Content

1. Introduction
1.1 Lignite Legend
1.2 Salient Features Of Mine
1.3 Unique Features Of Nlc
2.0 Geology
2.1 Quality Of Lignite
2.2 Mineral Contain
3.0 Survey
3.1 Location
3.2 Total Station
3.2.1 Fundamental Elements
4.0 Drilling And Blasting
4.1 Drilling
4.1.1 Specification
4.2 Blasting
4.2.1 Specification
4.2.2 Procedure
5.0 Methodology
5.1 Details Of Mine Operation
5.1.1 Production Of Different Units Of Nlc
5.1.2 Power Generation
5.1.3 Number Of Benches In Mines
5.2 Benches
5.2.1 New Surface Bench
5.2.2 Top Bench
5.2.3 Middle Bench
5.2.4 Bottom Bench
5.2.5 Lignite Bench
6.0 Machinery
6.1 Bucket Wheel Excavator
6.1.1 Limitation
6.1.2 Full Block Method
6.1.3 Lateral Block Method
6.1.4 Specialized Mining Equipment’s

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6.2 Conveyer Belt
6.3 Track Shifting
7.0 Hydrology Of Neyveli
7.1 Recharge Area
7.2 Unconfined Aquifers
7.3 Semi-Confined Aquifers
7.4 Confined Aquifer
7.5 Hydrology Problems

7.6 Control of ground water pressure

7.6.1 Site location for drilling
7.6.2 Pressure control
7.7 Drilling a pump well
7.7.1 Well construction and developments
7.7.2 Pump erection and power supply
7.7.3 Pumping operation
8.0 Pollution
9.0 Conclusion

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1. Introduction
Neyveli Lignite Corporation limited (NLC) is a government owned lignite mining and
power production company in India. Neyveli is situated in Cuddalore district in Tamil
Nadu about 200kms south of Chennai. Existence of lignite in this area is known since
1870. In 1956 NLC was formed as the corporate body. NLC operates the largest open
pit lignite Mines in India, presently mining 28.5 MT of lignite in Neyveli (10.5 MT
from Mine-I, 15 MT from Mine-II and 3 MT from Mine-IA) and 2.1 MT in Rajasthan
and has installed capacity of 2740MWin Neyveli (600MW from TPSI, 420 MW from
TPSI Exp., 1470MW from TPSII in Neyveli) and 250 MW from Barsingsar, Rajasthan
of electricity. On April 11, 2011 it joined the elite group of Navratna companies.

The major problems faced by the lignite Mines in Neyveli is firstly due to the confined
aquifers which when left untreated due to the high pressure exerted by the aquifers
may flood the whole Mines up to +30m and secondly hydrological problem is due to
rain.

This exploration was followed by a detailed survey by the Geological Survey of India
in 1943. In 1956 government of India formed Neyveli Corporation limited for
commercial exploitation of lignite for generation of electricity. The project was
inaugurated by Pandit Jawaharlal Nehru in 1957.

1.1 THE LIGNITE LEGEND OF TAMIL NADU

A CHRONOLOGY

It is a long history with lots of efforts behind the birth of baby of Coal family, the fossil
fuel, "LIGNITE" arrival in the coal starved Southern region of India. The following is the
gist of events that took place in the legend of Tamil Nadu before the formation of
Neyveli Lignite Corporation as a Corporate body.

Table:- 1.1 showing the chronology of NLC

Year Chronology of events
Occurrence of "PEAT" a low calorific fuel of coal family near point
1828 claymore is reported to the then Madras Government, by the sub-collector of
Thanjavur Mr. Nelson
General Cullen discovers lignite deposits at the base of the cliffs on the Sea-
1830 shore near Cannanore - Later near varkala near Quilon and also at Vaikom
in Kerala
Captain New bold discovers Lignite at the foot of the cliffs of laterite on the
1840
river banks near Beypore.

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 Peat bogs found in Nilgris (Peat is considered to be the first stage in the
1870
formation of Coal from vegetable matter accumulating in swamps)
Mr. W. King of the Geological survey of India takes up a study of artesian
1877
wells around Pondicherry. He comes across a carbonaceous strata.
Mr.Poilay a French Engineer encounters a Lignite seam in a bore hole at
Bahoor, the then French territory. Further exploration along the belt
1884 indicates possible Lignite deposits at Udharamanickam, Aranganur and
Kanniarkoil, near Cuddalore. Lignite deposits are indicated at Kasargod and
the Collector of South Kanara reports kit to the board of Revenue
Industries Department of the then Government of Madras drills bore holes
for tapping artesian water in the neighbour hood of Neyveli. Lignite particles
1934
encountered are taken as "black - clay" by unlettered workmen engaged in
drilling.
Borewells sunk in Jambulinga Mudaliyar's land in Neyveli and the Black
1935 particles gushing forth attract the attention of camping Geologists engaged
in some other mission in the Neyveli Vriddhachalam area.
Samples of the black substance taken from the above form well sent to the
1937-38
Government of Madras for analysis.
M/s. Binny & Co., Madras put down four or five bore holes at Aziz Nagar,
1941 near Neyveli. Two of them show evidence of Lignite deposits; but for want
of casing pipes and drilling equipment, further work is given up.
The Geological Survey of India starts drilling operations near Neyveli.
1943-46 Preliminary investigations indicate the existence of Lignite to the extent of
about 500 tonnes in that area.
Mr.H.K.Ghose, Geologist and Mining Engineer deputed by the Government
1947
of India arrives in Neyveli and starts his operations
The first bore holes sunk by Mr. Ghose have to be abandoned because of
1948 water logging and sand - beds. The third one "September 1951" yields
samples of Lignite
Mr. Ghose draws experimental open cut plan and calls for tenders to start
1949
excavation.
Sinking 175 bore wells in a cluster punctuating the chosen area, Mr. Ghose
proves the existence of about 2000 Million tonnes of Lignite reserves in the
area. State Government's Industries and Commerce Department also sinks
over 150 bore wells South of Vriddhachalam Mr. Paul Eyrich, a Mining
1951 Engineer is deputed by the Bureau of Mines, United States of America, to
assist the Government of Madras under point four programme to determine
the Engineering and Economic aspects of Lignite Mining in Neyveli. Upon
his recommendation, the US Government sponsors a study on the subject
under the direction of Mr. V.F.Parry.
The High Power Committee for Lignite Mining recommends the Pilot
1952
Quarry project.
Pilot Quarry being commissioned by Dr. U. KrishnaRao, Minister for
1953
Industries, Madras Government.

