : Coal : In the Dynamics of India's Energy Sector

28th October, 2013 at New Delhi

I. Land Acquisition *

New Land Acquisition Act is more unfriendly than the earlier one. Leasing of land is more viable

solution which should be adopted. After payment of initial agreed amount at the time of

possession of land, the lease charges be linked to per te of coal produced or deemed produced.

II. MoEF clearance

The procedure should be streamlined in agreed time schedule so as to cut down the delays. Also

fix up responsibility of timely clearance & its execution. More emphasis on monitoring of MoEF

conditions laid for clearance.

III. Forest Clearance *

To expedite this, a bank of compensatory land suitable for reforestation should be identified in

each state. After payment of initial agreed amount for commencement of reforestation work, the

balance payment be linked to per te of Coal produced or deemed produced.

IV. Role of States *

Minerals & land being a state subject, the role of state need to be made more effective and

accountable for mining projects.

Law & order is again State subject & this need to be improved for faster implementation.

V. Speedy Exploration

lFocus on establishing Coal Reserves lying between 300-600 mts depth with special focus on

proving dip side extension of already established Coal mines / blocks

lPriority of establishing Coking Coal reserves.

l3D class Seismic Exploration, a world class technology, for expediting Coal Exploration.

lMixing of Coring & non-coring drilling coupled with geophysical logging for accelerating

the exploration work.

lProspecting license & forest clearance be obtained.

VI. Master Plan of Coalfield including infrastructure for Coal evacuation

lNeed to be prepared

lIntensive monitoring of Rly lines like Tori – Shivpuri, Mand – Raigarh, Ibvalley, Talchir thAreas to Cater needs of coal offtake in 13 Plan.

RECOMMENDATIONS


53

lRapid loading System for large O/C mines specially mines above 10 mte/an capacity for

faster turn around of wagons.

VII. Technology upgradation – Stepping up Coal Production

lBench marking of Productive norms

lFocus on Expanding underground Coal Production.

lFocus on bringing in International mining companies as MDO / JV Partners.

lImproving availability of indigenously manufacture of mining equipments / spares.

lGovernment to approve operating mines both in Govt and Private Sector to step up

production upto 20-30% over the sanctioned capacity, wherever feasible.

VIII. Manpower *

lFocus on training manpower for upgrading its skill both in private and public sectors.

lRationalisation of HR Policies within PSUs.

IX. Mismatch of mine Development Vis a Vis end use plant *

Coal Sector be opened up without captive use restrictions

X. Supplementary Energy from Coal resources

lSubstantial additional energy can be obtained through new technologies of

CBM/CMM/Shale Gas/Underground gasification.

lA separate subsidiary within CIL to be formed to harness the above and to act as

independent Profit centre.

XI. Improving Coal Utilisation

lAdoption of clean Coal technologies for improved Coal utilization.

lAdoption of modern combustion technologies like IGCC, Fluidised Bed Combustion etc for

more efficient use of Coal and significant reduction CO2 emissions.

XII. Restructuring of Coal Industry

lGreater autonomy to subsidiaries of CIL by granting them status of independent PSUs.

lSetting up of Coal regulatory authority to be expedited to have uniform controlled over

both public and private sectors.

lOnly fully explored blocks to be put for auction for future allocations.

* Recommendations of earlier Coal Summit 2012. These earlier recommendations are being repeated as they require urgent

immediate attention and delaying their implementation would have further adverse impacts on the mining industry.


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Uma Shankar - Adani Enterprises Limited & S.K. Grover – Former GM (Fuel Mgmt NTPC)

Coal - Global & Indian Scenario-24x7- Power for All

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Coal is not going away – Global prospective

ØCoal plays a pivotal role in sustainable development and will continue playing a role inthe world’s energy mix in decades to come.

ØCoal is the fuel of choice in Southeast Asia due to its relative abundance andaffordability. The region’s projected energy demand will grow by 80% in 2040 in termsof electricity demand.

ØMost widely used energy source for electricity generation and an essential input to moststeel production.

ØCurrently coal provides 29.9% of global primary energy needs and generates 41% of theworld’s electricity.

ØThe share of coal in the US will be @ 27% after 15 years of clean power plant, todayshare of coal is between 33% to 35%.

ØThe world coal (hard coal & lignite) production reached a record level of 8022.5 Mt in2014.

2

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ØProven world coal reserves is 892 billion tonnes .

ØEnough coal to last us around 110 years at current rates of production.

ØOil and gas reserves are equivalent to around 52 and 54 years at current production levels.

World Coal reserves ( in billion tonne)

Country Reserves % Share R/P

US 237.30 27.6 257

Russian Federation 157.01 18.2 443

China 114.50 13.3 31

Australia 76.40 8.9 177

India 60.60 7 100

Germany 40.70 4.7 207

Ukraine 33.87 3.9 384

Kazakhastan 33.60 3.9 289

South Africa 30.15 3.5 116

Indonesia 5.53 0.6 14

2013 estimate , WCA

( Top ten Countries)

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World coal production- 2014 e

ØTop five coal producers are China, the USA, India, Australia and Indonesia.ØMuch of global coal production is used in the country in which it was produced;Øonly around 15% of hard coal production is destined for the international coal market

Top five coal producers (2014e)

PR China 3748 Mt Russia 334 Mt

USA 916 Mt South Africa 253 Mt

India 668 Mt Germany 187 Mt

Australia 491 Mt Poland 137 Mt

Indonesia 471 Mt Kazakhstan 116 Mt

Source: IEA Coal Information 20154

Top Coal Exporters(2012e) in Mt

Country Total of Which Steam Coking

Indonesia 383 380 3

Australia 301 159 142

Russia 134 116 18

USA 114 51 63

Colombia 82 82 0

South Africa 74 74 0

Canada 35 4 31

Source- World Coal Association

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Abstracts&

Technical Papers

Background

As coal mining projects have long gestation period, 7 to 8 years for underground mines and 4 to 5 years

for open cast mines to reach peak production, a new concept in designing modular coal preparation

plants offer the advantages of gradual build up in beneficiation capacity in keeping with the increased

production and thereby obviate the necessity of blocking capital investment at the outset. Modular

plants of unitized construction pre-fabricated and in knocked-down conditions, can be transported to

the mine pit head and reassembled. Modular Plants with capacities range of 150 to 200 tonnes per hour

can be installed within a period of six months.

Construction of Modular Plant

All structural steel in the Modules are in accordance with the current standards of the steel

construction relative to the design and fabrication of structural steel for buildings. Structural steel

connections are designed for field bolted assembly.Each Module has wide flange floor members with

"T" Cord upper members which fit together as Modules are stacked. All necessary bracing is included

on each Module prior to shipment. This results in a rigid frame strong enough to withstand lifting with

equipment in place. When assembled together, the Modules produce a very stable structure.

Pre-engineered Size of Modules

The framework of all Modules is pre-engineered and standardized to the same size. The size of a

Moduleis 11'-0" wide by 12'-0" high by 40'-0" long.

Interconnection of Modules

Each Module is manufactured in the shops with high quality workmanship including jigs and fixtures

to insure that all connections will match when lifted into place during field erection. Most connections

are by hi-tensile steel bolts with all the holes drilled in the shop prior to shipment. Splice plates are used

on all column connections.

Foundation Requirements for Modular Plant

Foundation work consists of establishing construction lines and levels from customer's benchmarks,

furnishing and installing concrete, forms, reinforcement steel and anchor bolts. The actual foundation

can be piers or a slab to support the structural Modules and depends on the site conditions.

Electric Powering of Modular Plant

Each Module is pre-wired with wiring in rigid galvanized steel conduit except flex conduit is used for

field connections between Modules. Each Module has a junction box and once the Modules are stacked

in place, the flex conduit is simply connected from the upper Module to the junction box of the next

lower Module. The pre-wiring includes all electrical devices within the Module such as motors, stop

jog switches, lighting and electrical outlets.

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Metso Modular Coal Preparation Plants –A Cost Effective Approach


— Sunil Yadav

64

Preparation Equipment Utilized

The basis for the selection of all preparation equipment within a Modular coal preparation plant is the

same as would be used in a conventional coal preparation plant. The customers raw coal size analysis

and washability data are reviewed by coal preparation engineers to determine the most efficient and

economic method of cleaning to meet the particular quality requirements. Then the various Modules

are assembled to develop the circuits determined to be the most efficient and economical by the coal

preparation engineers. All the equipment utilized in the Modular plants is the same type and high

quality as has been used in conventionally constructed coal preparation plants for years. Even though

the Modules are standardized, variations in Module stacking to obtain different circuits and

combinations of circuits to create a functional plant gives the flexibility necessary to product an

efficient plant design. A 7'-0" space is even left between stacks of Modules to accommodate such things

as a stair system, machinery well, piping, etc. A small elevator could even be included.

Logistics and Transporation of Modules

All Modules are designed for rail or truck transportation with lifting lugs provided on each. If after a

few years of operation it becomes necessary to move a plant, it could be disconnected at the Modular

connections and transported and re-assembled at a new site.

Field Erection and Commissioning

Once the foundation work is completed, the field erection of Modular plant primarily consists of lifting

each Module from the truck or rail car and placing it in the proper position. After a Module is lifted into

position, all that remains to be done is the connections to anchor bolts and other Modules, connecting

flexible electrical connections between junction boxes, piping connections, and adding the necessary

chutes, hoppers and sluices to complete the circuits.

A typical modular heavy media cyclone circuit coal washing plant is depicted below :


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Advantages of Modular Coal Preparation Plants

• Modular Plants are having the shortest completion time.

• Overall capital cost is the lowest.

• For pre-engineered Modular Plant capital cost savings is 10% to 15%.The capital cost reduction is

due to different constructions methods and pre-engineering because all the equipment is of the

same type and high quality as is used in conventional constructed plants.

• On a modular Plant the majority of the assembly work is done with high quality workmanship in

the shops under controlled environmental conditions.

• Field receiving, storage and fit-up problems are virtually eliminated by modular design.

• There is also a lower loss due to pilferage since smaller pieces of equipment are not laying around

in some open storage area at mine pit head site.

• There is an ease of assembly for moving.

• The modular design also makes it relatively easy to add future modules and/or arrangements to

handle customer's future needs.

• Modular units can take care of even the scale down requirement in case of lesser final demand of

the beneficiated coal.

Conclusion

Modular units, therefore, offer great opportunity in terms of flexibility, proper utilization of capital,

prompt erection, optimization of beneficiation capacity and offer safe-guards if the production plant

needs to be modified due to unforeseen circumstances.


Overview of Energy needs of the country

The need for additional inputs of energy in a country like in India cannot be contested. It is a country

with a strong economic engine with healthy prospects of growth in the foreseeable future with many

claiming the country's economy to be one of the few bright spots in an otherwise grim global economic

landscape.

However, energy continues to be a key issue that remains at the centre of the country's aspirations for

future growth, especially so, as availability of domestically produced energy, particularly that of oil

and gas, far lags the native demand for these primary inputs to any economic activity.

The country today imports as high as 80 percent of its crude oil requirements, while for gas, in absence

of any transnational pipelines connecting the country to regional gas exporters, imports of LNG has

seen a rise in the past few years. The rise in LNG imports is, of course, also aided in no small measure by

the drop in global prices of commodities by more than 50 percent in the space of the last 2 years.

The issue of high crude imports is already at the top of the priority list for the Government with the

Prime Minister issuing a national call to take concerted action to reduce oil imports by 10 percent by

2022. Imports are a serious drain on the sovereign exchequer - in the last 10 years till FY'16 we have

spent almost a trillion dollars in payments for imports for crude oil.

Although the value of the these imports have witnessed a sharp decline in recent times owing to

decline in global crude prices, we cannot hope to rely on price cycles to alleviate our troubles on this

front as our volumes continue to remain strong and once prices recover the financial strain of imports

will be hard to ignore again.

In this scenario, gas is a vital component in the country's overall energy basket. Not only is gas the

cleanest among the fossil fuels which places it in a strong position in an evolving global energy map, it

is also a resource that a country has in abundance. Strong domestic gas availability is a huge benefit and

places the onus on the domestic operators and the government to develop a framework for

monetization of these resources that is commercially attractive to the companies as well as helps the

country in its efforts to bolster its energy security.

