INDEX

S.NO CONTENT PAGE NO.

1 Introduction 1
2 Literature Review 2
2.1 Conditions favorable to adopt conversion process 4
2.2 Precautions to be taken before conversion process 5
3 Procedure 7
3.1 Procedure before extraction of developed pillars 7
3.2 Operation procedure 10
3.3 Blasting 14
3.4 Problems during conversion process 17
4 Statutory provisions 19
4.1 Precautions against coal dust explosion 19
4.2 Blasting in fire areas 21
4.3 Firing of shots in fiery areas 21
5 A Field Study of RKPOCP Mine 23
6 Conclusion 40

1
 LIST OF TABLES

S NO. TABLE NO. TABLE NAME PAGE

NO.
1 5.1 History of RKPOCP Mine 24
2 5.2 Particulars of the seam 26
3 5.3 Production details 28

4 5.4 Machinery details (SCCL) 36

5 5.5 Machinery details (Dott company) 37

2
 LIST OF FIGURES

S NO. FIG NO. NAME OF FIGURE PAGE

NO.
1 3.1 Different zones in conversion 8
2 3.2 Drilling pattern in single section 10
3 3.3 Drilling pattern in two sections 11
4 3.4 Drilling pattern in Superimposed galleries 12
5 3.5 Drilling pattern in non super imposed galleries 13
6 3.6 Pattern of holes on pillars 13
7 3.7 Charging in 150mm dia. Hole 14
8 3.8 Charging in 250mm dia. Hole 15
9 5.1 Mine plan of RKPOCP Mine 27
10 5.2 Bore Hole Data 29
11 5.3 Extraction by Shovel – Dumper 33
12 5.4 Blasting Design of RKPOCP 35
13 5.5 RKPOCP view point 39

3
 1. INTRODUCTION

Coal, in spite of all the ills associated with its use, is recognized as the major source of
energy which provides about 40% of total electricity generation of world.

The energy crises of early seventies focused the attention of the world on coal and
plans to draw it commercially. Since then coal mining has been changing fast, in recent
decades with sophistication in mechanization, automation etc., in the present days
technological explosion, total winning of coal is become easy where the importance of
conversion of underground mine to opencast mine arises.

Conversion of underground to opencast mine consists of removal of overburden

above existing mine, provide safe parting between opencast workings and leftover pillars
before extraction which include blasting that avoid bogging of machinery. Preparation of
plans is the major aspect in the conversion with respect to left behind coal where
misjudgement in old and new plan leads to accidents such as fall of surface to development
galleries.

Extraction of coal can be done in both underground and opencast method, where 3.7
million tonnes of coal is left behind to support surface structures after the underground
development of mine. It causes a huge loss in the extraction of coal. To extract such left
over pillars, underground to opencast conversion arises, hence opencast extraction is more
safer and economical compared to underground to complete retrieval of resource. It is
crucial to analysis the favourable conditions, challenges, implementation, and scope to
extract all left over underground pillars.

4
2. LITERATURE REVIEW

E. Bakhtavar ( 2009)
Bakhtavar reviewed that deposits that have the potential to be mined by a combined method
of open-pit and underground. In this manner, the most sensitive problem is the
determination of the optimal transition depth from open-pit to underground or vice versa.
To calculate this depth, a model based on block economic values of open-pit and
underground methods together with the Net Present Value (NPV) attained through mining is
first presented. During the model, NPV of open-pit is compared to the value of underground
for the similar levels. A hypothetical example is used in order to analyze the model in detail.

Based on the assumptions made such as: a discount rate of 15 %, each pair of contiguous
level-cuts have to mine during one year, and one level as the height of crown pillar, the
optimal transition depth was determined to be equal to 62.5 m. Then, level 6 was considered
as the suitable crown pillar. Finally, maximum total NPV of the combined mining was
calculated to be 25.54 units of currency.

David Whittle (2015)

Whittle described that many Ore Reserves are harvested by a combination of open cut and
underground methods. In these cases there is often a choice to be made as to whether to
mine particular material by either open cut or underground, typically when an open cut mine
is above a proposed underground mine. The area, in which this decision is to be made is
referred to as the transition zone.

He introduced the widespread application of mathematical optimisation of pit outlines had

its beginnings with the release of optimisation packages by Whittle Programming (now
owned by Dassault Systemes Geovia) in the 1980s. The optimisation is based on the graph
algorithm developed by Lerchs and Grossmann (1965). This algorithm, commonly referred
to as the LG Algorithm, provides an exact method to determine the optimal closure of a
directed graph consisting of vertices, representing potentially mineable blocks, and arcs
representing the mining precedences imposed by the requirement to uncover blocks and to
maintain safe pit walls.

Picard (1976) showed that the pit outline optimisation problem was equivalent to a
maximum flow problem, meaning that a large number of existing maximum flow algorithms

5
could be applied. Giannini et al. (1991) developed a software package using a maximum
flow algorithm and others (for example Zhao and Kim (1992)) have proposed or devised
methods that produce equivalent results to the LG Algorithm with the potential to do so in
less time. However the LG Algorithm is still thought to be the most commonly used pit
optimiser.