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 Pandit Nehru's Visit to the Pilot Quarry. Government of India's Committee
comprising Mr. C.V. Narasimhan, ICS Mr. A.C. Guha and Mr. A. Lahiri
1954 inspect the Pilot Quarry and submit a report to the Government Under the
Colombo Plan, Services of the UK firm PDTS (M/s. Powell Duffryn
Technical Services Limited) are availed of for a Project report.
Neyveli Lignite project's affairs, hitherto managed by the State Government,
get passed on to the Central Government with full Financial responsibility.
1955
Mr. T.M.S. Mani, ICS, Secretary, Department of Industries, Labour and Co-
operation, takes over as the Chief Executive of the project.
Formation of NLC as a Corporate body. NLC is born as a Government
1956
sponsored commercial concern.

Table:-1.2 Silent features of mine-I, NLC

PARTICULARS UNIT MINE-I
Mining area Sq.km. 36.354
Capacity/Annum MT 10.5
Lignite reserve MT 466.32
OB thickness Mts. 45 to 110
Lignite thickness Mts. 8 to 26
Average stripping ratio Tons :M3 1:5.5
Mining started on Date 20.05.1957
Lignite first exposed on Date 24.08.1961
Overburden excavated for 2014-15 MM3 57.043
Overburden excavated up to 31.03.15 MM3 1800.49
Lignite mined for 2014-15 MT 9.05
Lignite mined up to 31.03.2015 MT 324.94
Balance reserve as on 01.04.2015 MT 141.38
Area mined out up to 31.03.2015 hectares 2057.83
Area reclaimed up to 31.03.2015 hectares 1537.23
Area afforested up to 31.03.2015 Hectares 1426.63
Trees planted during 2014-15 Nos. 10,100
Tress planted up to 31.03.2015 Nos. 70,60,624
Linked power station Name TPS-I(600 MW) &TPS-I
expn. (2x210MW)
Generation capacity MW 1020

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 1.3 UNIQUE FEATURES OF NEYVELI LIGNITE MINES

A. Occurrence of Ground Water Aquifer below lignite Bed:

A huge reservoir of ground water occurs below the entire lignite bed, exerting an
upward pressure of 6 to 8 kg/cm2. Unless this water pressure is reduced before mining, it
will burst the lignite seam and flood the Mines. This problem was overcome by
continuously pumping out water round the clock through bore wells located at
predetermined points and thereby reducing the water pressure at the lignite excavation
area. Over the years, through continuous study and implementation of new methods, the
quantity of water pumped out has been reduced from 50,000 GPM to 32,000 GPM. (For
mining one ton of lignite, about 13 tonnes of water has to be pumped out). The water
level is continuously monitored through observation wells for

B. Higher Ratio of Overburden to Lignite:

The overburden to lignite ratio at Neyveli Mine-I is 5.5 to 5 M3 1 ton. This requires
huge quantity of overburden to be removed (11 T. of overburden is to be removed for
mining 1 ton of lignite). High capacity excavators are used for handling large volume of
overburden, after forward preparation.

C. Hard overburden strata:

The highly consolidated overburden stratum consists mainly of Cuddalore
sandstone and is hard and abrasive in nature. This problem was overcome by carrying
out suitable modifications in the bucket wheel teeth and by instituting a systematic
drilling and blasting programme.

D. Cyclonic area:
The Mine is located in a predominantly monsoon and cyclonic area. The average
rainfall in a year comes to about 1200 mm and the wind velocity goes upto 160 KM per
hour. Every year, an Action Plan for monsoon is prepared well in advance in detail.

2. GEOLOGY:
Neyveli is located at 11.533° N- 79.48° E and has Panruti as Taluk headquarters. The area is gentle
terrain having upland in the west and gently sloping in the east towards Bay of Bengal, which is
40Kms east of the lignite mining area. The average rainfall per annum in this area is around
1200mm. Two seasonal rivers are running over this lignite fields. The maximum ground elevation
of +100m exists in the uplands west of mining area whereas at the mining area (MINE-I) it is
between 60m to 45m
The geological exploration of the region was carried out during 1942-1953. Lignite is spread
over an area 487sq.Km. The Neyveli mine-I area in the tertiary formation of cuddalore comprising
argillaceous sandstone, pebble bearing sandstones, ferruginous sandstones, grids and clay. The
lignite doesn’t consist of any folds and faults. The dip is 1 in 100.

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Fig :-2.0 geological exploration

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The coal/lignite seams form in two different ways and are perceived by theories that explain the
processes. One is insitue theory and other one is drift theory. The lignite in mine-1 is of drift theory.
The thickness of the lignite at mine-1 varies from 6m to 28m and the average thickness of lignite is
about 15m. The upward thrust on the ground is about 12-15kg.

2.1. The lignite is a mixture of different components.

> Moisture content : 50-55%.
> Volatile matter : 20-25%.
> Fixed carbon : 18-22%.
> Ash content : 3-5%.
The densities of:
> Over burden : 1.7-2.2kg/cu.m
> Lignite : 1.15kg/cu.m

2.2 MINERAL CONTAINS:

Lignite contains 65-70% of carbon, 20-25% of oxygen, about 5% of hydrogen and small amounts of
Nitrogen and Sulphur. The average Calorific value of lignite is 2600 Kcal/Kg. It cannot be
compared favourably with the high Calorific value of pure Coal. Yet lignite has an advantage of
being free burning (non- coking), having low ash and giving rapid and complete combustion.
Since the volatile matter is usually high, lignite burns readily. Air dried lignite is quite suitable for
direct burning. For high capacity boilers, lignite can be burnt in the pulverized form.

Fig:- 2.2.a showing sample of lignite

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Fig:-2.2.b Geology of Neyveli

3.0. Survey

Fig:- 3.0. Lignite Mine blocks in Neyveli area.

3.1. Location
Neyveli is situated in the cuddalore district of Tamil nadu about 200km
south of Chennai.
The mines IA is located in the northern party of neyveli lignite field over on area 39
sq.km (the mine I & IA covered about of 24.69 sq.kms) the mine fall between
11 33֯ and 11 35֯Longitude. The mineable reserves of lignite is estimated to be 485MT
out of which the reserves under mines I and IA is reported to be 365MT

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Mine surveying that focuses on the exploration of mineral wealth that are of economic
importance. Surveying in mining region commonly involved liner measurement, angular
measurement, elevation etc.
Mine-I, at neyveli is equipped with advanced instruments that can measure the above
mention parameters with high accuracy.