We have over 1200 bcm of balance recoverable conventional natural gas reserves which translates to an

R/P ratio of 40 at our current rate of production. But in view of our growing demand and the

continuing depletion and stagnating production from our legacy gas fields, it is imperative to focus on

the country's substantial unconventional gas volumes for augmenting our indigenous gas supplies.

For instance, in FY'16, against a latent demand of 446 MMSCMD across sectors, only 128 MMSCMD of

gas supplies were made available, of which ~70 MMSCMD was met through domestic supplies and

~58 MMSCMD was sourced via LNG imports (term and spot). With only about 30 percent of demand

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CBM in India: Prospects and Present Status— Sudhir Vasudeva*


*Former CMD, ONGC

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fulfilment, it is not difficult to assume that a lot of growth and consumption-related activities have been

hampered.

Needless to say, unconventional gas resources - such as CBM, Shale and Gas Hydrates - have a

strong role to play in this scenario

While we have made some headway in all of unconventional gas resources to be found in the country,

it is CBM that is at a more advanced stage of development relative to Shale Gas and Gas Hydrates. The

incidental gas production from CBM blocks started in 2008-09.

This does not, however, in any way, discount the potential of the other two going forward.

Programmes to establish the commercial viability of shale gas has already been initiated by ONGC and

OIL and second expedition under the National Gas Hydrates Programme was completed in 2015 and

the initial results are quite encouraging with 134 tcf already established in the KG Basin on the basis of

NGHP-II expedition.

CBM Resources- Global

Globally, the estimated resources of CBM are beyond 7000 tcf. Countries that are currently major

producers are US, Australia, and Canada with US leading the pack by a huge margin. CBM output

accounts for almost 10 percent of the total domestic gas output in the US.

Leading CBM Resource Holders

Country Resource Size

USA ~1750 tcf

Russia ~1730 tcf

China ~1300 tcf

Australia ~1030 tcf

China also holds massive reserves of CBM but production is still low in most projects compared to the

top producers. Also, difficult reservoirs and structural complexity have posed severe technical

challenges, whilst the fiscal incentives have not been as attractive as those for shale gas in the country.

CBM- Indian Scenario

As an unconventional resource, CBM holds strong potential in terms of adding to the country's

domestic gas output. India has the fifth largest proven coal reserves in the world and thus holds

significant prospects for exploration and exploitation of CBM. The prognosticated CBM resources in

the country are about 92 TCF (2600 BCM) in 12 states of India.

In order to harness CBM potential in the country, the Government of India formulated CBM policy in

1997 wherein CBM being Natural Gas is explored and exploited under the provisions of Oil Fields

(Regulation & Development) Act 1948 (ORD Act 1948) and P&NG Rules (1959) administered by

MOP&NG.


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Under the CBM policy, till date, four rounds of CBM bidding rounds have been implemented by

MoP&NG, resulting in award of 33 CBM blocks. Total prognosticated CBM resource for awarded 33

CBM blocks, is about 62.4 TCF (1767 BCM), of which, so far, 9.9 TCF (280.34 BCM) has been established

as Gas in Place (GIP).

The vast majority of the best prospective areas for CBM development are in eastern India, situated in

Damodar Koel valley and Son valley. CBM projects exist in Raniganj South, Raniganj East and

Raniganj North areas in the Raniganj coalfield, the Parbatpur block in Jharia coalfield and the East and

West Bokaro coalfields.

As it stands, most CBM activities in India is pursued by domestic Indian companies. As on date,

GEECL, Essar Oil, RIL and ONGC are the only four companies that are active in the domestic CBM

scene, with only GEECL and Essar Oil having started commercial production of the gas., with the

latter's Raniganj (East) Block in West Bengal becoming the country's first CBM asset to cross the 1

mmscmd production milestone.

RIL has also started test production of CBM from two of its blocks, Sohagpur East and West in Madhya

Pradesh, subsequent to which commercial production will be initiated.

Current CBM production for FY'16 is around 390 MMSCM from 5 CBM blocks which includes test gas

production from 4 CBM blocks and commercial production from 1 CBM block.

Although it accounts for just over 1 percent of the country's overall gas output, it marks a significant

jump of over 70 percent from FY'15's output. Furthermore, as more players bring their projects online

and with achievement of greater clarity in terms of the regulations that govern CBM development in


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the country there is meaningful room for posting impressive growth in the years to come for CBM.

Production in FY'17 is already witnessing an upswing with CBM output in July 2016 having grown

close to 47 MMSCM from 37 MMSCM in April 2016.

Challenges in CBM Production

However, despite the promise that this unconventional resource holds, there are a few hurdles that

throttle its unhindered development, not just within the country, which anyhow is at a nascent stage,

but also across the globe.

Different Production Philosophy : One of the fundamental differences between CBM and

conventional gas production is their production profile - while conventional wells begin with

maximum production and then tapers off, output from CBM increases over time before reaching a

peak. It means average output from CBM wells are less than that of a conventional well as a result

which any CBM project usually requires drilling of more number of low-producing wells.

In addition, CBM blocks are never uniform and companies usually have to implement different

schemes and plans according to the specific geological conditions of each block. CBM drilling can

include vertical, deviated or horizontal drilling, and the technologies developed always differ between

blocks and drilling sites.

Water Management

Another key concern central to CBM development program is water management as there is a rapid

depletion of groundwater in certain projects that involve hydraulic fracturing. As such, managing the

excess groundwater released during CBM extraction activity must also form an essential part of any

developer's cost schedule for the project.

So, CBM projects do tend to become progressively more cost-intensive as one moves farther along the

development cycle to add more production. Although minimum prices for CBM development at

global level vary due to different geographical and fiscal/regulatory factors, it is usually within the

range of $5-7/mmBtu.

In India, particularly in the 4 blocks (Jharia, Raniganj, Bokaro and North Karanpura) that are owned by

ONGC, the average gas price at which the projects become commercially viable is $6/mmBtu.

Under current circumstances of low energy prices, with domestic gas price currently priced at

$3.06/mmBtu on a GCV basis for the period April-September 2016 and set to dip even lower even in the

next period (October'16-March'17), steady and strong investments in CBM projects will be, as a result,

severely challenged without adequate financial incentives or provisions in place.

Land Acquisition

CBM projects are mostly located onland and, due to its significant drilling requirements, comes with

the attendant issue of land acquisition. In a densely populated country like ours, vacating,

rehabilitating or rewarding local population for the necessary movement away from prospective

drilling sites can often be painstakingly long and expensive process, fraught with sizeable financial


70

and legal implications for the operator. This has often been cited as a pain-point by CBM players in the

country. Hence, extensive and continuous stakeholder management at the local as well as

administrative level is a pre-requisite for the success of any CBM venture here.

Overlapping Issue with Coal Blocks

But beyond all these operational and financial hurdles obstructing CBM's growth here, the one single

issue that has really derailed efforts and projects and compounded the complexity of operationalizing

any CBM project in the country is the longstanding matter of overlapping mineral rights.

Until there is a clear ruling that dictates the development of CBM along with coal in blocks with

multiple lease owners for the respective resources, investors will always tend to approach CBM with a

great deal of uncertainty.

For example, ONGC's CBM blocks in Jharia and Raniganj have overlapping issues with coal mining

which have stalled any kind of CBM-related activity in those blocks for quite a while now

In Jharia, for example, almost 45 percent of CBM Initial-in-Place is held in the overlapped area. While

ONGC-CIL consortium owns the CBM block, SAIL owns the Parbatpur coal mining block that

overlaps the area.

Over the years, attempts to resolve the overlap issue have yielded no results. In view of the safety

concerns raised by MoC/ DGMS, ONGC was directed by MoP&NG to stop their operations till GoI

takes a final decision on the overlap issue.

However, despite numerous discussions between ONGC and SAIL to sort out the issue, no headway

has been made primarily on account of the absence of any statute or regulatory body for regulating

simultaneous coal mining and CBM activities in the overlapping areas exists as on date.

In US, for example, the Bureau of Land Management executes the function of lease management and

vertical segregation of land for rights of different mineral leases.

Even globally, there are hardly any examples of simultaneous coal mining in the same area and at the

same time by different Operators is known as it involves significant safety hazards. As a result,

draining of CBM always precedes coal mining activity.

It must be understood that viability of the Jharia FDP is hinged to the Parbatpur Sector, as other areas

do not sustain economics alone. Therefore, if this prime prospective area for CBM is not accessible due

to the overlapping issue then the FDP may be unviable. Not to forget, over the years, ONGC has carried

exploration risk, established the CBM potential and invested about Rs. 500 crores in the block.

ONGC also faces multiple overlapping issues in its Raniganj block, both in FDP and assessment areas.

Even here, the project becomes unviable without the overlapping coal blocks in case the company is

required to relinquish the overlapped areas.

It is worthwhile to note that of the 9 CBM blocks that were awarded to the company, 5 have already

been surrendered due to a host of issues and, in the event that there is no timely resolution to this

overlapping issue, ONGC would find it difficult to continue ownership of the contentious blocks.


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Drilling horizontal multiple lateral wells from outside the coal area to bypass the issue of vertical

mining was also undertaken in the Parbatpur area. However, the results have been unflattering, and it

is further compounded by the huge volumes of water that is produced during dewatering.

Subsequent to this initiatives, the Steering Committee advised not to proceed with further drilling of

such wells. Also, no other CBM Operator in the Country has ventured into drilling of horizontal wells

for CBM exploitation to date.

Regulatory policy

All these concurrent issues point to the urgent need to set up a regulatory body that clearly governs the

monetization of CBM in the country as well as executing necessary modifications in the Mining and

Mineral Concession Rules for facilitating development of both the resources. Most of the existing rules

such as the Mines Act 1952 or Oil Mines Regulations 1984 hold good for conventional drilling, but the

same merit a reassessment while applying these in CBM domain as geological profiles and production

methodologies differ conspicuously in both the cases. Another regulation which mandates CBM

operators to ensure that the flare islocated not less than 90 meters from any part of aproduction

installation or petroleum storage tanks also requires a relook. Pressure regimes in CBM wells are

different from conventional hydrocarbon wells in that most of the wells are sub-hydrostatic and

therefore do not need stringent application of the same safety standards. In CBM field development, a

small cluster of wells can be aggregated,hence requirement of flare distance of 90m may be considered

mandatory.

Pipeline network

Once operational and regulatory issues pertaining to the development of CBM is adequately

addressed, availability and easy access to the required pipeline network for evacuation of the

produced gas to the demand centres is an equally important factor that will determine the efficacy of

CBM in terms meeting the country's growing gas needs. Lack of adequate pipeline infrastructure will

result in low utilization rates in the sector, as has been observed with China's CBM sector. GAIL's

proposed Jagdishpur-Haldia pipeline, set in the vicinity of the CBM blocks, once realized, will go a

long way in catering to this need.

Conclusion

CBM development in India, despite its strong potential, has moved on a slow track. However, it should

not take away from the resource's promise for the future energy basket of the country. The Petroleum

Minister has recently said that domestic CBM output, in the near future, should grow to represent 5

percent of the total gas production in the country from its present share of just over a percent.

Despite its many bottlenecks, CBM canplay a vital role in the energy sector. With a collaborative

approach among the many stakeholders, necessary technical/ technological repertoire and enabling

regulatory environment, most of these hurdles can be overcome to pave the way for CBM's future.


Abstract

Dry separation process is used for thermal coal which has many obvious advantages in economy,

environmental protection and so on. The study of Telligent Dry Separator (TDS) solves the problems

in principle that traditional dry separation equipment have, such as low separation accuracy and

seasonal moisture variation impacting separation, which can completely substitute for wet

separation equipment. The process of TDS for lump coal and together with wet separation for small

coal will be the leading development direction for thermal coal separation in the future. Besides that,

combining deep screening of flip flop screen opens new thoughts for thermal coal process design.