2.1. CONDITIONS FAVOURABLE TO ADOPT CONVERSION

PROCESS

 From conversion point of view, opencast method of work provides better recovery
of coal when compared to underground method.
 Keeping in view the disturbed geo-mining conditions, opencast method of extraction
is safe compared to underground mining method.
 The coal seams are occurring at a relatively shallow depth of 30metres.
 The deposit should be close to surface. Usually a depth of up to 90mts was
considered to be the limiting depth in India. But with the advance of technology now
opencast mining of coal is considered feasible up to about 300 mts depth and one
mine in Jharia coalfield is projected to depth of 480mts.
 The ratio of overburden to coal should be less. A ratio of 4:1 is considered desirable
but in some situations opencast mining up to ratio of 6:1 is also considered
economic. Abroad much higher ratios have been considered feasible.
 The coal seam should be of uniform thickness and preferably flat.
 There should not be excessive make of water: sites where aquifers are encountered
create problems. Also sites close to the sea may get heavy seepage of water in the
workings.
 A mild climatic condition is generally favoured: with excessive rain or heat or cold
the mining operations are hampered.
 Geological disturbances: It is not uncommon to find some seams have too many
intrusions (dykes & sills), faults, wash puts etc., When they occur, they break the
continuity of the Coal Seam makes roof weak of underground developed mine.
 Thickness of the seam: The thickness of the Coal Seam varies from a few
centimetres to several metres. The common thickness of seams in which mining has
been going on in world are 0.4m to 10m thick, in India Seams more than 4.8m are
considered as thick.

6
  Surveying: Surveying is very important in conversion of underground mine to
opencast mine. Survey has to be conducted by using latest survey equipment’s like
total station etc., and positions of workings including the disturbances and falls
should be clearly demarcated on the plan.

2.2. PRECAUTIONS TO BE TAKEN BEFORE CONVERSION

PROCESS

2.2.1. GENERAL PRECAUTIONS :

 Fire area shall be demarcated by Red flags. Demarcation of galleries and pillars in
the area shall be given before starting an work in the fire area.
 Placards / Boards shall be displayed at each and every junction of the galleries
indicating location and parting at the place.
 No person / machine / vehicle shall be taken in to the fire area without the
knowledge of an official.
 The persons including supervisors and officers working in the fire area must always
stand on the marked pillars only..
 While dozing and drilling the movement of dozer and drill should be perpendicular
to the galleries direction.
 Dozing work shall be carried under the constant supervisions of an official in day
light hours.
 The operator shall ensure that the drill is standing on the solid pillar while drilling.
 Truck mounted drill should be provided with a separate platform with railing for
standing of driller. Driller shall also use safety belt without fail. The helpers shall be
away from the drilling area, except while changing the drill rod.
 Ensure safe parting by drilling a test hole before starting drilling operations.
 If any hole is connected to the galleries which is on fire, plug the hole immediately
to prevent air passage. Avoid sending water through the hole into the active fire
gallery which may result in water gas explosion.
 No person including operator shall stand on the gallery top on which drilling is going
on.
 The entire drilling operations shall be conducted under the direct supervision of an
official.

7
2.2.2. ADDITIONAL PRECATIONS

 At the beginning of the 1st shift the blasting in-charge will take the report of the
drilling of back shifts.
 The surveyor along with his team inspects the place and makes a sketch of the area
with actual depth of the holes regularly.
 Blasting over man then takes the temperature of each hole and down the field book.
 Whenever the temperature of the hole exceeds 60o C the holes are to be filled with
water and charging will be done after temperature comes down below 60oC.
 No NG based explosive shall be used when there is fire is galleries only slurry and
emulsion explosive shall be used.
 Blasting shall be done with detonating fuse down the hole.
 Temperature inside the blast holes shall be measured (before filling with water)and if
the temperature exceeds 80oC,in any hole ,such hole shall not be charged. Records
of measurement of temperature in each hole shall be maintained in a bound paged
book.
 All blast holes shall be kept filled with water. Where any holes is traversed by cracks
or fissures, such hole shall not be charged unless it is lined with an asbestos pipe and
the hole filled with water. In addition, bentonite should be used for sealing any
cracks at the bottom of the holes.
 All holes in the last OB bench and/or in coal shall be charged with water and
ampoules or with moist sand of atleast 0.6mts in length at the bottom of the hole on
the high active fire area where temperature exceeds 100oC.
 Where there is any doubt particularly where there cracks and crevices, the bottom
2mts length of the hole shall be filled with sand.
 Detonating fuse shall not be laid on hot ground without taking suitable precautions
which will prevent it from coming in contact with hot strata.
 The charging and firing of the holes in any one round shall be completed soon and in
any case with in two hours even if watering of the holes is done before charging.
 Blasting operation shall be carried out under the direct supervisions of an assistant
manager.

8
3. PROCEDURE

3.1. Process before starting extraction of developed pillars by Opencast methods are as
follows:

The U/G working to be quarried shall be isolated by explosion proof stoppings or by

any other approved manner from any active working area either in the same seam or
different seam or section as the case may be, so as to prevent transference of danger to the
said workings area.

Before intended to close the U/G mine for conversion to O/C, a detailed off set survey has to
be conducted by using latest survey equipment’s like Total Station etc. and the position of
workings including the disturbances and falls should be clearly demarcated on the plan. The
U/G mine Manager should see that the plan prepared for handing over to Opencast mine
manager is flawless, because once the U/G mine is abandoned, the O/C operation become
blind folded and only guidelines remains with the O/C management is U/G plan submitted
by the surveyor of U/G Mine. It should clearly picturise each and every detail of U/G
workings.

Cleaning of all coal dust and thick stone dusting before commencement of extraction of
pillars.

Retaining of key personnel of U/G mine, like Surveyor, Overman and Officers for safe and
effective operation of O/C mine.

After completion of all legal and statutory formalities, the mine is developed as per the
permission conditions of DGMS. For safe and systematic excavation, the mine is divided
into four zones viz. as shown in fig. 1.