3.2 Total station

Fig: 3.2 showing the construction of robotic total station

For many years, the optical transit was the surveyor’s tool of choice to layout property
lines and building sites. By the 1970s, however, the electronic theodolite began to
Replace the transit since it could measure angles more accurately on both the horizontal
and vertical axes. In the early 1980s, “total stations,” which measure distances very
accurately by using electronic distance meters (EDMs), became the instrument of
choice. Then in late 1990, Geodimetric, Dandryd Sweden introduced the first “robotic
total station, “adding automatic tracking and radio communication to a radio and data
collector at the “target” or pole. Thus, for the first time, no person was required
At the instrument only at the target, reducing the size of a survey crew.

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Today three companies manufacture robotic total stations, Trimble (now the owner of
Geodimetric, although it no longer uses that name), Leica, and Topcon. Once a tool for
surveyors only, robotic total stations are currently being purchased and used in
numerous ways by contractors—especially concrete contractors. One large
contractor/construction company owns more than 75 Robotic total stations.

3.2.1 The fundamental elements

Each manufacturer of robotic total stations has its own features and benefits, but the
basic elements are all the same. All robotic total stations are servo-motor-driven and
measure angles both in the X-Y (horizontal) plane and the Z (Elevation) axis. These
measurements are very precise and accurate: most instruments measure 3 seconds of
accuracy or Less (5-second instruments are typically required for construction
purposes).Each total station has an electronic Distance meter (EDM). Through either
laser technology or infrared sensors, it can precisely measure the distance from
The instrument to the target within millimeter accuracy. Precision tolerances of 1/1 0 0
foot (less than 1/1 6 inch) in 1000 Feet are typical. Every system uses a target, which
has a prism to reflect light back to the instrument for measurement, and an electronic
data collector, which communicates with the instrument through radio communication
also known as telemetry.
By using servomotors, prisms, and infrared technology, robotic total stations search for,
and then lock onto, the target, automatically following it as the layout person moves it
around a jobsite. At the same time, the data collector built into the target is being
updated with information radioed from the instrument.
All manufacturers provide computer software to download and upload coordinate
information. This information can come from computer aided drafting (CAD) files
downloaded from office computers, PCMCIA card s (flash cards similar to those used
for digital cameras), ASCII files, or coordinate points manually entered into the
instrument.

4.0. Drilling and blasting

The overburden benches were excavated after drilling and blasting with the help of
bucket wheel excavator. About 70% overburden was blasted using high explosives.

For blasting of overburden benches, blast holes were drilled with the help of drilling
machines (ingersoll rand and revathi engineering limited). For blasting the overburden,
mines were using high explosives supplied by

1. M/s tamil nadu Explosives limited

2. M/s Sri krishna Explosives Accessories company, tirupathi.
3. M/s sua Explosives, Bangalore.
4. M/s keltech Energies, bangalore.
5. M/s Raja Explosives, Erode.

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The lignite seam in neyveli is deposited at a depth of 80-120mts from the surface. In
order to extract it, many methods are to be followed, one of them being drilling and
blasting. It is one of the important division of mining. This department holds both
drilling ( using is INGERSOLL RAND machines) and blasting ( using SME). Five
benches have been created in order to reach the seam namely new surface benche, top
bench, middle bench, bottom bench and lignite bench. With the help of machines, the
soil in all the benches is fragmented. The crushing strenght of these machines is usually
about 50Kgf. Drilling and blasting operations are done only on the top three benches. (
O/B benches). Since the crushing strength required to disintegrated the soil in these
three benches is more than 50kgf.

Drilling
At neyveli mines, for drilling of the blast holes, rotary cum straight circulation method
of drilling with electric current is employed. The equipment utilized for this purpose is
named INGERSOLL RAND, manufactured by RITA machinaries private.Ltd. The
drilling is done in an 8*8 pattern, where the spacing of the blast holes is 8mts and the
burden (distance between two rows is 8mts. The depth of the hole depends upon the
height of the bench.

More the height of the bench more is the depth of the hole, with the depth being kept 3-
4mts short of the height of the bench.

4.1.1 SPECIFICATIONS:
 Diameter of the blast hole: 200mm
 Depth of the blast hole: 21 m
 Height of the bench: 25m
 Method of drilling: straight circulation(rotary)
The flushing in the holes is done by the use of compressed air. The drill rod consists
of flushing holes with diameter 5mm through which the compressed air of high pressure
enters into the hole. When the drilling begins, a corresponding action of flushing out the
material from the hole takes place, thus enabling perfect clearance.

4.1.2 EQUIPMENT SPECIFICATIONS:

The equipment is of electrically operated crawler-mounted type.

 Capacity of the motor : 400HP

 Rod length : 7m
 Diameter of the rod : 200mm
 Compressor capacity : 34m3 at 75kg/sq.cm pressure
 Total number of rods in the tower : 4 rods + 1 sub rod

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  Speed of drill rod : 100rpm
 Track speed : 1.47kmph
 Rotation pressure : 500kg/sq.cm

4.2 BLASTING
Neyveli area consists of Cuddalore formations. It is argillaceous sandstone.
Though it is of loss strata, for the convenience of excavation by BWE, blasting
operations are practiced. The main purpose of the blasting is to loosen the strata.

4.2.1 SPECIFICATION OF BLASTING:

 Diameter of the hole : 200mm
 Spacing : 8m
 Explosive used : site Mixed Emulsion (SME)
 Charging column : 8-9m
 Stemming column : 11-12m
 Booster : 250gm and length of 56.5mm
 Nonel : 25m length
 Detonating fuse : PETN coated with red colour plastic.
 Cord relay : 50ms
 Electrical detonator
 Battery condenser exploder.

4.2.2 PROCEDURE:
Cartridges are tied with one or two (if needed) down lines of 10gm/m detonating
fuse to ensure suspension along the axis of holes without the risk of breakage of cord.

First the boosters are dropped down the blast holes and then the holes are
charged with explosives, above which stemming is done. The blasting fuses (NONEL)
connected to the boosters at each hole, are extended and linked to the exploder with the
help of intermediate lines such as trunk line and main line. Finally, shot firing of the
holes takes place.