Key words : coal dry separation; telligent dry separator; deep screening; flip flop screen; thermal

coal separation process

The world's coal output is nearly 8 billion in 2015. As one of the important non-renewable energy, coal

consumption accounts for about 30% of world's non-renewable energy resources consumption. India

as one of the countries who currently have the highest economic growth speed in the world and

consumes energies in a rapid increasing way. And the coal consumption growth rate keeps more than

10%. In India, raw coal's ash content is high, which would lead to low efficiency and generate a large

number of sulfur dioxide, smoke and fly ash and cause serious pollution issues if it is used to burned

directly. Coal washing and separation process can effectively decrease ash content, so improving coal

washing percent is the most effective method to reduce coal burning pollution.

At present, wet separation is a commonly used method for thermal coal (heavy medium separation, jig,

drum separation with self-generated media, spiral separation, teeter bed separation etc.). Wet

separation method needs a great deal of water during the process, which are 2-5m³ circulating water

per ton raw coal and 0.05-0.10m³ makeupwater consumption per ton raw coal. Wet separation system

is complex and investment and operation cost is high too. In addition, slurrytailing treatment is an

important part for wet separation, of which investment is huge. Normally, tailing from thermal coal

process is not separated and has high ash content and moisture, which cannot be used directly. So it's a

huge waste and also has environmental pollution issue.

In terms of coal process technology development, there are two main development directions for thermal

coal separation. One is dry separation technology and the other is deep screening technology of raw coal.

Based on these two technologies, there will be surely some new thoughts on thermal coal separation.

1. Coal Dry Separation

Dry separation is an important development direction of coal process technology. There's no

water consumption and no tailing to be generated during the process. It has the characteristics of

simple system, small foot print, short construction period, low construction investment and

operation and management cost. There are twomajor technologies about dry separation.

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New Thoughts for Thermal Coal Separation— Dongping Wang, Changchun Mu

*dadi Engineering Development Group

73

• Air Jig/Air Heavy Medium Pulsed Fluidized Bed(AHMPFB)

• Radiation/Image Identification Separation

1.1. Air Separation Technology

Air separation used for coal process started earlier. At the beginning, it was air table technology,

then air jig was developed (FGX), till recent years, air heavy medium pulsed fluidized bed

technology has also been used for coal preparation.

FGX technology can treat particle size from 80mm to 0mm. The Ep is 0.20. Organic efficiency is

from 90% to 95%. The effective separationsize is 80mm to 3mm.

AHMPFB technology is to gain stable separation effect by adding heavy medium to fulfill

separation density from 1.3-2.2g/cm³. According to laboratory data, Ep value fluctuates from

0.05 to 0.07 and the separation size range is from 100mm to 6mm.

Figure1 : FGX Structure Figure 2 : AHMPFB Structure

Although air separation technology started earlier in China, but till nowit is not widely used. The

main reasons lie in the following important defects and limitation about its principle

Severe impact by seasonal moisture: required moisture content of raw coal is less than 5-

7%(Mt),otherwise which would block air hole of bed and worsening separation effect

Limited effective separation size: 80-3mm(Air heavy medium pulsed fluidized bed: 100-6mm)

Limited separation accuracy: organic efficiency is lower than 90-95%. Test accuracy of AHMPFB

is higher, but industrial application effect is lower than laboratory data.

Serious dust pollution: under the action of air, dust and coal dust pollution is severe.

Big energy consumption: air separation technology usually has raw coal drying procedure which

could make sure raw coal's moisture. Besides that, recovery system must be set for air heavy

medium pulsed fluidized bed, which is a complicated system and needs huge power

consumption.


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1.2. Radiation/Image Identification Dry Separation Technology

Radiation separation technology is a dry separation technology which firstly to make materials

in a line, then identify product and reject in a digital way after sensors and big data analysis, at

last, separate product and reject by actuators. Dry separation technology is applied for grain,

environmental protection industries at the earliest and gets very successful applications.Dadi

has been devoting itself to study the technology of utilizing radiation on coal separation since

2012 and has successful launched its product-TDS (Telligent Dry Separator) in 2015.

TDS includes four key parts which are material distribution system, material identification

system, execution system and control system.

Figure 3 : TDS Schematic Diagram

1.2.1. Material Identification System

Identification system is critical for separation accuracy of TDS.

TDS developed by Dadiuses X-Ray as a new identification system. X-ray has penetration ability

which is affected by material density. After X-ray penetrates materials, its strength will decay.

This variable is called K value, by which different materials can be distinguished and is also a

very effective way to identify coal and reject.

Figure 4 : X-ray image for coal Figure : 5X-ray image for reject


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According to our study, k value has a tight relevance with material density. Diagram shown as

below, the bottom curve is material real density and the upper curve is the corresponding k

value. So it says that materials are sorted and treated by various k values is equal to separate

materials by their own densities.

Figure 6 : Curve between material and K value

1.2.2. Distribution System

It effectively utilizes the width of belt conveyor as much as possible and prevents material from

stacking during material identification. distribution system is a key factor for a successful dry

separation. TDS adopts a special designed queueing system which can distribute material on the

belt in a high-efficient way and make sure one layer material to be conveyed.

1.2.3. Execution System

TDS's nozzles are designed as a matrix type. It can accurately and rapidly eject the material to

achieve separation through intelligent execution and control of nozzles. The reaction rate of the

executive system reaches up to millisecond level, which is one of the key factors of effective

guarantees for TDS's accuracy.

1.2.4. Technical Indexes

TDS adopts intelligent identification method which is to build corresponding analysis models

according to different coal quality characteristics and then takes digital identification for coal and

reject after big data analysis, and discharge reject or coal by intelligent reject discharge system

lastly. At present, the application range for lump coal is from 300mm to 50mm and 100mm to

25mm. Separation accuracy for industrial operation can realize the rate of coal in reject less than

1-3%, or rate of reject in coal less than 3-5%.


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The following table is the laboratory data of 300-500mm and 100-25mm coal samples from

Chinese Zhaozhuang coal mine.

Table 1 : 300-500mm Raw Coal Property Table

Test No. Sum(kg) Coal Reject

Output(kg) Yield (%) Output(kg) Yield (%)

1 482.35 137.15 28.43 345.20 71.57

2 569.50 160.75 28.23 408.75 71.77

Average 525.93 148.95 28.33 376.98 71.67

Table 2 : 300-50mm Separation List

Test No. Clean Coal Rate of Reject Rate of

Sum Coal Reject reject in Sum Coal Reject coal in(kg) (kg) (kg) coal (%) (kg) (kg) (kg) reject (%)

1 137.70 131.50 6.20 4.50 344.65 5.65 339.00 1.64

2 160.25 157.00 3.25 2.03 409.25 3.75 405.50 0.92

Average 148.98 144.25 4.73 3.17 376.95 4.70 372.25 1.25

Table 3 : 100-25mm Raw Coal Property Table

Test No. Sum(kg) Coal Reject

Output(kg) Yield (%) Output(kg) Yield (%)

1 292.90 204.95 69.97 87.95 30.03

2 396.10 287.10 72.48 109.00 27.52

3 360.45 262.30 72.77 98.15 27.23

Average 349.82 251.45 71.88 98.37 28.12

Table 4 : 100-25mm Separation List

Test No. Clean Coal Rate of Reject Rate of

Sum Coal Reject reject in Sum Coal Reject coal in

(kg) (kg) (kg) coal (%) (kg) (kg) (kg) reject (%)

1 206.45 204.00 2.45 1.19 86.45 0.95 85.50 1.10

2 296.00 285.50 10.50 3.55 100.10 1.60 98.50 1.60

3 266.15 261.50 4.65 1.75 94.30 0.80 93.50 0.85

Average 256.20 250.33 5.87 2.29 93.62 1.12 92.50 1.20


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It can be seen from test results that it can get very good separation effect and is also suitable for the

coal with high reject content difficult to be separated.

Presently, Dadi has completed 150t/h coal separation project for Zhaozhuang coal mine

• Project name : Shanxi Jincheng Anthracite Mining Group Co., LTD Zhaozhuang Coal

Mine

• Location : Changzi county, Shanxi, China

• Capacity : 10Mt/a

Main technical data of Zhaozhuang dry separation system are as below:

• Capacity : 150t/h

• Belt width : 1600mm

• Feed size : 300-100mm

• Separation accuracy : rate of coal in reject 2.26%?rate of reject in coal 3.5%

This project was completed and taken over in June 2016. According to system test results, all

of indexes are satisfied. China Coal Processing & Utilization Association convened a

national promotion conference on the project site in July 2016 where lot of coal preparation

experts and representatives from many coal mine companies took part in. All participants

highly praise TDS technology and acknowledge that TDS is a revolutionary technology.

Currently, Dadi are designing TDS proposals for lots of coal mines and most of projects

execution mode are EPC.


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1.2.5. Comparison between TDS and Traditional Air Dry Separation Technologies

Table 5 : Technical indexes Comparison List with Traditional Air Dry Separation Technologies

No. Dry Separation Processing Separation Out Moisture Installed Operation

Method Size Accuracy Requirement Power Mode

1 TDS 300-50mm rate of reject in

100-25mm coal < 3-5% Automation

rate of coal in --- <1.0kw/t.h operation

reject < 1-3%

2 FGX (air 80-3mm Reject discharge

fseparation) rate 80-90% < 5-7% < 2.5kw/t.h Manual

Rate of coal in operation

reject < 6-8%

Ep=0.20

3 AHMPFMB 100-6mm Ep=0.05 < 5-7% < 2.5kw/t.h Automation

operation

1.2.6. Comparison between TDS and Traditional Coal Process Technologies

Currently, TDS can be applied in 300-25mm lump coal separation which could also be processed

by traditional separation methods, such as jig and heavy medium bath. Compared with these

two wet separation methods, TDS also has lots of advantages of simple system, small land area,

short construction period, economical cost and environmental friendly and so on. Take a lump

coal separation system of a 3.0Mt/a thermal coal plant as an example.

Table 6 : Technical Indexes Comparisonwith Traditional Coal Separation Equipment

Parameter TDS Vibrating Screen Jigger Dense MediumVessel

The Main Equipment Sets 7 13 28

Installed Power 200.64 304.85 1009.16

Workshop Area(m²) 178.50 926 1300

Workshop Volume(m³) 2380.00 14525 20592

Compared with traditional dry separation equipment, TDS solves problems of low separation

accuracy, seasonal moisture variation affecting separation effect from the principle. Separation

accuracy is better than jig and reaches the separation level of heavy medium process for lump

coal, which can completely substitute for wet separation to be used as an effective separation

method for lump coal and achieve aims of water saving, environmental protection, lowering

construction investment and improving economic benefit improvement. It is studying TDS used

for -25mm raw coal now. Once it could be successful, this technology would bring a

revolutionary affection on thermal coal separation.


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2. Raw Coal Deep Screening

Tailing treatment system is a very important part of a coal preparation plant. However, because

of various slurry characteristics, slurry system affects capacities and separation indexes of many

plants, even directly impacts daily operation.After raw coal is washed, product's ash content will

be reduced and moisture will be increased.Smaller of the raw coal size, it will be biggersurface

area.So more moisture increasing is will be happened, the more negative affect is on product

calorific values. After washed, High moisture and low calorific value coal could not be sold as

product but to discard. So this causes a big issue of resourcewasting.

Dadi firstly develop, design and apply coal deep screening technology in China. This technology

is to use higher-screening-efficiency equipment (flip-flow screen)to remove fine by 6mm size

(even 3mm) before wash. Depends on coal quality of 6mm fine coal and product requirements,

fine coal could be totally or partially bypassed, only to wash part of +6mm raw coal. The

screening efficiency of 6mm flip-flow screen can reach 50-80% (varied by raw coal's moisture).

Because of deep screening process, less fine coal willfeed to washery plant and a relatively

simplified tailing system. And bypassed coal it's moisture doesn't increase, so calorific values is

much higher than that of fines being washed (In China, moisture of slime is decreased 1%,

calorific value will be improved 80-100kcal/kg.). It could be partially or totally mixed into

products while it doesn't affect calorific value and product property.

Flip flop screen is a solution for raw coal deep screening. Flip flop screen as key equipment of

deep screening technology takes advantage of tension and relaxation movement of elastic screen

panels. This creates up to 50G acceleration, which can take 6mm deep screening (even 3mm) and

gain 50% to 80% screening efficiency.