A. SAFE ZONE
B. CRITICAL ZONE
C. DANGER ZONE
D. COMPACTED ZONE

9
 FIG 3.1: Different zones in conversion

(A) SAFE ZONE: It is the zone of safety, where the parting is over U/G galleries is more
than 15m. in this zone all activities can be carried out and the zone is to be
demarcated with ‘White’ flags.
(B) CRITICAL ZONE: It is the zone, where proper precautions are required for
excavation. In this zone, the parting of working O/B benches over U/G galleries is
more than 4m and less than 15m. whenever, the plan parting reaches 15m to U/G
galleries, further reduction shall not be done unless it is proved physically. After
proving the physical parting, further parting is reduced to 4m hard O/B. in this zone
the excavation is done by Back hoe shovel in level loading. This zone is demarcated
with ‘Yellow’ flags.
(C) DANGER ZONE: Danger zone means, the area where the parting over U/G galleries
is 4m hard O/B or less. No work shall be done in this zone except dozing and drilling
for compaction. The dozing and drilling shall be done under proper supervision.
Danger zone is to be demarcated with ‘Red’ flags.
(D) COMPACTED ZONE: When danger zone is converted to safe zone by compacting
the U/G galleries by drilling and blasting (4m O/B and coal seam combinely), it is
termed as ‘Compacted’ zone. This zone is permitted for normal extraction of
coal/OB, as it is safe. It is demarcated with ‘White’ flags.

10
Note: As per DGMS guideline, the extraction of O/B in critical zone should be done upto
4m parting over galleries, but 4m hard O/B parting is no safe for running HEMM and
formation of pot-hole can’t be avoided. Hence for extra precaution, Critical zone is assumed
between 6-15m. When the working in critical zone reaches to 6m, it is treated as danger
zone.

Working in different zones:

 Whenever the area reaches to critical zone as per plan parting observed by the
Surveyor, test holes shall be drilled at demarcated places to prove the physical
parting. The critical area is demarcated with ‘Yellow’ flags.
 Based on the proved parting, O/B benches shall be lowered upto danger zone.
 Whenever the area reaches to danger zone, the area will be leveled for drilling under
proper supervision. Then the surveyor will mark the position of U/G galleries and
drill hole pattern on the benches with stone dust as per the approved plan. The
surveyor will display the placards at the junctions mentioning the place and plan
parting on it.
 The Surveyor will hand over the notice of the galleries and parting with sketch to the
Overman, Under Manager, Blasting In-charge, General shift In-charge and t the
Manager of the mine, before operating in critical and Danger zone.
 General shift In-charge will give the necessary instruction in writing to the
concerned Shift persons regarding drilling and extraction in critical and danger zone.
 Test holes shall be drilled to ascertain the parting before commencement of actual
drilling operation.
 Based on the above test hole report, the termination of holes over galleries will be
ascertained. In O/B, the holes above the galleries shall be terminated 1.5-2m before
touching the galleries and in coal 2-3m for providing proper confinement of
explosives column around the holes an to avoid blown through shots in the galleries.

11
3.2. OPERATION PROCEDURE

3.2.1. Drilling pattern for combined blasting when the galleries are developed in single
section:

When the operation of the mine falls in the danger zone (i.e. parting over galleries is less
than 6.0m), it needs careful progress to expose the developed coal seam. As per DGMS
guideline, at least 4m thick O/B parting (here 6m) immediately above the developed
galleries shall be blasted at once including thickness of coal seam to prevent any sinking of
HEMM and persons in to the U/G galleries during extraction of coal. Here, O/B and coal are
blasted simultaneously by drilling holes from O/B to floor of the galleries in coal to compact
the galleries is called Combined Blasting.

FIG 3.2: Drilling pattern for combined blasting when the galleries are developed in single
section

12
3.2.2. Drilling pattern for combined blasting when the galleries are developed in two
sections with superimposed galleries:

FIG 3.3: Drilling pattern for combined blasting when the galleries are developed in two
sections with superimposed galleries.

3.2.3. Drilling pattern for combined blasting when the galleries are developed in two
sections and parting between two sections is more than 6 meters:

If the parting between two sections is more than 6 mtrs, the combined drilling & blasting
should not be done in the fashion as shown in fig 4 below. If the combined blasting is done
in the fashion, there is coal loss of around 10-20% in the form of contamination. The
economical aspect is also taken into account in addition to safety factor. DGMS has
permitted to maintain minimum parting of 6m in coal or 4m in O/B. Therefore,
combined blasting can be done separately for both the sections, when the parting between
the two sections is nowhere less than 6 mtrs. First combined blasting is done in 6m (O/B)
and 3m Coal (i.e upto the bottom of the top section gallery). After exposure of Coal, the
above procedure is repeated separately for gallery compaction in bottom section. The
exposed coal is levelled with dozer and demarcation of bottom section galleries is made
with stone dust. Drill is engaged under proper supervision to test the parting of bottom
section gallery. Then pattern of drill holes are marked for drilling & blasting. After blasting
in coal, again it is compacted with dozer before lifting the coal.

13
FIG 3.4: Drilling pattern for combined blasting when the galleries are developed in two
sections and parting between two sections is more than 6 meters

Another disadvantage of combined blasting at a time of both sections is fire. When full
depth of coal is blasted combinedly and left for few days, the fire spreads more rapidly
throughout the depth of coal due to more area of contact with air and sometimes it becomes
very difficult to control the fire.

3.2.4. Drilling pattern for combined blasting when the galleries are developed in two
sections and both the sections are not superimposed (i.e. staggered):

When the galleries are staggered and parting between two sections is less than 6m, then
drilling & blasting activities become very critical. The author has applied many trial and
error techniques and finally established a system, which is being continued in the mine.
Both the galleries are marked with different colours. Top section gallery with white stone
dust and Bottom section with black coal dust, so that we can easily distinguish both the
sections. Then holes marking are done with reference to the top section gallery. Only care is
taken that the drill holes, which are close to the bottom section gallery, are terminated 3m
before touching the gallery and remaining holes are drilled upto floor of the bottom section
gallery as shown below....