The machinery used for the preparation of site Mixed Emulsion is named 1356
C/F that has two separate containers, each filled with Ammonium Nitrate and Gas Agent
respectively, the gas agent usually being sodium nitrate.

The capacity of the truck is about 7.5 tons.

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5.0 Methodology:
The lignite deposit in the Neyveli lignite field forms a part of Cauvery basin. A thick
formation of upper cretaceous, tertiary and sub-recent sedimentary rocks, both marine
and fresh water are overlying the Archean basement. A huge reservoir of artesian
aquifer water occurs below the entire lignite bed, exerting an upward pressure of 5 to 8
Kg/cm2. Unless the water pressure is reduced before mining, it will burst the lignite
seam and flood the mines. This problem is solved by selective formation of bore wells
and pumping to depressurize the water pressure to safe mining condition. The water
pumped out is being used in thermal power station.

5.1 Details of mine operation

5.1.1 Production of different units of NLC are

Unit production target lignite MT/A

Mines-I 10.5
Mines-IA 3.0
Mines-II 10.5
Mine-II(Exp) 4.5
Barsingsagar mines 2.1
(rajasthan)

5.1.2 The lignite is supplied to thermal power station to

Produce target power generation
(6X50)+(3X.100)MW-TPS-I 600Mw
(2X210)Mw-TPS-IIExp 420Mw
TPS-II.(7X210)MwTPS-II 1470Mw
(2X250)MwTPS-IIEXP 500Mw

5.2 Number of benches in the mines.

Mine –IA
New surface bench
Surface bench
Top bench
Middle bench
Lignite bench
Bottom bench

LIGNITE MINING:

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NLC Mines constitute a notable pillar of foundation for building the edifice of an
economically strong India with the installed capacity of lignite to meet the requirement
of its thermal power stations. Neyveli Lignite field (Tamil Nadu& Puducherry) is
endowed with a geological reserve of 8249.32 million tons of lignite (as on 01.04.2014
report).
Lignite is mined by open cast mining by the method of benching. Each bench is of about
20m height contains soft rocks which are excavated by Bucket wheel excavator (BWE).
This overburden soft rock is excavated and taken to the dump yard through conveyor
belts. The dump yard is always present on the opposite side of the advancing mine.
Once the lignite bench is exposed, using the BWE’s lignite is also mined out and taken
to the stock yard using the conveyor belts. From the stock yard, lignite is being used for
power production.

5.2 BENCHES:

5.2.1 NEW SURFACE BENCH

In Neyveli for the extraction of lignite five benches has been created namely new
surface bench, Top bench, Middle bench, Bottom bench and Lignite bench.New surface
bench, it is the top most bench with the height of 25meters and width of 80 meters. At
the sight two bucket wheel excavator has been employed for cutting the ore burden
(soil) and one spreader is used to spread the loose soil at dumping site.

Fig:- 5.2 view of new surface bench, top bench, middle bench, bottom bench

The machines are ordinary bucket wheel excavator (namely 1440) and bridge type
bucket wheel excavator 1447 respectively. Each bucket wheel excavator has a dozer and
a mobile crane. The dozer been used for levelling the surface of the bench and to pull
the equipment's that can't be handled manually and the mobile crane for lifting heavy
equipment's. Each machine is operated by 10 members and 2 drivers including mines

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incharge officer and mechanical incharge officer. The mines at Neyveli are fully
mechanized mines hence manually work force demand is less.

The soil present required crushing strength of 100kgf.The soil is hence loosened by
drilling and blasting operation and the strength is brought down to 50kgf, and then the
machinery whose crushing strength is above 50kgf performs the crushing operation. It
consists of soil and as well as sand stone, whose percentage is less in quantity and is
roughly above 20%.
The cutting of the soil is carried out by bucket wheel excavator and transported through
the belt conveyor to the spreader. The spreader is spread the ore burden (soil) at the
dumping site. The distance from bucket wheel excavator to the spreader is 7km.
There are about seven conveyors at mine-1 from NSB-1 to NSB-7. At each conveyor
station there is a drive head with motor capacity of 750kva and rpm of 1400 and the
speed of conveyor is 2.4m/min. The length of the conveyor between two consecutive
stations is about 1000m, there are 4labors for maintenance at each conveyor station per
shift, the tensioning arrangement is provided at conveyor station.

5.2.2 TOP BENCH

Top bench is next to the new surface bench, with a height of 25m and width of 80 to
100m
On the top bench there will be bucket wheel excavator to excavate the soil. The bucket

wheel excavator is 1355. For levelling the surface bench there will be dozer and mobile
crane. Mobile crane is used for lifting the heavy equipment's. Each machine is operated
by a working force of 10 member's and 2 drivers including the incharge officer.
The composition of the bench comprises of soil and sandstone, which requires a
crushing strength of 100kgf. The soil is hence blasted by drilling and blasting operation

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and brought down to 50kgf and then the machinery whose crushing strength is about
50kgfperfomls the crushing operation The cutting of the soil is done by the bucket
wheel excavator and transport through the belt conveyor and through the spreaders. The
distance from the bucket wheel excavator to the spreader is about 7 to 8 kms. There are
about 6 conveyor stations at mine-I from TB-I to TB-6. At each conveyor station there
will be a driver head with a motor capacity of 750KVA and speed of 2.4km/min. The
length of the conveyor between two consecutive stations is about 1000mts.

5.2c MIDDLE BENCH

The middle bench is all most same as the top bench except that the material of the soil is
different and length of the conveyor belt is less. There are total of 5 numbers of stations
from MB1 to MB5 with distance between each of the station being 900m. The height of
the bench is about2Om and the width is about80m, the hardness of the soil is about
75kgf.

5.2d BOTTOM BENCH

Bottom bench is the top most bench of the lignite bench. The height of the bench is
about 20m and the width is about 60m. Composition of the soil comprises chiefly of
white clay. The hardness of the soil is less than50. Only about one bucket wheel
excavator is used for braking of soil and three conveyor stations are provided. For
transportation a dozer and a mobile crane (particularly used for lifting of heavy
machinery equipment's) is used. There is no drilling operation carried out in the bottom
bench, which differentiates it from other benches. The ground stability is less due to the
ground water pressure and hence the soil has clay like quality. The capacity of the motor
(conveyor) is about 750Icva. The speed of the conveyor is 2.41unimin. The width of the
conveyor is 2m.

