Vocational Training Report

MIC (Longwall unit),Jhanjra Project Colliery

Submitted By-
Manish Kumar (15JE001194)
Shubham Gupta (15JE001019)
Santosh kumar Dubey (15JE001456)
4th Yr,B.Tech, Mining Engineering
IIT (ISM) Dhanbad
 Acknowledgement

First and foremost, we would like to express our deepest gratitude to our safety
officer Shri Satish Sharma for providing us with this training opportunity at
MIC,Jhanjhara Project colliery.

We would also like to extend our thanks to Mine Manager Shri Prabir Kumar
Mandal for all his help and support.

We would also like to thank all the various heads of departments for sharing their
expertise and providing us with enlightening knowledge.

Heartily thanks must go out to the canteen in-charge for providing us nutritious
meals.

Last, but certainly not least, we would like to thank all the workers for their
invaluable contributions in making this training a rousing success.

Thank you, one and all.

Manish Kumar

Shubham Gupta

Santosh Kumar Dubey

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 Contents

S.no. Topics Page no.

1. Introduction 4
2. History of Jhanjra Project Colliery 5
3. Jhanjra Block 6
4. Geology 7
5. Main Entries and Opening of the Mine 8
6. Mining Method : Longwall Mining 8
7. Equipments used in Longwall Panel 10
8. Achievements of MIC unit 14

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1. Introduction
Name of the Mine : Jhanjra Project Colliery

No of Units : 3 (Three)

Name of Units : (1) 1 & 2 Incline

(2) MIC (Main Industrial Complex)

(3) 3 & 4 Incline

Date of opening of the mine : 01/02/1982

Total Lease hold area : 783 Hectares except 3 & 4 Incline

Location

The Jhanjra Underground mine is located in north eastern part of Ranigunj Coalfield in the district of
Burdwan of the state of West Bengal.The Jhanjra project Colliery is situated about 30 km by road from
Raniganj railway station and 50 km by road from Asansol in North east and about 30 km by road from
Durgapur industrial complex in northwest direction.

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2. History of Jhanjra Project Colliery
 Feasibility report for Jhanjra Project (U/G) for 3.5 MTY was prepared in collaboration with

Soviet Experts from GIPROSHAKHT and was approved by Govt. of India in December 1982.

 The Mine was to achieve its target production by operating 9 powered supports Longwall

faces out of 12 nos sets of PSLW equipment provided.

 For development of Longwall panels 14 nos Roadheaders were envisaged.

 For initial and quick development of the mine two pairs of Inclines ( 1&2 , 3&4) were

envisaged in RVII seam in both sector A and D.The Main Incline was planned for evacuation

of the total production of all seams.

 Construction activities like Incline drivage, Mechanised Shaft sinking etc started in 1983-84.

 Some activities like Sinking of Shaft A, B, Main Incline drivage were carried out with Soviet

collaboration.

 Coal production from this mine was started from June 1985.

 Two sets of powered support were procured from Ex USSR in 1989-90.

 The First Longwall set started production from Nov 1989 in Topmost seam i.e. RVII seam

The second set was commissioned in Dec’90

 The Project faced problems in 90’s due to

 Disintegration of USSR

 Capital crunch in ECL

 Devaluation of rupees

 Thereafter Revised cost estimate (RCE) for Jhanjra Project (Ph-1) for 2 MTY

was approved in 1995 considering 4 nos Longwall sets .

 Two Russian KM-130 PSLW equipment sets were already in operation since 1989-90. Another
two nos set namely Ex-Dhemomain and Ex- Churcha were Transferred to Jhanjra Project to serve
as 3rd and 4th set at the project.

 Finally Ex Satgram set was also brought to Jhanjra in 2000 as replacement of one

of the surveyed off Russian KM-130 set.

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  Seven Roadheaders were purchased for Jhanjra and two old Road headers were brought from
Chinakuri, Dhemomain for development of Longwall panels.

 Jhanjra project (Ph-1)

1) was foreclosed in 2005 for a capacity of 1.03 MTY

 To augment
ugment the production capacity Continuous miner technology was introduced at Jhanjra
Project Colliery and started production in Sec C of RVI seam from Sept’2007.