Figure 7 : Flip Flop Screen Schematic Diagram

Because of the movement type of screen panels of flip flop screen, it effectively solves the

problem of panel-blocking during small size screening to achieve high-efficient screening.


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According to much experience of application in many new projects in China, deep screening

technology effectively simplifies slurry system for thermal coal plants and facilitates plant

operation.

Explain the effect of flip flop screen applied in the Selianerhao coal mine

• Project name : Selianerhao coal mine CHPP

• Client : China Huainan Coal Mine Group

• Location : Erdos, Inner Mongolia China

• Capacity : 10.0 Mt/a

• Deep screening: 6offsets flip flop screen, 3.0m×9.3m, single layer

• Process : +13mm heavy medium bath+13-6mm cyclone, - 6 mm fine coal bypass

Based on the practical operation for more than two years in selianerhaoCHPP, all of operational

indexes are obviously superior to the nearby plants without deep screening process. Take slime

quantity and calorific value as examples to explain.

(1) The total quantity of slime tailing is 4-5%, which is far lower than the plants around with 10-

15% slime tailing without deep screening process.

(2) The screening efficiency of flip flop screen with 6mm screening is 75%.

(3) Product calorific value after 6mm fine removal process is same as that separated by total

washing process. But the product yield is 3.5% increased with deep screening.

3. New Thoughts for Thermal Coal Separation

Traditional thermal coal plants adopt processes: +13(25) mm H.M. bath, 13-1mm heavy medium

cyclone.

As the promotion and application of TDS

and deep screening technologies, a new

process technology for thermal coal is

TDS for +25mm lump coal, deep

screening for -13mm raw coal, heavy

medium cyclone for 13-6mm size coal,

totally or partially bypassing -6mm size

coal depending on coal quality and

product requirements, which must be

got a widely use.

This new process is suitable for all

thermal coal plants. According to coal

quality and produce requirements, it

could be configured by module.


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(1) TDS for +25mm lump coal+ bypass -25mm small coal

(2) TDS for +25mm lump coal+ deep screening for small coal+ heavy medium cyclone for 25-

6mm size coal+ bypass all -6mm size coal

(3) TDS for +25mm lump coal+ deep screening for small coal+ heavy medium cyclone for 25-

6mm size coal+ bypass part of -6mm size coal

When coal quality is good, it can consider combining No. 1 or No.2 or No.3 in order to simplify

system and reduce investment. TDS replaces hand picking and crushing procedures, which

decreases power consumption for crushing lump reject and lower labor strength. Deep screening

of flip flop screen fulfills -6mm fine coal to be not washed and further reduce slime quantity to be

immersed in water and washing cost and gain the maximum economic benefit of thermal coal

washing.

When all raw coal needs to be washed, it could combine wet and dry separation technologies

namely TDS for lump coal and heavy medium/jig for fine coal to push +25mm lump coal into

TDS for separation in order to reduce the quantity of lump coal and crushed slime to be immersed

in water, decrease water consumption and slurry system load. TDS's separation accuracy is

higher than jig. For the total jig process, TDS can effectively reduce the rate of coal in lump reject

and improve recovery rate of clean coal. Simultaneously, TDS also increase economic benefit by

its lower construction investment and processing fee per ton coal.

Based on the coal quality data of a certain coal plant in India, after calculation and comparison

between combined wet and dry separation process and total heavy medium or total jig process,

coal quality and main calculation indexes are as below:

Table 7 : Raw Coal Screening List

Size(mm) Wt% Ash% Moisture%

+200 3.2 40.5 1.0

200-150 12.4 38.6 1.1

150-100 12.1 37.2 1.2

100-50 14.4 37.0 1.1

50-25 17.5 39.2 1.2

25-13 15.3 36.5 1.0

13-6 9.1 37.2 0.9

6-3 7.1 35.1 1.1

3-0.5 5.4 29.4 1.1

-0.5 3.5 26.1 1.2

Total 100.0 36.7 1.1


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Table 8 : Comparison between Combination of Wet and Dry Separation Process and Heavy

Medium or Jig

No. Separation +25mm Rate of Coal in Annual Water Total water Slime

Process Lump lump reject % loss of consump- consump- immersed

Coal lump tion of tion of lump in water3

coal lump coal coal (m /a) quantity of3

(t/a) (m /t) lump coal

system (t/a)

1 Combination 2%(1-3%) 29800 0 0 0

of wet and dry

process

2 Jig 2.98Mt/a 5%(4-6%) 74500 0.05 100000 30000

3 Heavy medium 0.75%(0.5-1%) 11175 0.05 100000 30000

Continued Table 8 : Comparison between Combination of Wet and Dry Separation Process and

Heavy Medium or Jig

No. Separation +25mm Medium Total Electricity Processing Investment

process Lump coal consump- medium consump- fee of lump per ton

tion of consumption of coal (%) lump coal

lump coal tion of lump coal (%)

(kg/t) lump coal (kw.h/t)

(t/a)

1 Combination of 2.98Mt/a 0 0 1 40-50 50-60

wet and dry

process

2 Jig 0 0 2.5 70-80 60-70

3 Heavy medium 0.5 1490 3 100 100

Note : It is calculated as 5.0Mt/a capacity and 1.5% slurry quantity of lump coal system.

Compare with total heavy medium or total jig process, combination of wet and dry separation

process has great advantages on construction investment per ton coal, processing fee, water

consumption, electricity consumption, slurry quantity immersed in water. And it reduces lump

coal system investment and processing fee about 50% and decreases project total investment and

processing fee about 20% to 30%. Meanwhile -25mm small coal enters into heavy medium

cyclone or jig for separation. Because of its low feed size, it facilitates to improve separation

accuracy of heavy medium or jig.


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4. Coarse Slime Separation for Thermal Coal Plant

For thermal coal plants with high ash

content raw coal, it usually adopts total

washing process. The application of

TDS could reduce secondary slime

generation at a certain extent, but small

coal washing process would still lead to

small coal and original slime to be

washed. Because of the lower limit of

separation of small coal separation

equipment, coarse slime separation

procedure is often set for thermal coal

plants.

Presently, spiral separator and teeter

bed separator are main effective

separation equipment for coarse slime.

For thermal coal plants, spiral

separator is widely used, which has simple structure, low operation cost, but low Ep value which

is only 0.15-0.21,moreover has low recovery rate. Though teeter bed separator's Ep valueis 0.12-

0.15, it's intermittent discharging during separation process, which would cause unstable

washing process, and bring on problems of hardening bed and non-fluent discharging when

treating high density separation.

In order to improve separation accuracy of coarse slime, Dadi has an original study on TCS.

Based on teeter bed separator, it fulfills continuous and stable discharging in the underflow by

changing discharging method. Several teeter units and flowmeters are set to get on-line control

and adjustment during process. The Ep value of TCS is not more than 0.1. Separation range for

size is from 1.5mm to 0.2mm, which can replace spiral separator and teeter bed to realize high

efficient separation for coarse slime. When all raw coal needs to be washed, it can make thermal

coal wash in high efficient way by combining TDS and small coal wet washing process. However,

it needs further tests on the equipment applicability for coal quality in India.

5. Conclusions

(1) TDS will be bound to getvigorous development in light of its advantages in economy and

environmental protection.

(2) TDS overcomes the defects of low separation accuracy, seasonal moisture impacting

separation which traditional dry processes have and can completely substitute for wet

separation process for lump coal now.

(3) The combination of wet and dry separation process is the leading development direction

for thermal coal process in the future. Combined with deep screening of flip flop screen, the


84

process of TDS for +25mm lump coal, heavy medium or jig for 25mm to 6mm size, and no

washing for -6mm fine coal opens a new thought on thermal coal process.

(4) When all raw coal needs to be separated, TCS, TDS and together with small coal wet

washing process can fulfill high efficient separation.

References

1. Li G M, Yang Y S Application if Compound Dry Cleaning Technique in China 1005-8397 (2006)

05-0033004.

2. Chen Q R., Yang Y F. Development of High Effective Dry Coal Beneficiation Technology in 21

Century

3. Dong L., Zhao Y M. Study on Fluidization Characteristics of Air Heavy Medium Pulsed

Fluidized Bed 0253-2336 (2011) 12-0127-03

Author's brief Introduction

Dongping Wang graduated from the China University of Mining and Technology (CMUT) in 1981

with a bachelor degree in coal processing technology. For many years Mr. Wang was process plant

manager, and later director of operations, at Pingshuo Antaibao coal mine; a World Bank funded USA -

China joint venture project. Mr. Wang then became general manager of Long-Airdox (Tianjin) where

from 1997 he was instrumental in introducing modern coal process technology from Australia to

China. Mr. Wang became general manager of Schenck (Tianjin) and worked there from 2001 until 2007.

Dongping Wang then helped in establishing the Dadi Engineering Development Group, now China's

largest engineering group in the coal industry. Mr. Wang is now chairman of Dadi Engineering

Development Group. Mr. Wang has worked at the highest level within the Chinese coal industry for

over 30 years and is a highly renowned coal processing expert, and a prominent figure in the Chinese

coal industry. Mr. Wang brings extensive management experience and an intimate knowledge of

modern coal process technology to Metro Mining Limited.


Every nation tries to adapt to its resource base. Those nations which are not blessed by nature, have

evolved skills and technologies which they export and enable their country to support its population

based on the income generated from such exports. Japan is a prime example of such adaptation to a

poor natural resource base.

India is fortunately blessed with natural resources in different forms, especially metallurgical

minerals. That unfortunately has not challenged the creative capacities of its engineers, scientists and

managers involved in mineral processing to the extent that they are capable of.If one examines the

dominant technologies in this sector, most of it is imported or modifications of imported technologies.

The same is applicable for coal.

However, in coal, the situation gets complicated because it is a mixed story - huge resource base but

relatively poor quality. To improve the quality of the coal, the coal industry has initiallyimplemented

conventional wet technologies primarily of British origin and most coal process engineers have a fair

degree of experience with these technology. Even our mining institutes teach these technologies fairly

competently but are relatively at sea when it comes to emerging technologies, especially those

emerging from India.

There is a catchwhen it comes to applying wet beneficiation methods for coal. Huge amounts of water

are required. While the water requirement varies from version to version, an average unbiased

estimate is that on an average about 160 litres of water is required to treat one tonne of coal before it is

dispatched from the washery. Translating into an overall requirement of water, Indian needs to wash

nearly 500 million tonnes of coal by 2020. Total water requirement is estimated at 80 billion litres of

water per year.

An added complication is the absence of high quality magnetite. Without good quality magnetite,

there is sacrifice of yield and usable carbon is wasted as rejects. Imported magnetite is hugely

expensive and several washeries are making do with whatever they can lay their hands on rather than

depend on imports. While jigs have done a remarkable job in the past, with a large percentage of near-

gravity material in most mines, the misplacement factor is high.

One top of this, the quantum of water required for washing is not available everywhere and even if it is,

every conscious Indian needs to ask, should the coal industry monopolise so much water when

millions of fellow citizens do not even get water to drink. Is there no alternative?Or is it that the inertia

to adapt and optimize the use of resources, especially water, is too high. This lethargy of thought and

action needs to be overcome. And tools are available today that have been developed in India, by

Indian companies, with support of Indian government institutions and developed keeping in mind

Indian resource conditions.

85

Evolution of Appropriate Technology - ArdeeSort

— Dr. G.V. Ramana*


* Managing Director, Ardee Hi-Tech Pvt. Ltd.

86

Ardee developed "ArdeeSort" dry beneficiation technology with support from Department of

Scientific & Industrial Research (DSIR). This technology is implemented in GMDCLTd., Bhavnagar

and commercial operations have begun. The objective of this plant is to reduce pyritic content in the

lignite and thus in the process remove sulphur to the maximum extend possible. The overall

technological schematic for pyrite separation from lignite is:

1. Two strong and ultra-light Rotary Breakers designed and built by Ardee with highest aperture to

surface area ratio and least power requirement for capacity being handled.