14
FIG 3.5: Drilling pattern for combined blasting when the galleries are developed in two
sections and both the sections are not superimposed

3.2.5 Pattern of holes on pillars:

 For 10 m hole depth, the burden & spacing pattern shall be 5m X 6m for 150mm
diameter drill and 6m X 7m for 250mm diameter drill.
 For 10m – 15m hole depth, the pattern of burden & spacing shall be 6m X 8m for
250mm diameter drill.
 For more than 15m depth of the hole, the burden & spacing pattern shall be 7m X 9m
for 250mm diameter drill.
 The distance between first line of holes and edge of the gallery should be 2.5 to 3.0m,
as shown below (Fig.9);

FIG 3.6: Pattern of holes on pillars

15
3.3. BLASTING

3.3.1 Charging & Blasting operation:

 After completion of drilling, Blasting In-charge shall inspect the area and shall make
estimation of explosives required on the basis of depth of holes. As far as possible, the
drilled holes shall not be left for long time to avoid catching fire. As per DGMS
Charging and blasting in hot blast-holes, no slurry or emulsion explosives shall be used
in fiery holes and we can’t avoid fire in holes drilled for combined blasting purpose.
Hence, only LDC explosives with detonating cord shall be used for blasting to compact
the galleries.
 Temperature of the holes shall be measured with Infrared based thermometer and if it
exceeds 800C, the charging shall be stopped. Charging and blasting in fiery holes shall
be done as per the DGMS guidelines.

3.3.2. Charging of holes on pillars:

 If the galleries are developed in single lift in Top section of the Seam as shown in Fig.
3.2.1, the depth of holes on pillars shall be in range of 9m to 13m, in which O/B
parting will be 6m to 10m and 3m coal (up to gallery height). Charge columns in O/B
and Coal shall be separated by a Deck of 2-3 m height.

FIG 3.7: Charging pattern of 150mm diameter hole

Total charge in a hole = 93.75 to 125 Kgs

16
 If the galleries are developed in single lift in Bottom or Middle section of the Seam and
Coal parting above the galleries is more than 6m, then combined Blasting is not
required. Coal will be exposed in a normal way and after exposure of coal seam; total
thickness of coal will be blasted at a time taking all necessary precautions narrated
above. Only extra precaution to be taken is that, the advance test holes at junctions
shall be drilled in OB benches to know the coal parting above the galleries.
 If the galleries are developed in double lifts or sections as shown in Fig. 1 & 2, the
depth of holes on pillars shall vary as per the thickness of coal seam. Let us assume
that, the thickness of coal seam is 16m, then depth of holes on pillars will be in the
range of 22 to 26m, because OB parting will increase along Dip direction.

FIG 3.8: Charging pattern of 250mm diameter hole

Total charge in a hole = 600 to 750Kgs.

17
3.3.3. Charging of holes on Galleries:

Parting above gallery in OB varies between 6- 10 m. Hence, depth of the holes above the
gallery in OB will be 4- 8m, terminating the hole 2m before puncturing into the gallery. The
amount of explosives required will be 62.5 Kgs to 125 Kgs.

3.3.4. Compaction of gallery after blasting:

Immediately after blasting, a dozer (minimum of 355 H.P.) with experience operator shall
be engaged under proper supervision for levelling & compaction of the blasted galleries.
After proper compaction, the area will be marked with `White` flags to treat as safe zone for
extraction.

3.4. PROBLEMS DURING CONVERSION PROCESS

 Drilling and blasting

 Bogging down of HEMM while Working over U/G galleries (drill machine.
Dozer, Shovel, Dumper etc.
 Drilling holes
 Transportation of explosives
 Handling of explosives
 Exceptional delays in firing of shots/sleeping of holes. Note: sleeping of
holes is not permitted in this mine. The following precautions are only in
case of un avoidable situations, which are beyond the control of management
with drawl and taking shelter, firing of shots, misfire
 Movement of HEMM
 Failure of vehicle.
 Stability resulting toppling.
 Run over by vehicles/HEMM
 Sliding of Dumpers/tippers/dozers at dump edge.
 Operation at loading points

For this purpose the following are considered as (separate) individual operations.

 Drilling
 Charging & blasting

18
  Dozing
 Grading
 Loading
 Unloading
 Crossing 3 way/4 way junction
 Unauthorized riding on HEMM
 Spillage of boulders from loaded tippers/dumpers
 Stoppage of HEMM/vehicles on active haul roads due to breakdown
 Formation of pot holing / cavities:

Partition reduced due to old underground falls and also due to heavy blasting’s.
Partition reduced due to burning of gallery top by underground fire. Partition
reduced due to excavation. Parting failure due to accumulation of water/seepage of
water over or through weak or cracked strata.

 Sliding of benches / Failure of dump yards:

 Sliding of OB or coal due to more height of the bench than the digging height
of the machine.
 Sliding of OB/Coal while excavation near fault plane. Sliding of material left
against fault plane. Sliding of Dump slopes edges. Failure of Dump yards
two types: a) Dump yard sliding. b) Dump yard shrinking. Fall of hot
material or ash on mean and machinery while excavating fiery material.
Electricity.
 Movement of coal transport lorries and lorry loading point:
 Movement of men and Lorries near loading point. Shale picking operation on
moving Belt. Movement of men and machinery near loading point.
Inundation