3. Jhanjra Block
Jhanjra block covering an area of about 11.50 sq. km is surrounded by numb
number
er of faults with throws
varying from 15-110
110 m. Jhanjra block has eight extractable seams with a total reserve of about 200
million te. The block has been divided into six sectors namely Sector A. B, C, D. E and F.The present
working is confined to Sector A, C, D of RVII, RVIIA and RVI seam.

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 4. Geology
There are seven coal seams, which are as follows:

Name of Seam Depth Reserve RM Grade Degree Inclination

Seam Thicknes in m R of
s in m Gassin
ess

Total Mineable Standing

on
pillars

R VII
12.75- 5.57 54.. 1st 1 in 16 X I in 22,
Banbahal 1.5-3.5 4.54MT 1.03MT G5
210.01 MT 6 Degree S 48 Deg. E

R VII A
20.60- 8.56 1st 1 in 16 X I in 22,
Local 1.5-3.0 7.29MT 1.27MT 65.5 G5
240.28 MT Degree S 48 Deg. E

R VI Chora 30.84
53.90- 33.34 1st 1 in 16 X I in 22,
3.0-5.0 4.61MT 58.6 G4
321.80 MT MT Degree S 48 Deg. E

R V Dobrana
78.65- 45.9 1 in 16 X I in 22,
2.9-6.64 Virgin
345.70 MT S 48 Deg. E

R IV
3.75- 64.9 1 in 16 X I in 22,
Purusottampu Virgin
11.27 MT S 48 Deg. E
r

R III
Bamanbad

R II Ponihati

Mineable reserve in R-VI seam for longwall nominated property equal to 11.51 MT.

Mineable reserve in R-VI seam for continuous miner nominated property equal to 5.95 MT.

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5. Main Entries and openings of the Mine

Pit/Incl. Depth/ Gradient Dia(m) Utility

Length (m) X sec
Incline 1 120 1 in 4.5 4 x 2.6 Intake, coal transport
Incline 2 120 1 in 4.5 4 x 2.6 Intake Man, Material
Incline 3 120 1 in 4.5 4 x 2.6 Intake. Coal transport
Incline 4 120 1 in 4.5 4 x 2.6 Intake Man, Material
Transport

Air Shaft At 1&2 64 4.5 Return ventilation

Incline

Air Shaft At 3&4 28.15 4.5 Return ventilation

Incline

Main Incline 1241 M 1 in 4.7 6.5 x 3.5 Return Ventilation, coal

transport, Haulage

Shaft-A 282 (upto R 6.5 Intake Man, Material

IV seam)
Shaft-B 285 (upto R 5.5 Intake
IV seam)
Shaft-C 180.52 5.5 Intake
Shaft-D 266 (upto R 5.5 Intake for R VI
IV seam)
Shaft-E 175 (upto the 5.5 Return
roof of R V
seam)

6. Mining Method: Longwall Mining

Mechanisation of longwall system comprises of a Double Ended Ranging Drum Shearer with chock
shield supports. The shearer is mounted on afc. Behind the afc on the goaf side, the powered supports are
laid out. These powered supports are connected to afc through double rams every few meters. The
support system is fed by pressurized fluid which contains (5:95 ,oil: water emulsion) for its operation
through suitable pumping system and hoses called power pack.

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Coal cut from face by shearer is automatically loaded on AFC laid along face. The upper cutting drum of
the shearer cuts the top portion of the coal seam while lower cutting drum cuts the remaining portion of
the seam. A width of 750mm of coal slice is cut by shearer on one cut (web).

The coal from AFC goes to belt conveyor through Bridge Stage Loader. A lump breaker is installed over
the BSL to break the big lump of coals. The BSL overlaps the belt conveyor by 9 meter. As the face
retreats, the BSL is pulled by winch. The gate belt conveyor can also store about 100 m of belting by loop
take up arrangement. With these arrangements, the belt conveyor can be shortened once a week or
whenever required. The face electrical, control panels and power pack are kept on rail mounted trolleys
about 25-30 m from the face.