2. A set of six ArdeeSort modules to handle sizes from 100 - 50, 50 - 25 and 25 - 10 mm.

ArdeeSorthas a compact modular design which enables seamless expansion of capacity as and when

the need arises with minimal modifications to existing structures. ArdeeSort uses dual X-ray energy

attenuation to give mass-compensated organic to inorganic ratio. For ejection, a series of small

pneumatic ejectors operate in synchrony in ArdeeSort. The ArdeeSort system generates a dual energy

attenuated signal image from an array of sensors from which the processor calculates the ratio of

organic to inorganic (combustible to incombustible ratio). Once a particle is identified as a

contaminant, based on the threshold values set by the operator, a corresponding array of ejectors are

activated for the precise time and divert the contaminant particle to the reject path. The activation

andde-activation take place within a millisecond whichprevents "mis-firing" or the wrong particle

being ejected. Further, the contaminant particle is so close to the nozzle that it requires minimal energy

to divert the particle.

During commissioning of the GMDC Lignite beneficiation plant, there were a few surprises. In the

initial testing at design stage as well as GMDC's own analysis there was no indication of clay being

present in the lignite. The presence was first detected in the high efficiency Rotary Breaker designed,

manufactured and installed by Ardee. Samples collected from overflow of Rotary Breaker indicated

presence of clay which had escaped detection earlier due to adhesion of lignite on surface of the clay.


GRIZZLY FEEDER- 100 MM

ROTARY BREAKER-100 mm

ArdeeSortMODULE

SCREEN– 50 mm

SCREENING- 10 mm

ArdeeSortMODULE

REJECTSDISPOSALSTORAGE

CLEAN LIGNITEBUNKER

RAW LIGNITE 400 tph

- 10 mm

- 100 + 50 mm

+ 100 mm

- 50 + 10 mm

CLEAN LIGNITEBUNKER

100 tph

4 tph

96 tph300 tph

248 tph

148 tph

142 tph

6 tph

48 tph

200 tph

8 tph192 tph

QUANTITATIVE PROCESS FLOW DIAGRAM GMDC BHAVNAGAR

87

In the ArdeeSort modules, lignite in different size segments, viz., 50 - 100 mm, 25 - 50 mm and 10 - 25

mm are fed to different modules, with two modules for each size. It was observed that while pyrites

were being removed, some clay was present in the clean lignite. The parameters in ArdeeSortmodules

were then adjusted to ensure that clay was also removed along with pyrites. There are a few areas

where further fine tuning is continuing and we expect the situation to stabilize with three months of

continuous run.

The entire beneficiation process uses no water. Even the dust suppression system in the plant is

designed for bare minimum water usage through high pressure misting systems at vulnerable points

such as receiving hopper, transfer points, ArdeeSort area, etc. Extensive use has been made of canvas

and rubber sheeting to keep the mist wrapped in a smaller envelope.

ArdeeSortis a boon for low grade lignitein Gujarat, Rajasthan, Tamil Nadu which cannot be washed in

the conventional wet method. By extension, it can be used for inferior Indonesian coals and high

moisture North-East coals which also cannot be washed using conventional wet washing technologies.

Coming to sub-bituminous coals, the predominant fuel in the Indian energy chain, the solution here is

even more interesting due to the large role that these coals play in the Indian economy. High ash levels

in coals necessitate the use of a beneficiation technology which fortunately has been made mandatory

by the Ministry of Environment & Forests and the Ministry of Coal. The question that needs to be asked

is then how to process such coals?How to treat them? What to do with the rejects since there is bound to

be a mountain of rejects? With ash levels being high in rejects, this will render them unfit for use even in

fluidized boilers. Washery operators have the unenviable job of finding ways to dispose the rejects.

Easiest method is to sweeten rejects with raw coal and sell the entire lot to a CFBC boiler-based power

plant. However, this practice has severe limitations and the decline of the coal market has led to stock

pile up of rejects everywhere. Besides, it is an unfriendly practice as far as the environment is

concerned since ash will in any case be generated once these rejects are combusted.

It is imagination that is limits the forms in which technology can used and adapted. Ardee has

implemented a deshaling project for coking coal at Madhuband, BCCL. In this project, raw coking coal

is deshaled in the 50 - 13 mm size fraction and the deshaled coal is fed to the washery which will help

reduce washing cost, enhance washery capacity, improve yield and reduce cross migration by

minimizing the "crowding out" effect.

What are the implications for washeryoperators ? We first look at the coking coal circuit. By bringing

down the input feed ash from 40 - 43% to 32%, at a loss in yield of between 27 to 38%, the original feed

parameters for thewashery are restored. This helps reduce cost of washing and improves yield.

Second, it enables the washery feed to be increased which improves the capacity utilization of existing

washery equipment.

In case of high ash thermal grade coals, dry beneficiation can handle + 6 mm coals. It is possible to

reduce ash by 8 - 18% overall and bring ash% level into the manageable sphere in the coarser size

segments. However, there remains the problem of fines which also have high ash. In such cases, wet

fine coal circuits can be combined with dry circuits. Such hybrid washeries can take care of maintaining

the target ash in clean coals, minimize water consumption, lower the additional moisture in clean coals


88

since a large fraction of the coal will be dry beneficiated. There may be any number of variations /

alternatives depending on type of coal, objective of beneficiating and of course, revenue model in

operation between washery operator and end customer and so forth.

Yes another approach will be to generate three products. The raw coal is first dry beneficiated to

generate clean coal having < 34% ash. The rejects then are re-sorted to generate two products - those

having more than 70 - 75% ash which are true rejects and need to be disposed off as back fill in the mines

since they do not have no useful heat value in any form of boiler. The balance is an intermediate

saleable product (ISP) which has heat value and applications in a number of technologies such as reject

based power plants. The normal ash% range in such ISP coals is 50 - 56%. We give below a typical

hybrid circuit.

What the above schematic does is to extract the maximum clean coal through the dry beneficiated

circuit which eliminates the need to wash such coals. The residue is resized and put through an

efficient wet washing circuit since in most cases, dry beneficiation cannot be applied on sizes below 6

mm. A further adaptation of the above circuit will be to have secondary sorting as explained above,

eliminate all particles having high ash, say more than 70 - 75% and then re-size(to liberate ash) and re-

process the intermediate products from this process. Alternatively, the same coals can be sold as an

intermediate product. The market for coal will have to be considered before opting for any such

method.

Dry beneficiation has come as a panacea for the coal industry which is battling several devils - quality,

costs, shortage of vital inputs like magnetiter, hostility towards this "dirty fuel" and the challenge of

finding process water. The way forward will be to use imagination and overcome inertia to implement

these technologies in the field.

The author thanks Department of Scientific & Industrial Research, Coal India Ltd. and GMDC Ltd. for

extending support to this technology.


HYBRID PROCESS FLOW DIAGRAMDUAL DRY BENEFICIATION CIRCUIT

SCREENING- 100 MM

SURGE HOPPER

CRUSHER– 100 MM

SCREENING+ 6 – 100 mm

ArdeeSortMODULE

6 – 100 MM

REJECTS /MIDDLINGS

TO WASHERY

RAW COAL

- 6 mm

PROJECT: HYBRID COAL WASHERY DRY BENEFICIATION CIRCUIT

CUSTOMER:SCALE : N.T.S.

CRUSHER- 13 MM

CLEAN COAL HOPPER

REJECTS

ArdeeSortMODULE

6 – 100 MM

SCREENING- 6 mm

CRUSHER– 100 M

Executive Overview - Business Transformation Together

Continuous capital investments and optimal utilization of assets drives the daily business in coal

mining operations. As commodity prices continue to hit historically low levels, Indian coal mining

industry will have to lose the rigid business models and practices of old and become flexible and agile

enterprises. The most fundamental change will be transforming supply chain using IT as a catalyst,

where the goal won't be to the push product out of the ground to dump on the market, but to respond

nimbly to sophisticated customer relationships and market dynamics

Coal Mining - Business Pain Areas

Mining companies wishing to develop and implement smart sustainability practices are often faced by

issues such as:

• Lack of Operational efficiency and effectiveness

• Effective governance

• No Technology to observe illegal mining

• Lack of a coherent energy and supply chain strategy

• Demand of coal to continue to outpace production

• Lack of actionable data and inability first to measure energy use and greenhouse gas emissions

and then to determine how to reduce them

• Infrastructure constraint for coal transport from pithead to consumption center

• Getting a bigger footprint - via alliances or consolidation with companies that are strategic fits

• Lack of understanding of the steps that must be taken to enter new markets where issues related

to energy, environment and sustainability may be paramount

• Immature supply chains that don't allow global consistency and adherence to environmental

policies

• Procedural delay in environment clearances

• Domestic production not sufficient to meet the growing demand

• Long delay in grant of forestry clearances

• Handling corruption bottleneck for technology adoption

89

Coal Mining - Beyond the Obvious

IT & Supply Chain Perspective

— Deep Krishna*


*Entrepreneur & MD - DKG Labs

90

Thoughts to Trigger - The Changing Game

•

operations, their customers and supply chain?

• Do we have visibility of our supply chain and customer?

• Did we leverage Information technology to its real potential for our industry?

• Did we leverage Information technology to its real potential for our industry?

• Are we ready for the impending increase in information volume, variety and velocity?

• Do we have any technology mechanism for mines to track the illegal mining from pit to port?

• What role will coal mining fraternity take in leading the world in environmentalism and

corporate social responsibility?

• Are we managing our customer relationships effectively?

• Is there a need for effective and economical use of technology to curb pilferage by tracking of

transportation routes and have a direct impact on corruption?

• Are you facing tighter margins with information systems that lack the ability to access your

business information?

Characteristics

How will coal mining companies use business innovation to transform the fundamentals of their


We are

here

Target

Perception of

employees,

professionals and

media as environment

unfriendly

Statutory requirement

is managed with little

automation or

integration

To change perception

attracting

environmentally aware

advocates to work and

support clean mining

operations

To track via formal

automated analytical

tools

We are

Here

Target

No integrated views of

mine performance for

monitoring, or

decision-capability

Poorly supported

programs exist to

promote qualityand

efficiency

Real time Reporting

and analysis of

operations Spendtime

“looking forward”

instead of reporting on

the past

Quality and programs,

such as lean, Six

Sigma, areutilized to

manage productivity

and to define optimal

processes.

Workers’ safety is

solely a function of

training,

procedures,policy and

chance.

To deploy GPS, RFIDs

and IoT based to

improve the safety of

employees’ day to day

and during fatalities

Learning is from

mining experience and

the past

Mining companies also

learn from other

industries,

partners,acquisitions

and other sources.

91

From Talk to Action - Key Drivers for Growth

What Goes Down Must Come Up

The drivers and approaches to sustainability are changing…

• Smart Supply Chain in leaner times

• Control cost for High performance.

• Sustainable growth.

• Innovative business model, operations and products.

Meeting the execution challenge -

Strategic

• Continues investment in Innovation from automation to data analytics and Mobile technologies

• Significant enhancement of domestic coal production through policy support is needed to meet

the spiraling demand.

• Enhance global footprints often by JV, M&A.

• Integration of supply chain and establish common process across the enterprise

• New models of innovation that use an open approach to harness ideas and expertise from around

the world, often at low cost and using collaborative technologies.

• Using IT processes and tools as enablers to encourage collaboration within the government and

coal mining companies

• Implement integrated energy programs in a way that balances risk and reward.

Operational

Digital technology is disrupting the mining industry and bringing new opportunities to reduce costs

and improve production and safety. Ensuring data integrity is an important element in taking

advantage of this revolution. Automation systems are capable in collecting rapidly growing volumes

of data.

• Production efficiency using Dispatch System to manage your moving assets and incidents

• Operating Model Review

• Working Capital Efficiency

• Improved Capital Allocation

• Data Integration

• Supply chain optimization

• Adoption of ERP Systems for Backend


92

•

cost for high performance

• Analysing existing consumption patterns and environmental impact

Proposed Measures/ApproachesAdaptation of IT based management system

Age of Industrial IoT

• Increase on-line monitoring using GPS, RFID and Mobile Apps

• Machine Learning

• Wearable - Safety of Miners - Signal Physical distress, exact location, Driver fatigue, Saving on

electrical costs

• Data integrity to enable effective decisions in mining operations.