19
 4. STATUATORY PROVISIONS

4.1. Precaution against danger of coal dust explosion while extracting pillars by
opencast method :

 Attention is invited to DGMS (Tech) Circular No. 11/1979 in which it was stipulated
that LOX shall not be used for blasting in overburden within 15m of the underground
workings in the coal seams immediately below or in the vicinity. It was also suggested
that:-
 No shot hole shall be drilled in O/B above underground galleries.
 A parting of at least 3m between the bottom of a shot hole and the coal seam shall be
left intact.
 The above precautions have to be observed not only with LOX but with all other types
of explosives used in opencast mines.
 After a coal dust explosion in an opencast mine, the previous guidelines were
elaborated to prevent a recurrence of the accident. The Precautions to be taken in this
connection are listed below-
 Survey, Cleaning and dusting: Where the U/G workings are accessible, the same shall
be surveyed and cleaned of all coal dust and thickly stone dusted before
commencement of extraction of pillars.
 Withdrawal : All persons from U/G in the same workings seam or any other seam or
section connected therewith shall be withdrawn before commencement of blasting
operations in the quarry and the work persons shall not be permitted into the said U/G
workings unless and until the same have been inspected by a competent person.
OR
 The U/G workings to be quarried shall be isolated by explosion proof stoppings or by
any other approved manner from any active working area either in the same seam or
different seam or section as the case may be, so as to prevent transference of danger to
the said working areas.
 Location of holes: The spacing of holes in the bench lying immediately above the coal
seam (referred to hereinafter as last OB bench) shall be so adjusted that the holes do
not lie immediately above the galleries as far as possible in order to ensure that the
blast holes do not directly fire into the U/G workings.

20
 Safe parting: The depth of the hole in the last OB bench shall be such as to leave at
least 3.0 m thickness of OB above the coal seam, and to ensure compliance with this
requirement a pilot hole be put for each round of blasting to determine the total
thickness of OB over the coal seam.
NOTE:-This condition has been modified in subsequent DGMS Circular, which is as
follows
 No person or machinery shall be deployed or permitted to be deployed in any portion of
the quarry lying over U/G galleries, free from water, where the thickness of parting is
less than 6 m in coal or 4 m in O/B.
 To comply this conditions parting of at least 4 m thick immediately above the
developed pillars shall be blasted at once including thickness of coal seam toprevent
any sinking of HEMM and persons into any U/G galleries during extraction of coal.
 Filling sand in holes: Where there is any doubt and particularly where there is any
cracks and crevices, the bottom 2m length of the hole shall be filled with sand.
 Delay detonators not to be used: Unless otherwise permitted by DGMS, no delay
detonators shall be used in coal and the manner of extraction of pillars shall be by
drilling & blasting holes in coal pillars only from top downwards.
 Workings developed in more than one section : Where more than one section of the
seam had been developed on pillars, the shot holes shall not be drilled 3m of a lower
section, and care shall be taken that, as far as possible the blast hole do not directly fire
into any U/G gallery. To ensure compliance with requirement, a pilot hole shall be put
for each round of blasting.
 Use of water ampoules/moist sand: All holes in the last OB bench and/or in coal shall
be charged with water ampoules or with moist sand of at least 0.6m in length at the
bottom of the hole.
 Shelter: No person including shot firer take shelter within 100m of the quarry
openings, and such shelter shall be of an approved design.
 Administrative control: The opencast working over U/G part of working shall be
under the administrative and technical direction and control of the Manager and Agent.

21
4.2. Blasting in Fire areas:
 A number of fires are known to be active in different Coalfields. Any attempt to win
coal from these areas involving blasting is fraught with danger. In a major accident, 6
persons were killed when a NG- based explosives was being used in an opencast coal
mine where fire existed. Some trial were carried out by R&D wing of DGMS in
collaboration with CMPDIL and CMRS in extraction of coal from fiery opencast mine
and recommended the following precautionary measures:-
 No explosives other than slurry and emulsion explosives shall be used. Blasting shall
be done with detonating fuse down the hole.
 Temperature inside the blast holes shall be measured (before filling with water) and, if
the temperature exceeds 800c, in hole, such hole shall not be charged. Records of
measurements of temp. in each hole shall be maintained in a bound paged book.
 All blast holes shall be kept filled with water. When any hole is traversed by cracks or
fissures, such hole shall not be charged unless it is lined with asbestos pipe and the
hole filled with water. In addition, bentonite should be used for sealing any cracks at
the bottom of the holes.
 Detonating fuse shall not be laid on hot ground without taking suitable precautions,
which will prevent it from coming in contact with hot strata.
 The charging and firing of the holes in any one round shall be completed expeditiously
and in any case within 2 hours. Blasting operations shall be carried out under the
direct supervision of an Assistant manager.
 It is however, clarified that permission/relaxation under different regulations, which
may be applicable (e.g. using more than one type of explosives etc.) shall invariably be
obtained before carrying out blasting operations.
4.3. Firing of shots in fire areas/in vicinity of hot strata in opencast Coal mines :
Recently, in a mechanized opencast coal mine, where extraction of developed pillars by
deep hole blasting was being carried out, one of the shot hole left charged, prematurely
detonated after a lapse of two and half hours. Fortunately no person was involved as the
holes were unstemmed and there was no one in the vicinity. The following additional
precautionary measures shall be taken over and above the measures stipulated vide DGMS
(Tech.) circular 2/1985.
 The blasting officer shall ensure accurate measurement of temperature at bottom of
the shot holes drilled in coal benches and in O/B benches immediately above the

22
 coal seam and other fiery areas to determine whether fire exists. The measurement
shall be recorded in a bound paged book kept for the purpose. For this purpose the
temperature shall be measured initially after completion of the hole and thereafter
at least once every shift. No hole shall be charged, if the temp. in the hole exceeds
800C.
 As a precaution against presence of pocket fires in coal benches in developed
seams, O/B benches immediately above the coal seams and other fiery areas in the
mine, the explosives charged shall be fired by detonator attached to the detonating
cord at the surface and not within the shot hole.
 All explosives, cast boosters, detonators, detonating cord and shock tubes shall be
subjected to proper testing in an approved laboratory in respect of temperature
sensitivity and impact sensitivity for safe handling in mines.
 Sleeping of holes shall not be permitted in coal benches, where fire or Spontaneous
heating has been detected and in O/B benches lying immediately above such seam
and at all places where there is likelihood of fire or Spontaneous heating.
No PETN/TNT based cast booster shall be used for initiating non- cap sensitive
slurry/emulsion explosives in coal benches and O/B benches of a fiery coal seam.