A high productive longwall package (1.7 million tonne per year) is being operated in R-VI seam.
Longwall retreating method is practiced in jhanjra. Each panel is consisting of one main gate and one tail
gate, each having length of approximately 1.5km which are 145m distance apart. These gate roads are
being driven by two road headers. The size of gate road is 4.8x3 m2.The cut coal is transported through
belt conveyors.

Production during development (Gate roads) = 2 x 4.8 x 3.8 x 1500 x 1.5

= 82080 Tones

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7. Equipments Used in Longwall Panel

Sl.No Description Specification Quantity

1 Electric Haulage Shearer MG650/1630- 1

GWD

2 Armoured Face Conveyor SGZ900/800 1

3 Bridge Stage Loader SZZ900/315 1

4 Crusher PCM200 1

5 Two Legged Shield Support ZY11000/26/56 80

6 Face End Shield Support ZY11000/26/56 4

7 Emulsion pump station 3 pumps & 1 tank BRW400/31.5 1

8 Spraying pump 2 pumps & 1 tank BPW315/6.3 1

9 Roadheader EBZ160 2

10 Chain conveyor SGB620/40T 2

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7.1. Electric Haulage Shearer
Shearer is used for cutting coal in from the face of longwall panel.

1. Drum diameter : 2800mm

2. Max. mining height : 5500mm

3. Dinting depth : 300mm

4. Nominal web depth : 800mm

5. Haulage speed (m/min) : 9.4-15.6

6. Total power : 1480kW

7. Rated voltage : 3300 V

8. Rated power of cutting motor: 2x650kW

9. Haulage type : Chainless

10. Control of system : Manual control in the middle electric control in the two ends

And remote control

7.2. Armored Face Conveyor

1. Length : 145m

2. Maximum transport capacity : 1800t/h

3. Line pan length : 1750mm

4. Pan width and height : 900x308mm

5. Chain speed : 1.1m/s

6. Distance between chains : 200mm

7. Distance between flight bars center 1008mm

8. Rated voltage : 3300 V

7.3. Bridge Stage Loader

1. Length : 40m

2. Maximum transport capacity : 2000t/h

3. Line pan Width : 900 mm

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 4. Type of chain tensioning : Hydraulic motor

5. Chain speed : 1.83m/s

6. Chain speed : 1.83m/s

7. Distance between chains : 200mm

8. Distance between flight bars center : 756mm

9. Rated voltage : 3300 V

7.4. Crusher
1. Installed power : 200kW

2. Maximum transport capacity : 2000t/h

3. Rated voltage of motor : 1100V

4. Rated power of motor : 200kW

5. Number of impact heads : 8

6. Impact speed of hammer : 22m/s

7. Rotational speed of crusher shaft : 408r/min

7.5. 2 Legged Shield Support

1. Support height range : 2600 ~ 5600mm

2. Support center distance : 1750mm

3. Support width range : 1650~1850mm

4. Support yield load @ 43.8Mpa : 11000kN

5. Setting load @ 31.5Mpa : 7916kN

6. Legs : 2

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7. Leg Type : Double telescopic

8. Stroke : 2945mm

9. Operation mode : Manual control

7.6. Road Header

Max. Cutting height : 4.8m

Max. Cutting width : 5.0m

Climbing capacity : ±18°

Speed of travel : 0 ~ 8m/min

Overall dimension : 9300x2300x1670mm (LxWxH)

Rated voltage : 1100V

7.7.Chain Conveyor
1. Designed length : 100m

2. Conveying capacity : 150t/h

3. Chain speed : 0.86m/s

4. Motor power : 40kW

5. Power supply voltage : 550V

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8. Achievments of MIC unit
Jhanjra team has successfully overcome many challenges like
o Fire at Longwall Panel

o Working at shallow depth ( about 30 m) by Longwall technology

o Changing to Indigenous valve system of Longwall supports when the

imported system failed

o Caving problem in Continuous Miner District was overcome by

 blasting of deep holes at a depth of 110 meters from the surface

 and about 50 meters hydrostatic pressure first time in Indian coal

 mine history

o Recently successful controlling of fire at 23Dip section with the help of CIMFR

scientists.

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