• Implementing wireless communication systems

• Environment monitoring

• Disaster forecasting and mine safety management

• Asset Management

• Decision support system with mining database

• Network architecture for connecting mining sites with area and head offices and providing

communication strategies.

Software Snapshots - Indicative

Software products to deploy supply chain optimization, ensure workplace safety and control


93


94


95


Conclusion

It is time for action to get to the root cause of the current issues and parade of challenges Indian coal

mining industry is going among global scenarios and low commodity prices. In terms of

implementation of these approaches we need to adapt to the best practices approach based on quick

win, mid-term and long shot strategies. IT and supply chain are the backbone and ground realties for

mining industry like any other industry and it requires immediate action and terrific effort from the

leaders of the industry who act as a change agent to bring this transformation

About Author

Deep Krishna, Managing Director of DKG Labs is a mining engineer from IIT-BHU by Education,

Serial Entrepreneur by Profession and Software Professional by Passion. He has worked with GE

Capital, KPMG Consulting, TCS and Mahindra in various capacities and customer facing roles scaling

service industries for 15 years. Operating and leadership experience across PAN India, US, Europe,

Middle East and APAC regions. Pioneered the design of portfolio of mining software's for Indian

mining Industry balancing trade-offs to optimize supply chain efficiencies. He and his firm is recipient

of several awards including NASSCOM Emerge 50 product companies, BSE-SME National Award of

Excellence, Hot 100 winner by CORE to name a few, for innovative software for mining industry. He

has published papers in Indian/international mining journals, PMP certified and in board of various

startups in healthcare and home services space. He can be reached at [email protected] or 91-

9810124321.

1. Introduction

In India coal is the critical input for major infrastructure industries like Power, Steel and Cement etc.

around 72% of the entire power generated in the country is coal based. The pivotal role of coal is

expected to continue in the foreseeable future, primarily because of abundance of power grade coal

reserves, easy availability and affordability. Annual coal production from CIL mines has grown from

79 MT in 1974-75 to 538.75 MT in 2015-16 majority of which coming from opencast mines. Coal

production from opencast mining method from the mines of CIL has increased from 16.4 MT at the

time of nationalization to 505 MT (approx.) during 2015-16.

Opencast Mining in India has gone through lot of changes in the past. The scale of operation has

increased considerably with some mines producing over 40 MT per year by using large capacity Heavy

Earth Moving Machinery (HEMM). Being cost effective, it is expected that coal production by

opencast system of mining will continue to grow in coming years by adopting modern and efficient

technological practices.

2. CIL/NCL's experience

NCL is one of the subsidiaries of CIL where entire coal production is achieved through highly

mechanized medium-to high capacity opencast mines. It supplies more than 90 per cent of its

produced coal to the nearby pithead thermal power plants and 12% (approx) of the installed power

generation capacity of the thermal power plants of the nation are met by NCL.

NCL has been able to enhance coal production from nearly 12 MT during formative years of 1985-86 to

more than 80 MT during 2015-16. The growth in production may be attributed mainly to bringing into

use operation of following high capacity HEMMs :

• Draglines : Upto 33/72 size

• Rope Shovels : Upto20 Cum Capacity

• Hydraulic Excavators : Upto 12.0 Cum Capacity

• Rear Dump Trucks : Upto170Te

• Blast Hole Drills :Upto 311 mm dia.

• Bull Dozers : Upto 860 HP etc.

CIL has been entrusted with achieving ambitious target of producing 1 Billion Te (BT) by 2019-20, share

of NCL being 110 MT. The ability to achieve 1 BT Coal production by the end of 2019-20 depends a lot

on how Technological and Infrastructure related issues to large scale mining are addressed.

96

Modernisation of Opencast Mining Technology forhigher production and higher productivity –

Human as well as Capital— T.K. Nag*


*Chairman-cum-Managing Director , Northern Coalfields Ltd. Singrauli

97

3. Modernization of Opencast Mines

In 2015-16 CIL's overall OMS of opencast mines was 14.35Te against the global average of > 15 Te

(according to World Coal Association). To improve the situation CIL has planned to focus on

increasing efficiency by making better utilization of available resources and adopting modern mining

techniques.

3.1 Up-gradation of size of equipment

CIL under its technology up-gradation plan has planned to upgrade the size of rear dumpers as

depicted in the following table :

Existing Size of Upgraded Size of Remarks

Dumper Dumper

170T 190/200 T Under implementation

120T 240T Deployed in Gevra & Dipka mines of SECL

--- 320T To be considered in future planning

Under the up-gradation programme, 20 cum Electric Rope Shovels have been procured by NCL and

deployed in Jayant & Dudhichua mines as replacement against surveyed-off of 10 cum Electric Rope

Shovels. Higher size of equipment have been deployed in Gevra & Dipka opencast mines of SECL.

Since 2009-10 onward following higher size equipment have deployed in SECL& NCL mines :

Year Equipment Mine

2009-10 42 cum Electric Rope Shovel Gevra & Dipka

2009-10 240T Rear Dumper Gevra & Dipka

2009-10 860 hp Dozer Gevra & Dipka

2009-10 381 mm Drill Gevra & Dipka

2009-10 70 kl Water Sprinkler Gevra & Dipka

2010-11 15 cum Hydraulic Excavator Gevra

2011-12 533 hp Motor Grader Gevra

2014-15 33/72 Dragline Krishnashila

In equipment configuration, future Scope exists to have

• Hydraulic Shovels of higher sizes (upto 34 Cum Cap)

• FEL of higher sizes (upto 42 Cum)

• Dozers with Rippers

• High speed inclined drilling


98

3.2 Planning technology up-gradation in CIL/NCL mines :

• More emphasis is being given in mines to have matching combination of Shovels-Dumpers viz.

10/12 Cum Shovel with 100 Te Dumper and 20 Cum Shovel with 200 Te Dumpers, 42 Cum

Shovel with 240 Te Dumpers etc.

• The obsolete Electric control systems in Draglines and Shovels are planned to be replaced with

updated systems, to have better machine availability and utilization.

• To improve the reliability of HEMM maintenance, utmost care is being taken to ensure that

spares are procured from OEMs/OPMs, as far as possible.

• The Dumpers are provided with Auto-dipping systems to improve safety in night hours

• In SECL, large capacity opencast mines are being planned with higher size of equipment to the

extent feasible depending on the geo-mining conditions and volume of coal & OB removal.

• In Kusmunda opencast mine of SECL, 53 cum Electric Rope Shovels & 400T Rear Dumpers have

been proposed in the project report for coal production of 50 Mty & removal of 66 Mcum of OB

per year. 34 cum Hydraulic Shovels with 240T Rear Dumpers have been proposed in

Samleshwari opencast of MCL.

3.3. Introduction of Surface Miners in opencast mines

Conventional opencast mining operations are invariably associated with drilling, blasting, loading,

crushing and transportation activities. Surface miner is an eco-friendly technology and is capable to

mitigate environmental pollution and other issues caused due to conventional activities like drilling,

blasting, crushing etc.

A wide scale application of surface miners at several projects of the NCL, MCL, SECL and CCL has

been found encouraging both from the point of view of selective mining as well as enhanced output. In

NCL, where 100% coal is being extracted departmentally, 4 number of Surface Miners having 4000 mm

drum width, have been introduced in 3 of its Mega projects. It has helped in increasing crushed coal

supply to consumers with associated benefits on quality and hence revenue front.

3.4. Mobile In-pit Crushing and Conveying System

Mobile crushing and conveying system is successfully operating in Piparwar opencast mine of CCL.

New opencast mines are being planned with semi mobile crushing and conveying system by

introduction by twin sizers. This technonology is under implementation at Jayant project of NCL.

3.5. Operator Independent Truck Dispatch System (OITDS)

OITDS offers a viable solution to improve communication, monitoring, dynamic allocation of trucks to

shovels avoiding idle times of shovels and dumpers both and helps to achieve maximum utilization of

shovel-dumper combination system working in the mine.

Operator Independent Truck Dispatch System (OITDS) has been working in a number of CIL mines

successfully, viz.


99

NCL - Jayant, Dudhichua, Nigahi, Amlhori, Khadia

MCL - Bharatpur, Lingraj, Kalinga

ECL - Sonepur Bazari, Rajmahal

SECL - Gevra, Dipka, Kusmunda

3.6 IT enabled monitoring

Application of IT is in vogue for monitoring coal transportation, controlling pilferage and improving

general safety of the mine. Some of these are

• GPS based Vehicle Tracking System

• RFID weighbridge Integrated system

• CCTV at Vulnerable location, with round the clock monitoring from Control Room etc.

Their importance will grow with enhanced output and scale of operations.

4.0 Modernization in opencast Mining Techniques

4.1 Equipment Selection

Mine planner will need to have such a combination of digging and hauling equipment that mismatch is

avoided. Capital Intensive HEMMs must be carefully selected to have enhanced machine productivity

with better capacity utilization, that will ultimately affect profitability.

CMPDI should re-visit its stance while equipment planning is done for Projects and objective should

be to incorporate high performance equipment in the system. It has two pronged benefits - Saving in

manpower and reduction in traffic congestion on Haul road.

4.2 Maintenance Management

Proper maintenance of HEMMs is key to their availability and hence utilization. In case of equipment

procured from abroad, the biggest challenge is lead time in procurement of spares. Present system of

human dependent, semi or least automated maintenance system is to be done away with to reduce

downtime and to increase availability. Use of ICT (Information and Communication Technology),

making the OITDS as a base, improvement of assets through design improvement measures to keep

away the obsolescence danger, remotely monitored online feedbacks are some of the key features of

maintenance which CIL is required to follow.

4.2.1 EAM, ERP & CMMS

EAM (Enterprise Asset Management) processes software will maximize HEMM's productivity while

minimizing its costs from acquisition to disposal. EAM software simplifies maintenance planning.

When used in conjunction with ERP software, it can generate resources required to carry out such

maintenance jobs and their availability. All these result in enhancement of productivity, and create

detailed maintenance records.


100

With change in equipment configuration, management procedures and key inputs, it has become

essential to have a system which is easily scalable and for this reason ERP (Enterprise Resource

Planning) software is essential for open pit mines to function effectively. ERP reduces the complexity

of an open pit mine management and allows to work with a neatly designed system of workflows.

High scalability, improved data access, improved supply chain management are some of the features

which will accrue substantial benefit through implementation of systems with ERP software.

4.2.2 Benefits of CMMS by using EAM & ERP Software

Switching to a CMMS (Computerized Maintenance Management System) reaps the following benefits:

• Reduce waiting time for maintenance - practically it will be zero

• Reduce maintenance time & costs

• Reduce production costs

• Reduce labor costs as the system is human independent

• Increase maintenance productivity

• Help improve HEMM maintenance practices

• Help in compliance of applicable regulations

• Minimize equipment breakdowns

• Minimize downtime

• Increases life of existing HEMM

4.2.3 Design Improvement Maintenance

Draglines and some other high capacity HEMMs deployed at CIL are mostly of imported origin. Over a

period of time, technologies used initially at the time of manufacturing became obsolete creating

problem in product support. This makes these high capacity equipment vulnerable to prolonged

breakdown. To avoid any such consequences, Design Improvement Maintenance (DIM) and Retro-

fitment, mostly in the electrical, electronics and micro-processor based areas are to be taken up. DIM

imparts a new lease of life to an old machine and prolongs the life of high capacity equipment without

any change in main structural areas. Replacement of DOM-II, DC-2000 Electrical systems with latest

DC-EXX System in 10cum and above electric rope shovels and Draglines with GE make electrical is one

such example.

4.3 Electrical Power Supply re-organization

A detailed planning is required to be done in advance to finalise scheme of distribution of electric

power in a mine. In opencast mines, power transmission is usually through open conductors installed

on transmission lines and use of cables is kept to minimum. If a load centre is far away from mine

substation, a smaller sub-station may be established near the load centre in the form of a unitized

substation for opencast mines. It is beneficial from the point of view of minimizing the chances of


101

excessive drop in voltage and power losses. In Mega/High Capacity projects there is a need to have

separate Power supply line for high capacity machines e.g. Dragline in order to have continuous and

trouble-free operation of the machine. In the main mine-substation, a capacitor bank of suitable

capacity should be provided to ensure that at least 0.95 Power Factor is achieved.