23
 5. A FIELD STUDY OF RKPOCP

INTRODUCTION:

 The Amalgamated Ramakrishnapur Opencast Project is situated at Mandamarri area

of SCCL in Adilabad district of Telangana state in Godavari valley coal field.
 The Mining lease of Amalgamated Ramakrishnapur opencast project block is located
on the central part of the Somagudem - Indaram coal belt. It covers an area of 9.0
sq.km.
 This is an opencast project started in the year 2013. The Overburden Removal
Operations at the Amalgamated Opencast mine was started on 25/12/2013 and Coal
production started on 23/03/2014.
 The project has an annual capacity of producing 2.5 million tonne of Coal along with
removal of 30.6 million m3 of overburden.
 The area is covered in Survey of India Topo Sheet No. 56 N/5&56N/9 and is
bounded by latitudes North180 54’ 11” to 180 57’37” and longitudes East 790 27’ 57”
to 790 30’ 35” and is falling in Mandamarri district, Mancherial District of Telangana
state. The project is located near Doragaripalle village of Mandamarri Mandal.
 This project was opened in 2013 to extract three abondend underground mines viz.
MK-4 Incline, MK-4a Incline, RK-4 incline.
 The net extractable coal reserves are 23.34 Mt, covering an area of 2.53 Sq.Km. The
total overburden to be removed is 226.91 M.Cu.m and overall stripping ratio is 9.72
Cum per tonne.
 This project consisits of totally 11 coal seams namely IB, IA, I, LB-1, IIB, IIA, II,
LB-2, III, IV, V

24
RKPOCP DATA (History of mine)

RKP OCP Phase-I

Date of opening of the mine 25-12-2013

Life of the Project. (Years) 10 Years

Mineable Reserves. 23.34 Mt

Total Over Burden to be removed. 226.91 M.Cu.m

Average Stripping Ratio. 9.72 c 9.72 Cu. m per tonne.

Annual OB removal (2018-2019) 410LBCM

Annual target (coal) (2018-2019) 22.0 L.T.

Grade of the Coal.(2018-19) G10, G11

Gradient of the Seam. 1 in 3.10 to 1 in 4.10

Maximum strike length of the quarry along surface 2712 m.

Maximum Width of the quarry 1054 m.

Minimum depth of the Quarry 30 m.

Maximum Depth of the Quarry. 180 m.

Area of the excavation 253.42 Ha

Maximum Height of the external dump 90 m.

Total Mineable seams 11 seams

Total land requirement 637.52 Ha

TABLE 5.1: History of RKPOCP Mine

25
LAND REQUIREMENT DETAILS:
The Total land requirement for RKPOCP is 637.52 Ha and 253.42 Ha for the area of
excavation.

GEOLOGY:
Godavari Valley Coal Fields (strike length of 470 Km.) is the southernmost coal reserves
basin in the Indian sub-continent.

The continuity of coal seams in GVCF is broken covering an area of 170000 Sq. m. and
missing at places due to faulting and therefore different coal bearing areas occurring are
generally treated as different coal belt.

Somagudem -Indaram Coal belt is in the Bellampalli Region in strike forms an integral part
of Godavari Valley Coal Field and located in the northwestern end of Coalfield.

DESCRIPTION OF COAL SEAMS:

In the OC block area there are no out crops of any coal seam. Normally up to a depth of 30-
40m from surface, coal seams are represented by Clay/Carb shale.

The detailed exploration in the OC block Area has revealed the existence of 12 coal
seams/horizons. These coal seams/horizons are named as IB, IA, I, LB-1, IIB, IIA, II, LB-2,
III, IV, V and VI in descending order.

Assessment has been made for 11 seams out of 12 seams (seam-VI not assessed due its low
thickness and parting between V and VI seam is more).

Only 11 seams have attained workable thickness (i.e. >0.30 m) throughout the block while
VI seam is of local nature and having limited occurrence in the area.

It is proposed to work only IB, IA, I, LB-1, IIB, IIA, II, LB-2, III, IV and V seams through
this opencast project.

26
PARTICULARS OF THE SEAMS IN RKPOCP:

Seam/ Thickness (m)

Parting Min. Max. Usual
1B Seam 0.07 3.05 0.90
Parting 16.55 21.94 18.00
1A Seam 2.13 5.39 3.00
Parting 15.11 25.40 19.50
I Seam 0.61 5.29 2.00
Parting 5.75 10.65 8.50
LB-1Seam 0.10 2.46 0.30
Parting 28.25 33.80 33.00
II B Seam 0.45 1.30 0.60
Parting 7.77 11.88 9.00
IIA Seam 0.07 2.27 1.10
Parting 27.72 39.12 34.50
II Seam 0.61 5.49 3.00
Parting 7.93 17.68 12.00
LB-2 Seam 0.15 1.52 0.40
Parting 10.36 20.88 14.50
III Seam 0.55 3.48 1.50
Parting 5.48 16.76 8.00
IV Seam 0.30 3.96 1.50
Parting 4.57 15.40 7.50
V Seam 0.14 2.27 0.70