5.2e LIGNITE BENCH

In Neyveli, we can find two lignite seams divided into Top lignite bench and
Bottom lignite Bench for easy excavation of lignite. The Top lignite bench is having
deposits of lignite at a thickness of 6 to 28mts and the average thickness of it is about
15mts. The bottom Lignite bench is having a thickness of about 3-8mts and the average
thickness is about 5mts. Among all the benches the lignite bench is the fifth bench.
Although the bench is dominated by lignite in terms of quantity there is a considerable
presence of Soil up to some thickness .hence the bench is not uniformly thickened. It is
thus, divided into lignite TOP bench and lignite Bottom bench.

The height of the lignite Top bench ranges between 5 to l8mts,whereas the height of the
Lignite Bottom bench, comparatively less, is about 5mts.Between these two layers, a
fair amount of clay is deposited whose thickness is about 3 to Snits _Aquifer sand,
which has great economic importance is deposited below lignite Bottom bench. The
lignite in both top and bottom benches, is excavated by the Bucket Wheel Excavator,
with capacity of each bucket being 700litres.The obtained lignite is transported directly
to the Thermal power station.

There are two modes of transportation of lignite from the excavation site to the
conveyor. One is Bridge type conveyor and the other is Dumper. The Bridge type

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conveyor is adopted when the occurrence of lignite is continuous, whereas the dumpers
are adopted when the lignite occurrence is in patches. There are about 6 to 7 dumpers,
each with capacity of about 35tones.The excavated lignite is modes of transportation.
After crushing the lignite to desired size, it is transported to the Thermal power plant
with the help of the conveyor belt system and this system only. During the first year
production (1961) the total amount of lignite. Produced was about 3 MT. And since
then, the production of lignite per year is about 7 to 10.5MT and per day production are
about 3000 to4000tones.

6. Machinery
6.1 Bucket Wheel Excavator

Fig: - 6.1.a 3d graphical view of BWE.

BWE is suited for mining large outputs in weak unconsolidated ground. BWE is fitted
with evenly spaced buckets on the periphery of the wheel. Excavated material is fed via
a transfer point inside the wheel (e.g., a rotating disc) to the belt conveyor system of the
excavator for discharge.

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Bucket wheel excavators (BWE)

Originally designed for relatively easy digging materials (gravel, sand, loam, marl,
clays, and lignites), BWEs can now dig in relatively hard material.
The machine digs out the material using a large wheel with buckets that revolve as the
wheel turns.
The teeth on the individual buckets break out the material from the ground.
BWEs are most often attached to a conveyor network where waste material is sent to a
spreader or to an ore stockpile. BWE can mine both thin OB and deeper OB conditions
where single bucket (dragline) is suitable.

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6.1.1 Limitations of BWE technology

• Hard consolidated materials, large boulders or blocky material cannot be

handled.
• Sticky material build up in buckets and can gum up the conveyor (although, with
modern systems, sticky material can be handled);

• Abrasive material produces excessive wear on the teeth.

• Very limited flexibility (can be flexible in certain geological and equipment

situations).

• High capital costs but may be the most economical method of mining weak flat
tabular deposits.

• Must be a matched system linking BWE, conveyor, belt system and spreaders.

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Fig:-6.1.b showing the cutting unit of BWE

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Fig:- 6.1.c showing the type of cut using BWE.

Fig:-6.1.d Full block Method

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Fig:- 6.1.d Lateral block method

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 Fig:- 6.1.e View of Excavation Benches with BWE

6.1.4 The following Specialized Mining Equipment’s are working in

MINE-1
Fig: - 6.1 specialized equipment’s in mine-1

Sl. NLC
Date of
No MACHINE TYPE CAPACITY MAKE
Commission
. No.
EXCAVATING EQUIPMENTS
1 1447 BWE 1400 L 10.06.2000 M/S KRUPPS FORDERTECHNIK
2 1448 BWE 1400 L 10.07.2000 M/S KRUPPS FORDERTECHNIK

FLOAT
3 1440 1400 L 31.05.1997 M/S O & K , GERMANY
BWE

4 1355 BWE 1400 L 28.08.1978 M/S O & K , GERMANY

5 1356 BWE 1400 L 01.05.1979 M/S O & K , GERMANY
6 1357 BWE 1400 L 28.12.1979 M/S O & K , GERMANY
7 1145 BWE 700 L 19.05.1961 M/S L.M.G , GERMANY
8 1144 BWE 700 L 18.10.1960 M/S L.M.G , GERMANY
9 1574 BWE 700 L 05.05.1989 M/S BUKAU WOLF GERMANY
10 1573 BWE 700 L 13.10.1990 M/S BUKAU WOLF GERMANY
11 1029 BWE 700 L 25.07.2014 M/s. MBE
12 147 BWE 700 L 01.12.1983 M/S BUKAU WOLF GERMANY
M/s.THYSEEN
13 1649 BWE 700 L 05.01.2009
KRUPP,GERMANY
14 1232 BWE 500 L 12.09.1969 M/S KRUPP, GERMANY
15 1142 BWE 350 L 04.01.1960 M/S KRUPP, GERMANY
BRIDGING EQUIPMENTS
1 1541 MTC 11,000 T/Hr. 01.12.1986 M/S BUKAU WOLF GERMANY

2 405 MTC 11,000 T/Hr. 16.11.1978 M/S GARDENREACH – INDIA

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3 406 MTC 11,000 T/Hr. 03.08.1979 M/S GARDENREACH – INDIA
4 17 MTC 4420m3/Hr 10.05.2004 L&T
5 19 MTC 4420m3/Hr 14.06.2004 L&T

SPREADING EQUIPMENTS
1 MAN III SPR 20,000 T/Hr. 15.06.2000 MAN TAKRAFFF GERMANY
2 429 SPR 11,000 T/Hr. 08.09.1978 M/S BUKAU WOLF GERMANY
3 430 SPR 11,000 T/Hr. 11.04.1979 M/S BUKAU WOLF GERMANY
4 431 SPR 11,000 T/Hr. 15.09.1979 M/S BUKAU WOLF GERMANY
5 117 SPR 11,000 T/Hr. 31.08.2007 MAN TAKRAFFF GERMANY
6 213 SPR 4,700 T/Hr. 31.03.1962 M/S L.M.G , GERMANY
TRIPPER EQUIPMENTS
M/S THYSSEN KRUPP,
1 245 TPR 11,000 T/Hr. 27.05.2009
GERMANY
M/S THYSSEN KRUPP,
2 232 TPR 11,000 T/Hr. 02.06.2000
GERMANY
3 144 TPR 11,000 T/Hr. 01.10.1978 WESPRKUTE & ELECON
4 145 TPR 11,000 T/Hr. 01.06.1979 WESPRKUTE & ELECON
5 146 TPR 11,000 T/Hr. 25.04.1980 WESPRKUTE & ELECON