4.4 Blasting technique improvisation

Conventional blasting practices & techniques in mining industry are unable to improve efficiency and

mitigate environmental hazards. Hence, innovations are taking place in the areas of planning & design

of blasts, drill hole deviation, use of new bulk loading explosives & initiation system, skill

development etc.

Improvised blasting techniques achievable through angular drilling, better explosive quality etc. shall

result in better rock breakage and improved fragmentation, which in turn will improve Swell Factor

and Fill Factor. Not only that improved fragmentation will cause lesser wear & tear of GET (Ground

Engaging Tools), reduce stress on machine parts and thereby will increase MTBF (Mean Time Between

Failure).

Computer aided Blast Design to suit specific site is available e,g, programmes like SHOTPlus 5, SOFT-

BLAST, I-BLAST-7 etc. for blast design are available which are able to predict the blast results well in

advance.

Drill Machine Navigation System, enables use of drilling machine with a GPS guidance System to

accurately locate planned position of holes and depth to be drilled. This system provides considerable

benefits including improved accuracy and consistency of the blast.

4.4.1 Blasting Accessories

Innovations in initiating devices are - use of shock tubes and electronic delay detonators

Shock Tube System

The shock tube system is based on a plastic tube, the inside of which is coated with a reactive substance

that maintains propagation of shock wave at a rate approx. 2000 m/s. This shock wave has sufficient

energy to initiate the primary explosive or delay element in a Detonator. This system provides better

fragmentation and burden movement due to in the hole delay, no damage to explosive column or

stemming due to bottom initiation, not susceptible to stray electric current due to non-electric mode of

operation, less ground vibration, less noise, less fly rocks etc.

Electronic Detonators

The electronic detonator (E-DET) has basically integrated circuits that produce timing in micro

seconds rather than in milliseconds, as it is the case with pyrotechnic delays.

Advantages include excellent breakage, reduced fly rock and ground vibration, flexibility of

programming to fire at any time from 0 ms to 10000 ms in steps of 1 ms etc.

E-Dets are being used in some of the Mega Projects of NCL. It has yielded benefits in terms of reduced

noise and ground vibrations on account of blasting operations.


102

Increasing number of mining operations are coming under pressure to monitor and reduce blasting

related environmental hazards. Ground Vibrations, air over-pressure, fly-rock, dust, blasting fumes

and in some cases leaching of chemicals in the blast holes and polluting ground water are major

environmental hazards. Hence, care has to be exercised and innovated technology has to be put into

use for blasting aimed at reducing environmental impacts.

4.5 Mine Water Management

In multi-seam mine operations, water management holds the key for continuity of mining activities

during rainy season. Assessment of required pumping capacity based on calculations of catchment

area, rainfall and sump capacity will need to be done accurately. The activities for checking possible

impacts of rainfall should be planned in advance and executed before the rainy season begins. Any

erroneous data will lead to miscalculation of pumping capacity and requirement of pumps/pipes etc,

that can halt mining activities for months together, in case of heavy rainfall in a season.

4.6 Mine Illumination

Mine working faces, Haul roads are continuously on move. Thee represent critical areas in opencast

mines where lighting installations are not permanent due to regular advancement of the working face.

Lighting in mines presents special problems because of the dark surroundings and low surface

reflectance. Hence, scientific design of artificial lighting is very important to achieve the required

lighting standards. In general, lamp selection is made mainly based on efficacy and suitability to each

situation. Mobile High Mast Towers, use of LED lamps will help improving illumination standards in

mines.

4.7 Haul Road Maintenance

Haul road is an integral part of opencast mining operation to facilitate movement of giant sized

HEMMs both inside the mine as well as outside (to Dump/stock yard) for Coal & OB transportation. In

opencast mining operations, ultra-heavy trucks operate on haul road networks which may be 5-10 km

in length. Condition of Haul roads is a critical factor affecting the heath of HEMMs plying over it. These

road networks, are therefore required to be optimally designed and maintained. Technique is,

therefore, required to manage haul road maintenance as and where needed with resultant reduction

in total road user costs - by having better tyre life of dumpers, operators comfort etc.

4.8 Human Capital - Skill Development

There is always 'brain' behind successful implementation of any new technology/ideas. Unless soft

skill of workforce is improved periodically the noble aim of having a leap forward in

production/productivity/profitability, may just become a distant reality. Therefore, training and

retraining of technical manpower needs to be planned and enforced to have desirable results.

All those involved in blasting and maintenance operations should be developed so as to be well versed

in new techniques. Retraining in blasting technology is needed at suitable intervals for blasters,

supervisors, designers, planners and executing personnel so as to keep them abreast of the latest


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technology. Similarly OEMs may be asked to provide specialised training to HEMM maintenance

personnel at suitable intervals.

5.0 Technology for improved safety in opencast mines

Stability of external OB dumps is a critical issue for safe mine operations. Radar Systems (Slope

Stability Radars) are available which can operate in mining environment to provide accurate, real time,

all weather surveying and slope movement measurements with customized alarm systems that helps

in taking proper preventive measures to monitor slope movements and plan action for its stabilisation.

Application of sophisticated radar system for monitoring stability of slopes in opencast mines is under

consideration in opencast mines of CIL.

• Introduction of anti collision alarm system for Haul dumpers is under consideration for opencast

mines of CIL.

• Benchmarking and adopting global best practices in the area of Risk assessment and Risk

mitigation, Training of operators in a simulated environment etc.

6.0 Future Possibilities

To enhance production at sustained pace, it is all the more important to adopt latest, technically

feasible and economically viable technology in mines. Some of these are discussed below :

A. High Angle Conveyor in opencast mines

Recent developments in conveyor capability and performance by way of improvement in belt

and drive technologies allow longer flights and higher lifts. Possibility of introduction of high

angle conveyor in opencast mines of CIL is being considered through Research & Development

Project by CMPDI. The system is generally known as 'Tyre less Mining' and it is in practice in

some of the countries abroad like Ireland, Australia etc.

B. Coal transportation on electric cables

This is another technique that reduces dependence on Truck/Dumpers for coal transportation.

Such systems are in use in South African opencast mines.

C. Remotely operated Trucks

These type of trucks are being used in mines of Rio Tinto and BHP Billiton in Australia. These

new-generation trucks have several in-built safety features which prevent them from colliding

with other trucks, allowing them to operate alongside manned vehicles. They have a GPS and a

number of scanners on the front of the machine, and a number of sensors on the machine itself.

While the trucks do all the heavy lifting, the brains behind the activity sit inside a control room

on-site at the mine.The control room workers are the eyes and ears of the trucks, and it is their job

to create a virtual map of the mine and make sure the vehicles stay on course.

D. Fuel management System and fuel efficiency with respect to Carbon foot print will need to be

looked into, since it is gradually becoming the global ecological concern.


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References :

1. ASCI Presentation - Managing Stakeholders

2. CIL Production data

3. www.worldcoal.org

4. Technology upgradation plan for CIL prepared by CMPDI

5. Mine haul road maintenance management systems by R.J. Thompson and A.T. Visser

6. Opencast Coal Mining in India : Analyzing and Addressing the Air Environmental Impacts - By

M.K.Ghosh

7. www.geovia.com : India Hopes to increase coal mine productivity

8. Coal Mining and Management Vol. I

9. Haul Roads Lighting System for Open Cast Mine using Green Energy Nitai Pal, S.Vamsi Krishna,

Ramjee Prasad Gupta, Ayodhya Kumar and Upendra Prasad


India ranks third in the world in total energy consumption and needs to accelerate the development of

this sector to meet its growth aspirations. Hence, it stands strong amidst others targeting significant

growth in energy and power sectors. At this juncture it is critical to identify technology trajectories that

would not only meet the near-term needs of the country but also focus on a path that would position it

better to respond to future challenges, more specifically climate change. As coal will continue to

dominate the energy mix of the country we need a program with sensible and balanced objectives with

proper emphasis to the various program elements and activities in tune with the National Agenda.

Hence, India needs to be active to take alternative route for production of liquid fuels derived from

coal. Research and technological developments have already been initiated by research institutes and

other organisations for production of liquid fuels from coal.

Liquid fuels from alternative route can be obtained either from gas or solid. Coal to liquids (CTL) is one

of the more rational approaches for alternative liquid fuels. There are primarily two processes for CTL

technology namely Direct Liquefaction (DCTL) and Indirect Liquefaction (ICTL). The direct

liquefaction technique is also named as Bergius Process in the name of Friedrich Bergius the inventor

who received Nobel Prize in 1931 in Chemistry. In this process, coal is directly converted to liquid

hydrocarbons by hydrogenation at very high temperature (400 ºC) and pressure (250 bar) conditions.

During World War I as well as World War II, this process was extensively used by Germany for

production of diesel and gasoline. Presently, this technology is not being much used due to its very

extreme reaction conditions.

In the indirect route, coal is first gasified to syngas a mixture of carbon monoxide (CO) + hydrogen (H ) 2

and then converted to liquid hydrocarbons over transition metal catalysts (iron, cobalt and ruthenium)

at moderate pressure and temperature (Pressure: 10 to 30 bar andTemperature: 200 to 320ºC) by

Fischer-Tropsch Synthesis. This process was discovered by two German Scientists Franz Fischer and

Hans Tropsch in the Kaiser-Wilhem Institut fur Kohlenforschung in Mulheim an der Ruhr, Germany

and it started commercial production in 1925. During World War II, Germany was also using this

technology for production of diesel and gasoline. Figure below explains both DCTL and ICTL in

brief.

It is a fact that in recent past (July, 2008) the price of crude reached to $147/barrel which now has

stabilized around $45/barrel. In this context, CTL should be considered as a strategic technology and it

is estimated that CTL crude is profitable only when Petroleum Crude price is above $70/barrel.

According to Petroleum Ministry, India is estimated to import ~ 188.23 million ton petroleum crude in

the FY 16. Importing foreign technology without the know-how or collaboration with technology

providers is not a permanent solution for the development of CTL technology in a country like India

where energy security is a major thrust area.

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Strategic importance of Coal – to - Liquid Technologyin India and its present status

— Dr Amalendu Sinha*


*Former Director, CSIR- Central Institute of Mining and Fuel Research, Dhanbad.

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Several Indian Universities and Research Institutes started working for development of catalysts for

CTL Technology in laboratory scale. The CSIR-Central Institute of Mining and Fuels Research,

Dhanbad has taken the initiatives and has set up a Coal – to – Liquid Pilot Plant (Catalyst Capacity:

10.0 L and Hydrocarbon Liquid Production Capacity: 5.0 L/day) through indirect route funded by the

Ministry of Coal, Govt. of India. Two indigenously developed Cobalt based catalysts have been

successfully tested. This is definitely a successful venture towards development of indigenous CTL

Technology in this country using Indian coal.


Abstract

For sustainable environment, scientists have been trying to find out alternative sources for

energy generation economically and safely, but for the industrial growth, energy will be

required. India doesn't have much alternative resources for energy generation and coal will play

the important role for another couple of decades till alternative energy sources are economically

established. Since coal is non renewable source of energy, for the interest of the country planners

should adopt a mass production technology where conservation of coal will be the most

important guiding factor.

The author has tried to explain the different types of available mass production as well as

different types of backfilling technologies. Based on the experience of the success of increasing

OB production from open cast mines, through outsourcing, the future underground mass

production technology is likely to come through outsourcing mode either on risk & gain sharing

basis or hiring mode where the operator will buy, own and operate. In order to attract the

potential operators and manufacturers, it will be necessary to develop operator friendly NIT

where the NIT will be transparent and is able to lead to a win-win situation. While the mass

production technologies are well established all over the world but it will require the active

association of the researchers, educational institutions, planners and DGMS to adopt the

appropriate technology suitable for Indian mining conditions.