TABLE 5.2: Particulars of the Seams

27
FIG 5.1: MINE PLAN OF RKPOCP

28
PRODUCTION DETAILS

COAL AND OVERBURDEN PRODUCTION DETAILS

Coal Production OB Production

Financial Target Achieved Target Achieved
Year Coal Coal OB OB
(in Tons) (in Tons) (in LBCM) (in LBCM)
2013-14 10,00,000 3,30,798 39.5 39.53
2014-15 8,50,000 9,02,076 157.34 192.82
2015-16 16,00,000 8,40,538 179.25 140.20
2016-17 24,00,000 17,14,830 342.90 250.20
2018-18 24,00,000 12,76,054 347.30 301.50
2018-19 (Up to
11,60,000 7,76,170 210.00 161.77
31.10.18)

TABLE 5.3: Production Details

Men on Roll (As on 31.12.2018)

Departmental : 304

Off-loading : 706

Total : 1010

TRANSPORT SYSTEM:

The coal is being transported by 35T (BEML), 60T (CAT) dumpers and the OB was
transported by 100T CAT dumpers and 100T KOMATSU dumpers.

29
Generalized sequence of the block is as given below (bore hoe section of BH No.304):

FIG 5.2: BORE HOLE DATA

30
METHOD OF WORK:

The method of work in the proposed RKP OCP Phase-I is as described below:

In U/G developed area:

In this case, the method of mining will slightly differ from the method described above. A
layer of parting of minimum 6.0 m thick will be left over the developed seams and the
equipment will be deployed above that parting so as to prevent them from falling into the
u/g galleries.

The drilling will be done in the lower horizon by deploying the RBH drill machine. The
drilling will be done both in solid parting of 6.0 meter thick and in coal seam together.
Drilling should be done over the coal pillars and drilling over the galleries will be avoided.
Then blasting will be carried out both in OB and coal. This will help in packing the galleries
with blasted materials, which will prevent the heavy machinery from falling into the
galleries.

This method is firmed up based on the experience at Gauthamkhani OC and RG OC-III of

SCCL, where developed pillars are being extracted by opencast method.

Then a horizontal trench cut will be made by the shovel. Dozer will be used to push the OB
material of triangular patch at the top of the seam to bring it within the reach of the shovel.
This is required in order to avoid the mixing of OB and coal. After cleaning the OB above
seam roof, the shovel will be deployed on the floor of the seam in same level to extract the
coal. Here also Dozer will be used to push the blasted coal to bring it within the reach of the
shovel, as the shovel movement will be restricted by the floor of the seam.

During extraction of coal, diesel operated hydraulic backhoe will be used to facilitate
selective mining and quick withdrawal of the machine in case of eventuality. While working
in the area, where coal seams are developed, adequate safety precaution will be taken to
ensure safety of men and machinery.

Safety rules in force and regulations are followed under Mines Act 1952 at the mine.
Various precautions as laid down in DGMS circulars issued from time to time in this regard
will also be followed. The main precautions are as follows:

31
The thickness of parting over developed seam will not be reduced to less than 6 m so as to
prevent the heavy machinery from falling into the underground workings.

Holes will be drilled in the pillar and the parting is allowed to be dropped so as to fill up the
void and compacted for easy working of the heavy machinery. As far as possible, the
spacing of the holes in the last overburden bench (immediately above the developed coal
seam) will be so adjusted that the holes do not lie immediately above the underground
galleries, and to ensure that the blast holes do not blow out into the underground workings.

The depth of hole, in the last overburden bench, will be such as to leave at least 6 m of
thickness of the overburden above the coal seam and to ensure compliance with this
requirement. A pilot hole will be put for each round of blasting to determine the total
thickness of the overburden over the coal seam.

The manner of extraction of pillars is by drilling and blasting holes only in the coal pillars
from top downwards.

EXCAVATION:

It is to extract both Coal and OB with Shovel-dumper combination. Bench slope has been
designed to be at an angle of 70 degrees to the horizontal, Working benches are proposed to
have a width of 40 m and a height of 10 m. Final slope of the quarry will be maintained at
410.

The entire OB is proposed to be removed by out sourcing and Coal will be excavated
departmentally. The entry to the deposit, i.e. the main haul road is proposed near to the in-
crop of V seam at BH.No.179 towards BH. No. 34 to touch the in-crop of V-seam. Different
roads from coal bench will be connected to this road.

It has been envisaged that wherever possible, coal and OB faces will be staggered along the
strike to avoid intermixing of material. Hydraulic Backhoe has been provided to assist the
selective mining process.

Suitable numbers of dozers have been provided to minimize the mixing of OB materials so
that the dilution is kept at a minimum possible extent. V- Seam floor forms as a base for
horizon mining system.

32
The quarry has been so planned considering difficult geo-mining parameters like strike
length, steep gradient of seams and working over developed galleries/depillared panels.

For coal production, it is proposed to deploy 3 Nos. of 3.0 Cum diesel hydraulic backhoes
(DHB) along with 35T/60T coal body dumpers, deployment of 3 shovels will provide
flexibility in the event of breakdown and to account for time lost for shifting of the
equipment from one seam to another seam (eleven coal seams/horizons).

Also the shovels are required to be deployed for cleaning of debris that will be falling in to
the galleries while blasting the last OB bench (above the coal seam) and removal of
blanketed OB, used for protection against fire.

 RKPOCP mine is a captive mine of the SCCL and is working since December-2013.
 The total lease hold area is covered for an extent of 637.52 hectares out of which
202.5 hectares falls inside the forest area and balance 435.02 hectares is non forest
land.
 The mining operation was being done by shovel-dumper combination and sizing was
being done at CHP (200 mm size).
 The sized coal was dispatched to SRP CHP and RKP CHP by road through Lorries.

33
FIG 5.3: EXTRACTION BY SHOVEL DUMPER

34
 BLASTING PATTERNS:
The details of Drill Holes Pattern showing the delays which are used for control blasting, the
amount of Explosives used and the method of accessories used in coal and various benches
of Overburden.