LIGNITE HANDLING EQUIPMENT

1 341 B.C.E 400 L 17.11.1967 M/S BUKAU WOLF GERMANY

New METSO MINERALS PVT.LTD.,
2 4,000 T/Hr. 20.06.2005
Stacker MUMBAI
METSO MINERALS PVT.LTD.,
3 Reclamier 2,000 T/Hr. 22.06.2005
MUMBAI

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6.2 CONVEYOR BELTS:

Fig:- 6.2.a conveyor belt loaded with lignite

Initially from 1959 to 1965 about 8 km of belt conveyor of 1000mm for lignite handling
(1000 TPH) and 1200mm (2500 TPH) wide belt conveyors for OB handling were in
operation. In the initial stages the conveyor carrying capacity was just matching with the
carrying capacity of the loading equipment. While using smaller width conveyor the
conveyor were designed to capacity that matched with equipment’s. The Bucket wheel
excavator at times due to lose strata condition used to deliver spurt loads which will be
more than the excavator capacity. When these load were transmitted to the belt
conveyor, there were stoppages due to overload, overflowing, choking of transfer points
etc. The above natures of stoppages lead to snapping of belts, burning of motors, and
also needs manual cleaning of the loaded belt to the entire stretch. Trouble shooting and
resetting of the electric contactor relay were time consuming. Due to overload the high
resistance fuse used flown off very frequently. Later the conveyor carrying capacity/
handling capacity has been designed at 25 to30% more than the capacity of the loading
equipment’s. There by the choking of transfer points and tripping due to overload has
been avoided. More over the running of the conveyor has become smooth. As the
strength of the conveyor belt is more and designed to carry 30% more than the loading
equipment capacity, the belt snaps / joint failures are eliminated. The belt joints were
snapped/ failed frequently since this system of power transmission from motor to belt
was normal gear transmission. As the drive power of the conveyor increased and fluid
coupling, slip-ring transmission etc., were introduced to transmit the motor power to
belt, there is smooth transmission of power and no belt joint snaps etc. The carrying and
return idlers were of fixed type and if any small misalignment of the conveyor / frames
causes the line out of the conveyor belt and there by damaging of the costly belt and
causing more stoppage for changing of the belt in premature damage. The installation of
suspended garland type idlers during 1980s (self-aligned idlers) instead of fixed idlers
was one of the major modification / break through development with belt conveyor

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system design. These idlers have an in built tendency to make the belt run centrally.
Thereby belt edge damaging is totally eliminated. Moreover the garland idlers station
(or) transfer points. The toughing angles also got standardized and for conveyor of 1500
mm the toughing angle is 30o and for 1800 mm and 2000 mm conveyors the toughing
angle is got fixed as 40o. Further all the fabric belts have been removed and only steel
cord belts have been introduced as given in Table-5. Initially NLC used 1000mm,
1200mm width fabric belts. Since their tensile strength is low each of the conveyors has
been laid for a length of 300 to 400 m. Due to short length of the conveyors the life of
the belt was only10000 hours which warranted frequent replacement of the belt. In
1970s 1500 mm overburden conveyor belts were changed to nylon x nylon with a drive
power of 4 x75 kW with fluid couplings. However in this case also conveyor length is
restricted to 75 kW motors by which the conveyor lengths gone up to 500 to 550 m
only. In late 1970s, 1800 mm wide steel cord conveyor belts were introduced with a
drive power of 3 x 400 kw were extended up to 1.2 km with a carrying capacity of 8000
tph. I 1980s fabric and nylon belts were removed and steel cord belts were introduced in
a phased manner. Presently steel cord belts of tensile strength of 4000 kg/cm width of
the belt are in operation. The length of the steel cord belt conveyors are increased to 2.5
to 3.0 km. The life of the belt also increased to 30000 to 350000 hours.

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6.3 Track shifting:
A method of deposition, utilizing a conveyor with tripper style spreader, where by the conveyor
is moved parallel to the length of the conveyor by moving each idler structure module by a
fixed maximum distance. Due to the reach of the spreader boom, the requirement to move the
full conveyor length is based on the development of the spreader. The top leg of the dump
allows for a separate line of material during downtimes associated with the track shifting
process. There are shift able conveyors at the mine cutting face and dumping yard. At the mine
cutting face / mine advancing side after completion of each block of 40/80 m face conveyor has
to be shifted to tackle the next fresh block of 40/80 m, since Bucket Wheel Excavator can cut
40 m block only at

Fig:-6.3 track shifting

a time and if Mobile Transfer Conveyors is provided then exploitation of 80 m block is
possible. Then exploitation of 80 m block is possible. Similarly in the dumping yard, dumping
of each 100 m to 120 m width, the dumping conveyor has to be shifted 100 m laterally to do a
fresh dumping block. Since in the initial stages the conveyors were small in size, the shifting of
conveyors was carried out just by pushing with dozers to new location. However in due course
the conveyor sizes were increased. The 2000 mm workshop type drive heads are weighing
about 80 to 100 tones and were pushed / shifted using bigger size bulldozers and special
equipment called pipe layers of 90 tones capacity. The 2000 mm conveyors are also heavy in
structure and the steel cord belt running in this conveyor is also of more in weight. Hence
instead of pushing by dozers, a unit called pipe layer fitted with shifter head are used in shifting
the conveyors. The 2000mm drive heads of latest type are weighed about 250 tones, since all
the drive powers / units with motor, gear box, electrical panel are mounted on the conveyor

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itself. They are weighing 250 tonnes and shifting these drive station are not possible by just

fig:- 6.3 shifting the conveyor

These heavy drive heads of higher drive powers are moved / shifted using hydraulic walking
pads. They lift the drive station using hydraulic power and moved about half a meter at a time.
Due to these slow process of shifting the idle time / non production time increases at every
shifting. More over in due courses the length and carrying capacity of the conveyor also
increased to tackle the need of high demand in material handling. Now a day’s conveyor of 3.0
km with a carrying capacity of 20000 tph, 2400 mm steel cord belt of ST 4000 are in use. These
conveyors having a drive power of 4 X 1250 kw (4 motors of 1250KW) at drive heads with
other drive units and electrical kiosks. These drive units weight is more than 500 tones. These
units cannot be moved with walking pads. Even if it is moved with walking pads, the slow
processing of shifting these conveyors will increase the down time of costlier production
system. Hence an improved type of transporting these drive heads called “Transport Crawlers”
were introduced. These transport crawlers can be inserted under these heavy drive units which
can lift the drive units and move at a faster rate (8 m/min).