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Conservation of coal - Guiding factor for choice ofappropriate underground mass production technology

— B.N. Pan*


*Former CMD , BCCL

Abstract

Coal preparation has been practiced in India for well over 50 years. With Indian economy

progressing at a fast pace and with increasing number and requirement of end users of coal, the

scenario of coal preparation is changing rapidly. Industries like Power, Cement, Iron and Steel

Making are creating a tremendous demand for coal with stringent qualitynorms which has made

coal preparation a basic necessity. The environment issue is also a vital factor which has added to

this changed perception of industry on coal preparation. It is being realised that in order to match

the pace of development, coal preparation has to be made mandatory for most of the raw coal

being mined in our country. The Government of India is planning to change our country's

current status from being a coal importer to an exporter of coal, which will help India becoming

an energy surplus country by the FY-2017while at the same time lower the trade deficit in energy

sector. In line with the development plan of the government, the largest coal producer of India,

CIL has planned to increase the coal production fromthe current fiscal year achievedcapacity of

538MTPA1 to a billion tonnes per annum by year 2020. Apart from state run facilities, private

sector mining companies have been allotted coal mines through e-auctions in recent times; which

Government of India expects to contribute another 500MTPA raw coal production by the same

time period.This paper investigates the current proven coal preparation technologies like

Deshaling Jigs, Under Pulsated Jigs, Heavy Media Bath & Cyclone processes. The technologies

discussed in this paper shall certainly help the end users of coal in deciding on which technology

to be adopted to meet their specific requirement while maximizing the recovery of good quality

coal from the continuously deteriorating raw coal in terms of quality.

Keywords : Coal Preparation, ROM® Jig, BATAC® Jig, Heavy Media Separation

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Review of Proven Coal Preparation TechnologiesTreating Indian Coal

— Gurudas Mustafi*, Arpit Gupta*


*MBE Coal & Mineral Technology India Private Limited

The International Energy Outlook 2016 (IEO-2016) stated that coal remains the second-largest

energy source worldwide—behind petroleum and other liquids—until 2030. From 2030 through

2040, it is the third-largest energy source, behind both liquid fuels and natural gas. World coal

consumption increases from 2012 to 2040 at an average rate of 0.6%/year, from 153 quadrillion Btu

in 2012 to 169 quadrillion Btu in 2020 and to 180 quadrillion Btu in 2040.

The Economists suggest that for the sustenance of 8-10 % economic growth rate the enhanced

energy supply needed. Coal becomes the Prime source of Energy in India & will remain so in

foreseeable future. The Coal accounts for over 52% of India's commercial energy consumption as

per the published notes of CIL. As per the published data, about 66% of domestic coal consumption

is dedicated to power generation. Compared to the world scenario, the India's domestic coal

consumption in power sector is higher as the world consumption stands at about 29% of

commercial energy produced.

According to IEO-2016, coal use in India and the other countries of non- Organization for Economic

Cooperation and Development (OECD) - Asia continues to rise. India's coal use surpasses the

United States total around 2030, and its share of world coal consumption grows from 8% in 2012 to

14% in 2040

The Integrated Energy Policy document (2006) of Planning Commission projected coal based

energy requirement for GDP growth rate over 8% till 2031-32 as 1022 Mtoe (2555 Mt) for a coal

dominant scenario & 632 Mtoe (1540 Mt) with utilization of full potential of nuclear, hydro &

renewable resources . This puts an arduous responsibility on coal sector to meet requirement.

As per the world coal statistics, India forms the 3rd largest coal producer in the world. The current

coal production in India is around 645.8 Mtpa (2015-16). Of which Coal India Ltd (CIL) has

produced 538.75MT (83% of total produced coal) during 2015-16. There exists an ample growth

opportunity for coal sector in India due to high demand in future. There is ample opportunity to

produce gas by underground coal gasification and chemicals from coal. The domestic production

enhancement would thus require extensive exploration activities to meet the future high demand

for coal. For the purpose, in India, advance technologies for intensifying exploration have been

adopted to prove existing resources and to establish new finds at a faster pace.

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Modernization of Coal Exploration Technology and Reserve Assessment System – Indian Scenario

— B. N. Shukla*


*Director (T/CRD), CMPDI, Ranchi

Synopsis

The Daniels Company and GT Global have engineered, procured and constructed over 725

coal processing plant and material handling systems since 1956. Capacities of up to 2000

ton per hour have been brought on line worldwide. We have the capabilities to custom

design and engineer coal processing, coal storage, coal reclaim and load out systems with

our in house staff of expertise. The company has also developed and installed over 550

Processing Plants utilizing our 3 Product plant design. This design will be very useful in

the processing of difficult to process Indian coals.

The company manufactures a variety of coal processing equipment including the world

famous Daniels Heavy Media Washer, the 3 Product Cyclone system, vibrating screens,

sieves (both curved and flat), centrifugal dryers and screen bowls, cyclones, jet flotation

cells, jigs and clarifying thickeners. We also have to capability to fabricate steel structure,

plate work, sumps and fabricated trusses.

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The Daniels Company Presentation


Advanced Design of Process Technology for Indian Coal

Synopsis

Mining activity starts with mineral extraction that is often associated with many

environmental concerns. Large-scale excavation is often necessary to extract a small

amount of ore. Ore extraction disrupts the topsoil and can displace or cause global stability

problems which may lead to heavy landslides. Rainfall, high seismicity, steep gradient,

adverse climatic conditions are some of the factors which generally govern the stability of

slope. Proper measures if adopted at the time of extraction can prevent the failures and

landslides, thereby reducing the potential loss anticipated to environment and mankind.

Various composite solutions comprising of flexible gravity retaining walls, soil reinforced

structures or simple erosion control measures could be adopted. The closure of mine and

reinstatement of ecosystem is one of the most important activities in the life cycle of mine

operation. Rapid re-establishment of vegetation and soil erosion protection systems can

help to complete the closure operations. A properly managed and sustainable re-

vegetation program using advanced measures will ensure the effective return of land to an

agreed post-mining land use.

It will fit into the following topics :

• Making Coal Mining and Coal Utilisation more environment friendly

• Improvement in Infrastructural facilities particularly Rail connectivity for un-

developed / under developed coalfields

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Maccaferri Environmental Solutions Private Limited


Advanced Engineering Measures for Erosion Controland re-vegetation

Synopsis

Coal, the most dominant secondary source of energy, is an extremely important sector for the

economy. Its importance gets enhanced also due to the fact that it is available indigenously in

substantial quantity and it has also proven to be the main stay of the energy economy of the country.

Despite the challenges, the indigenous coal industry has done well to reach a stage of significant

reliability and surety. Today, country produces coal in excess of 500 MTPA and which is expected to

double to touch the Billion mark soon enough. The indigenous coal is not of the highest quality in

terms of its composition but is good enough for use in thermal power plants and quite appropriately,

most of the coal mined in the country, finds its way to the power plants in India. The mutual

dependence of coal and power can be easily gauged by the fact that nearly 80% of the indigenous coal

gets used for power generation and nearly 85% of power generated in the country is based on coal.

While the growth has picked momentum and the road ahead looks promising, there are challenges that

are lurking and would need to be dealt with, well in time to safeguard the longer-term interests of the

coal industry as well as the Indian economy. Unlike the experience in the past, these challenges

looming on horizon are essentially from factors external to the sector and the coal industry may find it

difficult to either ignore or influence them. These challenges would need to be faced and countered to

ensure longevity and relevance of the coal industry to the economy.

Up till now, a robust demand for power by the economy used to translate into similar robustness in

demand for coal. The linear mutual dependency equation worked well for a long time as no disruption

was encountered. However, going forward, while the demand for power may continue to grow at a

healthy rate, it may not reflect in the same way for the coal industry. It is more than likely that a major

shift is witnessed in the way the power demand is met in the country and not necessarily depending on

coal as critical input. The techno-economic as well as the geo-political factorshave played their roles

and alternatives are now available for power generation that are not just getting close to viability in

terms of economics and reliability but are threatening to improve further to emerge as a better and

more desirable option going forward. Renewable technologies have truly arrived and are here to stay.

This would most likely change the energy equation irretrievably, forever.

The concerns of global warming, etc. are serious in nature for the humanity and are recognized

globally as a collective action item for mitigation/ containment. This would be an extremely potent

threat to the coal industry, both indigenous as well as global. The global indicators are that coal usage

for power generation may soon be relegated to the unwanted category, lest the coal industry gears up

and offers alternatives that ensure longevity to the industry while effectively mitigating concerns on

these external factors. Coal industry needs technology infusion of a serious kind and undergo a

significant metamorphosis.

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Tata Power


Coal for Power

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Overland transportation of coal traversing difficult terrains.

Thursday, September 01, 2016 1

Presented by : Shri S K Nayak & Shri S K Grover

6th Coal Summit

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Coal for Power SectorArun Srivastava

6th Sept 20166th Coal Summit & Expo

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About Author

Arun Srivastava

Chief, Regulations & Advocacy

Tata Power

Past Experience

May 2011 – till date Chief, Regulations & Advocacy, Tata Power

Nov 2002 – Mar 2011 Executive Director, Business Advisory, Ernst & Young

Sept. 1998 – Nov. 2002 Associate Director, Business Advisory, Arthur Andersen

January 1998 – Sept. 1998 Sr. Manager Business Development, Marubeni Corporation, Japan

Nov. 1981 – Jan 1998 NTPC Ltd.

May 1995 – Jan 1998 Ministry of Power, Investment Promotion (Deputation from NTPC)

October 1988 – January 1992 Planning Commission, Energy Division (Deputation from NTPC)

July 1981 – Nov. 1981 Coal India Ltd.

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6th Coal Summit & Expo 20166th & 7th September, 2016 - Hotel Le Meridien, New Delhi

BY

N. A. VISWANATHANSECRETARY GENERAL

CEMENT MANUFACTURERS’ ASSOCIATION

Importance of Coal for Cement Sector:Constraints in Supply of Domestic Coal

and way forward

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About Author

Shri N.A. Viswanathan is a retired I.A.S. Officer from U.P. Cadre (1972 Batch). He has had a very rich and varied administrative experience as a Senior Administrative Service Officer with a distinguished career. Shri Viswanathan has held various important assignments with both U.P. State Government and Government of India ranging from Divisional Commissioner, Meerut, C.E.O. of NOIDA and Greater NOIDA to Additional Secretary & Financial Advisor, Ministry of Home Affairs with distinction.

During his earlier deputation to the Government of India between 1988 and 1996, Shri Viswanathan worked as Deputy Election Commissioner of India and was very closely associated in Planning and

Execution of free and fair conduct of Elections to the Parliament and State Legislatures as also to the office of President and Vice President of India. Shri Viswanathan has also worked as Managing Director of two U.P. State Government Public Sector Undertakings, namely U.P. Small Industries Corporation and State Spinning Mills in his earlier stint with the State Government of U.P. At the time of retirement, Shri Viswanathan was Director General of National Productivity Council and Secretary to the Government of India and was a Member on the Board of Governors of Indian Institute of Management, Ahmedabad, Bangalore, Kolkata and National Institute for Training and Industrial Engineering (NITIE). He is currently heading Cement Manufacturers' Association as its Secretary General. Shri Viswanathan holds a Post Graduate Degree from University of Delhi and an MSc. in National Development & Project Planning from University of Bradford, (U.K.) in addition to a Post Graduate Diploma in Management from AIMA

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ADVANCED DESIGN & PROCESS TECHNOLOGY FOR INDIA COAL

THE DANIELS COMPANY (USA)A Member of GT Global

Robert HollisVice President

The Daniels Company

USA

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B. P. Singh, Director of Mines Safety

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About Author

B. P. Singh, is a mining engineer with 35 years of experience in coal and non-coal mines.

He is presently working as Director of Mines Safety, Western Zone, DGMS, Nagpur

Maharashtra, India. He has specialization in rock- mechanics & ground- control, micro-

seismic and rock bursts in deep mines. His experience includes science & technology,

mine environment, and e-Governance. He visited many countries and presented

technical papers.

INSTITUTE OF INDIA

ME

TALLU

RG

ICA

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ING

GE

OLO

GIC

AL

&

1906

DELHI CHAPTER

Section-5

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