BLASTING PATTERN FOR COAL BENCH

Drilling Pattern Explosives Companies

Depth : 6 to 7 Mtr 1.SriVishnuExplosiveLtd.

Spacing : 5 Mtr 2. Anjana Explosives Ltd

Burden : 4 Mtr 3. Solvo Explosives and Chemicals.

.

All holes to be Drilled in staggered pattern.

Amount of Explosives to be used : 6.25 Kgs in Cat ridge form

Accessories:

In line for every two holes : 50 ms delay (AP Explosives)

Line to line : 50 ms delay

Detonating fuse : SOLVO AND ANJANA Explosives,

BLASTING PATTERN FOR OB BENCH

Drilling Pattern Soft Strata Explosives Companies

Depth : 6 Mtr 1. RIPL Explosives Ltd

Spacing : 6 Mtr 2. IDL Explosives Ltd

Burden : 5 Mtr 3. Boosters: RIPL and IDL(100 grams)

35
Drilling Pattern Hard Strata Explosives Companies

Depth : 6 Mtr 1. RIPL Explosives Ltd

Spacing : 5 Mtr 2. IDL Explosives Ltd

Burden : 4 Mtr

All holes Drilled in staggered pattern.

Accessories: Nonels: Indra Excel (RIPL), Raydet (GOCL).

In line for every holes : 67 ms/400ms delay

Line to line : 42 ms delay

FIG 5.4: BLAST DESIGN OF RKPOCP

MACHINERY DETAILS Used in SCCL:

36
TABLE 5.4: MACHINERY DETAILS OF SCCL IN RKPOCP MINE

Sl.
Equipment Description Make Nos
No.

1 Dumper 35T BEML 04

2 Dumpers 60T CAT 02

3 DUMPERS 60T BEML 04

4 Dozer BEML 02

5 Shovel (3 Cu. m) L&T PC-450 Komatsu 02

6 Shovel (1.0 Cu. m) TATA HITACHI 01

7 Shovel (1.0 Cu. m) BEML 01

8 Drill 150MM Atlas copco,IDM30 01

9 Motor Grader BEML, BG605I 01

10 Mobile Service Van Ashok Leyland,1618 BSIV 01

11 Water Sprinkler HM 1035 01

12 Water Sprinkler BEML, WS28-2 01

13 Crane 10T ACE 01

14 Tyre Handler BEML,BL 14TH 01

M/s. DOTT SERVICES PRIVATE LIMITED

37
S.NO. EQUIPMENT Make Nos.

1 Dumpers 100T CAT777D 24

2 Dumpers 100T KOMATSU D785 24

3 Hyd. Excavators HITACHI 09

EX1200-5 6.5CUM

4 Hyd. Excavators HITACHI 02

Ex2500-6 -15CUM

5 Hyd. Excavators 3 cu,m HITACHI 02

6 Hyd. Excavators 3 cu,m SANY 07

7 Hyd. Excavators 3 cu,m VOLVO 02

8 Dozer KOMATSU D155A 03

9 Dozer CAT D10R 03

10 Motor Grader CAT140H 02

11 Motor Grader CAT160M 02

12 Single drum roller SANY 01

(Compactor)

13 Water Sprinkler 20KL SINO Truck 06

14 Fuel Bouzers 12KL Eicher 02

15 Light Motor Vehicles MAHINDRA 06

16 Tyre Handler BEML 01

17 Conveyance Bus Eicher 01

18 Mobile Servicing vans Eicher 02

38
 19 Tippers 16 cu.m Volvo 14

20 Tippers 16 cu.m Bharat Benz 15

21 Tippers 16 cu.m Sino 07

TABLE 5.5: MACHINERY DETAILS OF DOTT COMPANY IN RKPOCP MINE

SAFETY MEASURES:

Recommendations of safety measures to improve the stability of dumps are as follows:

 Alluvium material will be dumped separately to prevent mixing with hard rock waste
material.
 After mining of coal, a layer of crushed rock, left out crushed coal and water lies on the
de-coaled quarry floor- this heterogeneous mixture is termed here as interface material.
This interface material covering the steeply inclined quarry floor will be one of the
major causes of any internal dump failure. Before backfilling, this interface material will
be cleaned with a dozer.
 Garland drains should be provided around the external dumps to divert the flow of
water.

39
FIG 5.5: RAMAKRISHNAPUR OPENCAST MINE (from view point)

40
 CONCLUSION

To avoid collapsing of underground galleries and bogging down of men and machinery,
effective compaction of galleries will be done to extract coal from standing pillars by
opencast method and safely. Surveying is very important in Underground turned Opencast
mines. The plan submitted by the Underground mine manager should be very handy and
informatics. Surveying should be conducted with latest instruments like total stations etc.

Moreover, a strong communication must keep between each department and officials.
Proper management and effective use of resources for development pillars with a time
bound plan makes the conversion smooth and profitable. Due to increase in the energy
consumption day by day demand for coal also increasing so the conversion is essential, to
increase the productivity and conservation hand in hand.

41
REFERENCES:
1. Surface Mining Technology (S.K.Das)
2. Principles of Mine Planning (Jayanth Bhattacharya)
3. Safe Extraction of developed Pillars by open cast method : A Case study (Tikeshwar
Mahto)
4. Statutory Provisions (Mines Act 1952)
5. RKPOCP Mine Data ( Ravinder Kumar, Safety Officer of RKPOCP)
6. Transition from Open-Pit to Underground as a New Optimization Challenge in
Mining Engineering (Ezzeddin Bakhtavar)

PLACES VISITED:
RAMAKRISHNAPUR OPENCAST MINE, MANDAMMARI

42