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Fig:- 6.3 clawer arrangement of track shifting

7.0 Hydrogeology of Neyveli area:

The base of cuddalore formation contains mainly of sandstone which occupies a large
portion of area and has vast potential for ground water. This upper Miocene consists of
argillaceous sandstone, pebble bearing sandstone, pebbles, sand, clay, lignite lying
above the aquifer. The ground water in the cudallore is found under confined condition,
unconfined condition, shallow, perched and deep water situation. There are two
confined aquifers below the lignite bed and one semi confined aquifer above the lignite.
This confined aquifer covers the large area. Semi-confined aquifer materials consists of
laterites and lateritised sandstone.

7.1 Recharge area:

Ground water recharge potential of the basin is the amount of water repeatedly added
through the natural process like infiltration of precipitation, seepage from streams and
percolation of irrigation water. Ground water reservoir or a basin is a physiographic unit
containing one or more connected and interrelated aquifers and the region contributing
water to the ground water basin is called the recharge area. The recharge area is located
in South Acrot district of Tamil Nadu. The area is bounded between Gadilam and Vellar
rivers. This recharge area is about 2600 sq. km. This area is influenced by both south-
west and north-east monsoon. But, the effect of the north-east monsoon is predominant.
The mean annual rainfall of the region is about 1200mm.

For any sub-terrain activity, water is a potential hazard. Ground water becomes a major
hazard for open cast mining. The source of water that hinders the activity in any open
cast Mine can be broadly classified into four types.

7.2 Unconfined Aquifers:

It is defined by the water table just below the ground level up to a maximum depth of
15m. Excavation of any Mine-I is bound to reach beyond this level. In that case water
may seep into the Mine from all sides. In case of river/lake/ponding in the vicinity of the
Mine cut, may increase the seepage influence.

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7.3 Semi-confined aquifers:
This is seen above the lignite seam in the southern part of Mine-I and predominant in
Mine-II, with a thickness of about 5-10m. There is not considerable ground water
pressure and the water from this aquifer is being tackled by constructing the pump wells
exclusively in semi-confined zone and both in semi confined and confined aquifers as a
combined well. In addition, percolation wells are also drilled to tackle the semi confined
water and toe drains are provided for tackling the seepage of water from these aquifers.

7.4 Confined aquifers:

These are confined on either side of the aquifers by an impermeable layer. This aquifer
is present in the entire region of Neyveli. Its maximum thickness is around 400m in the
core lignite region and pinches in the west. Within the lignite bearing area there is
almost continuous thick barrier of clay at the depth of about 40-50m which divides the
aquifers into two parts viz. upper and lower confined aquifers. The upper confined
aquifer exerts an upward hydrostatic pressure of about 5-8 kg/sq.cm within the mining
area. These artesian aquifers mainly fed by the recharge zone located about 15 kms west
of Neyveli lignite field in and around Virudachalam. Here the strata exposed are highly
permeable. Since the water is at high pressure it always exerts an upward thrust and if
this pressure happens to be higher than the downward thrust exerted by the strata above
the lignite then the Mine floor will burst with sudden surge of water upwards from
below, resulting in flooding of Mines.

7.5 HYDROLOGICAL PROBLEMS:

In case of Neyveli, the stratumbelow the lignite contains artesian aquifers. These
confined aquifers are divided into upper and lower aquifers. Upper aquifer is under high
pressure of 5-8 kg/sq.cm. These two aquifers are separated by clay of 3- 5m thickness.
The pressure of the aquifer is kept in control by the overlying strata containing
sandstone, lignite,clay. They exert a downward pressure of about 10-15 kg/sq.cm. But
when overburden is excavated in stages in order to Mine lignite, the down thrust of the
overburden progressively get reduced and a stage will reach when the upward pressure
due to the confined aquifer water and the downward pressure due to overburden yet to
be excavated are under equilibrium conditions. If the excavation is allowed to proceed
beyond that stage, the exceeded upward pressure will burst the Mine floor and ultimate
flooding of the Mine.

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 +40 +40
+30 +30

-25 -25

-40 -40
-42 -42

-80 -80
-85 -85
-90 -90

Fig:7.5 Hydrological problems in lignite Mines (Confined aquifers)

7.6 CONTROL OF GROUND WATER PRESSURE:

In order to control this problem, the only way is to bring down the water pressure below
the lignite formation. This is done by lowering the pressure of the upper confined
aquifer by pumping out the water. In order to make this success, pumping activity
should be done continuously from a series of pumping wells situated at hydrological
calculated distance from the lignite mining/excavation zone.

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Fig:7.6 Solution for confined aquifer below the lignite

7.6.1 Site location for drilling:

The number of pump wells to be drilled and the discharge to be maintained for time to
time are dependent on the progress of the Mine and the bottom of the lignite seam, since
it is to this level the pressure has to be depressed by pumping. But the actual location of
the boreholes and determined taking into consideration, site condition, and space
availability for drilling, equipping and laying of disposal mains. Besides, mining aspects
like conveyor shifting, spoil dumping, advancement of the Mine, deep-cut program etc.,
we have to be reckoned with, not only for choosing the drilling site, but also for fixing
the priority for drilling. Besides, drilling and pumping activities should not be a
hindrance to the progress for mining operations.

7.6.2 Pressure control:

The influence of pumping operations on the ground water pressure is constantly studied
by monitoring the water level in the observation wells, standby pump wells, by
regulating the discharge by examining the Mine floor etc., This is done to make sure

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that the pressure is depressed to the required extent and maintained below the base of
the lignite seam. Thus, the original pressure head which was around +30M above the
MSL in the Mines before the commencement of GWC operations has been now
depressed almost to -63 M. That means, the ground water pressure has been controlled
satisfactorily.

By following all the stages of operations enumerated above systematically and

scientifically, the ground water pressure, which was a potential hazard in the mining of
lignite from this field, had been kept under control permitting smooth and successful
mining operations.

7.7 Drilling a pump well:

Drilling a pump well and construction constitute the most important phase in the GWC.
Operations as pumping efficiency depend mainly on proper drilling and pump well
design. Method of drilling depends upon the location of the borehole whether on the
manmade bund or on the benches or the surface. Drilling through the manmade bund
(semi-consolidated refilled soil), necessitates adopting dry drilling techniques using
AUGER drill to a depth till the original formation is met. With the available auger drill,
the maximum depth that could drill through the unconsolidated strata adopting dry
drilling technique is only 25 m.For the stability of borehole and for preventing the
seepage the boreholes are lined with conductor pipes and annular space is cement
sealed.

Wells located at the benches are drilled using Reverse Rotary Drills. These boreholes
are of 40”/36” diameter and are drilled through the entire thickness of the aquifers and
stopped at the top of the clay seam separating the upper and lower aquifers. Depth of the
drilling varies from 50M to 90M., depending on the actual location of the borehole.
Likewise, spacing between the wells also varies between 80M and 100M. At present 5
to 10 wells are drilled every year for ground water control purpose.

7.7.1 Wells construction and development:

As soon as the drilling is over, the borehole is cased from top to bottom with 500 mm
(20”) diameter Plain and slotted pipes, the latter against sand strata in the aquifer. On an
average, 18m of slotted pipes with 3mm wide slot opening at present lowered in each
well. The annular space between the casing pipe and the borehole is shrouded with
graded gravel normally 5-8 mm size to the required depth and the remaining annular is
filled soil.

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Fig:7.7.1a Slotted pipes Fig:7.7.1.b Plain pipes

After the well construction is completed the well is developed using the air compressor
of 100 psi and600 Cft. Capacity for removing the contamination in the formation around
the well and for bringing out the fine sand so that the permeability is increased and the
well loss is minimized.

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Fig:7.7.1c Well Development setup

7.7.2 Pump Erection and power supply:

After the completion of the development of the well a 250 HP submersible pump with a
designed pumping capacity of 1000 gallon per minute for a head of 150 M is erected in
the well. The power supply to the pump is obtained from the Mines electrical sub-
station through 11 KV landline cable which is routed at each pumping well site though a
H.T.skid and then stepped down to 400 V by means of transformer 11KV/400V –
250KVA capacity before feeding to the pump. Power consumption per well discharging
1000 GPM is approximately 180 KWh depending on the installed pump.

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Fig:7.7.2.a Pump erection setup for GWC

7.7.3 Pumping operations: A well is commissioned with an initial discharge of

500 GPM and progressively stepped up to its rated capacity of 1000 GPM, after
studying its efficiency factor. A bypass line of 200 mm (8”) diameter with an orifice
plate arrangement is provided for testing and measuring the discharge. Aft testing, the
water is let into20/22/24” dia., main disposal line to which normally 8 or 10 wells are
connected. The disposal line discharges the water in the Booster tank located inside
Mine and finally in the reservoir or a lake specifically constructed to store this water for
supplying to the industrial unit. As the Mine goes deeper/ coming up consequent to the
dip in the lignite seam in the advancing stages of the Mine, the quantum of pumpage
will have to be correspondingly increase/decrease. At present in Mine-I 10-12 wells are
in operation to maintain the ground water pressure at the bottom of lignite ie. -63.00m

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Fig: - 7.7.3 pump setup for GWC

8.POLUTION
Installation of high efficiency of 99.5% electrostatic precipitator. Construction of tall
chimneys for wider dispersion of the gases. On line monitoring system is available.
Water sprinkler system is available for dust control in LHS. Fly ash utilization is done to
80% and efforts are being made to achieve 100%. On line SPM and analyzer is in
operation in all units Green belt development has been taken on a large scale basis in
line with the requirement of TNPCB. Flow meters are available for all inlets of water
and values are recorded.

Green belt development: NLC had raised 17.1 Million trees in the region over a period
of time. This acts as a dust barrier by absorbing dust penetration into Township side.
Reduce mean temperature by 2 degree Celsius. Bring down noise level by 10 decibels
per every 10m wide green belt development Trees in 0.405 ha of land has the potential
to absorb six tons of sulphur dioxide.

Electro Static Precipitators (ESP): High efficiency ESP (100%) is installed in the Flue
gas exhaust of Thermal power plants. Tall chimneys up to a height of 220 meters are
constructed for wide dispersion of flue gases. Employing machineries with Electrical
power: Most of the machineries used in mines are electrically operated and hence the
emission of carbon & noxious gases, which is usual with diesel- operated machines, has
been substantially reduced.

Dilution of gaseous emissions: The Neyveli lignite mines are spread over a large area.
Natural ventilation dilute of any gaseous emission by diesel vehicle. Harp teeth for
Bucket Wheel Excavator: Using sharp tooth for bucket wheel excavators to reduce dust
generation. Optimization of ground water pumping: NLC has optimized the pumping
operations by localized draw down of water around lignite excavation area.

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Rain water harvesting & Artificial recharging: Rainwater harvesting system has been
introduced in the mines, power plants and township. Artificial recharging of ground
water work is taken at Nadiyapattu and Maligampattu villages near Neyveli and has
proved very successful. Storm water treatment: 8000 GPM of storm water pumped from
Mine-1 has been diverted to treatment plant at surface. The treated water is sent to
township for domestic use.

TM Sewage treatment plant: A modern sewage treatment plant has been established for

treating sewage water from township and the treated water is let out for irrigation
purpose.

Fig:- 8.0 TM sewage water plant

9.0 Conclusion:

With rich experience gained over past four &half decades in the mining cum power
sector, today NLC has transcended as a pioneer in lignite exploitation. In Neyveli, three
operating Mechanized mines and linked modernized thermal power station are working
to their fullest capacity. The technology base and innovations have been improved upon
from the word go when it was transferred from Germany in late fifties in a raw fashion
to a peak level for Neyveli’s goe-mining conditions. The success story of NLC in both
mining with BWE and effective & efficient de-pressurization of high confined pressure
of the aquifer below lignite seam have opened new vistas for starting further mining
propects with greater confidence.

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