AN OVERVIEW OF UG

COAL MINING
S K JAIN,GM(UG),WCL & RANJEET
KUMAR,SR.MANAGER(M),PROD. DEPT, WCL ,NAGPUR

153
 Coal Production from Underground Coal Mines

• Around 60% of World Coal Production comes from Underground Mining

• India emerged as the Second Largest Coal Producer in the World only after China
producing about 10.78 % of the total Global Production.

• UG Coal Production World-wide:-

COUNTRY % OF UG PRODUCTION

CHINA 95

USA 34

AUSTRALIA 26

INDIA 06

154
 Production (million tonnes)

100
400
500
600

200
300

0
1974-75

1976-77

1978-79

1980-81

1982-83

1984-85

1986-87

1988-89

1990-91
CIL (UG)

1992-93

1994-95

Year
1996-97
CIL (OC)

1998-99

2000-01

2002-03

2004-05

2006-07
Contribution of UG mines

2008-09
Production trend of CIL since inception

2010-11

2012-13

2014-15

2016-17
0%
10%
20%
70%
90%

30%
40%
50%
60%
80%

155

Contribution of UG mines
 Contribution of UG mining in CIL during
past ten years
600.00 25%

14
4.
55
57
8.
53
42
500.00

2.
1

46
2
2.
45
20%

83
Production (million tonnes)

27

32

5.

Contribution of UG mines (%)

1.

1.

43
43

43

24
4.
73

49
3.
40
46
94

9.
37
0.

400.00
36
37
3.
34

15%

12.0%
11.5%
300.00 10.9%
13.3%

10.0% 9.3%
8.8%
8.4% 10%

7.8%
200.00

6.3%
7.1%
5.7%
5%
100.00

0.00 0%
2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17

Year

156
157
 COAL INDIA LIMITED
Coal Production - 2016-17
UG Coal % OC Coal
Name of
Production Contribution Production Total
Company
(MT) from UG (MT)
ECL 8.127 20.05 32.394 40.521
BCCL 1.680 4.54 35.357 37.037
CCL 0.736 1.10 66.301 67.037
NCL 0.0 0 84.096 84.096
WCL 5.368 11.76 40.264 45.632
SECL 14.547 10.39 125.456 140.003
MCL 1.015 0.73 138.133 139.208
NECL 0.003 0.50 0.538 0.601
CIL 31.476 5.68 522.659 554.135

158
 COAL INDIA Ltd-2016-17 Production-
• Total Coal Production : 554.135 Mte
• OC Production : 522.659 Mte : 94.32%
• UG Production : 31.476 Mte : 5.68%
• 76.60 % UG Production from Intermediate
technologies
• 19.62 % from Mass Production technologies
• 2.12 % by Manual Mode
• 1.66 % by Highwall Mining
159
 UG cost of Production = 7 X Average Cost of OC coal Production
Sales Realisation from UG Mines = 2.5 Times that of OC Coal Production

• Just after nationalization coal production from UG Mines

in 1974-75 – 58.0 MT (73.41%)out of 79.0 Mte.
• 2016-17 – 34.0 Mte (less than 7.0%)
• Producing no of UG Mines in CIL – 255 (2015-16)
• 13 Mines > 0.5 MTY
• 06 Mines – 0.3 to 0.4 MTY
• 17 Nos. – 0.2 to 0.3 MTY
• 53 Nos – 0.1 to 0.2 MTY
• Rest Nos of Mines – Upto 0.1 MTY
• Nearly 60 % of total MP of CIL - deployed in UG Mines.
• 1.6 Bte. Of coal- standing on pillars.
• Projected production of CIL in 2019-20 - 908 Mte.
• Anticipated production from UG mines in 2019-20- 56.20 Mte.(6.19%)

160
 Method-wise & Technology-wise Break-up of UG Coal Production during
2016-17

Methods /Technology UG Prodn In MTe %age of total UG

Conventional B&P Manual 0.668 2.12

Mechanized B&P (SDLs & 24.113 76.60

LHDs)

CM 4.689 14.90

Long-wall(PSLW) 1.486 4.72

High-wall 0.521 1.66

Total 31.477 100

161
Cause of Diminishing Trend of U/G Coal Production
•Delay in implementation of underground projects which were in pipe line and even
after revision of the project reports where technology opted during their formulation
stands un-economic now and desired IRR(Internal rate return) falls below 12%.
•Meager adoption of appropriate technology with relatively bulk output
•Delay in assessment of presently operating underground mines for their technological
up-gradation particularly where the thickness of coal seams are 2.7m and above due to
non-viability.
•Continuation of old technology with deployment of SDL and dependency on large
manpower. For more than 2.7 m thick seam LHD can yield double the SDL production by
only 50% of the Manpower for Machine operation.
•Not going for larger machine where possible. Were thickness increases say 3m and
above, LHD with 3Cu.m bucket can yield double the production of usual (Std) LHD with
1.5m3 bucket capacity keeping same machine operating manpower.

162
Cause Diminishing Trend of U/G Coal Production

• Slow pace of change to improved management system. E.g. It is most pertinent for
mining coal by blasting free technology where practicable so that “All men all job”
system and relatively higher output /sized output without time loss in cyclic mining is
possible.
• Less focus on R&D analysis and assessment for adoption of leading edge technology
like short wall, CM, Longwall, high wall techniques of mining with higher
underground production and productivity.
• Bleak possibility of existing mines to incorporate LCCM and CM with the available
outlets, ventilation system, evacuation possibility and winder availability due to non-
viability and infrastructure constraints.
• Not techno-economic examining of the geo-mining condition for extraction with
high capacity PSLW or multiple CM’S operation adopted for bulk output as planned in
the mines like Jhanjra, Moonidih,Kurja-Seetaldhara, Churcha etc.

163
 MAJOR CONCERN of UG Mining in Coal India-
• Continuously declining trend of coal production and its declinining
contribution to the total production from UG Mines
• Increasing cost of production from UG Mines
2009-10- Rs.2885.24/ Te. 2016-17- Rs.6656.23/Te.
• Increasing cummulative loss from UG Mines- more than 9000 Cr. 2014-15
• Decreasing Sale value of coal- 2663.74/ Te.
• Not recovering of even salary and wages cost of employees from most of
UG Mines.
• Low level of mechanisation & modernisation of UG Mines-
> 50% of UG mines produce less than 1.0 Lte/yr and only 4.5% mines
produce > 5.0 Lte/yr.
• Geo-mining conditions
• Restrictions in depillaring operations-due to non-availability of surface
land and due to extraction below surface structures and Forest Land.
• Availability of skilled Man-power
• Contract Management issues 164
 RESEARCH & DEVELOPMENT PROJECTS
• High speed Incline drivage and Shaft Sinking

• Steep Seam working (> 1 in 5)

• Thin Seam working (<1.2m)

• Thick Seam working (> 5m)

• CM with high speed stowing/Active Fill Technology

• Instrument for detecting the Hidden Slips- 9th Safety Conference, 2000

• Dislodging of already Cement grouted Roof Bolts

• Alternative to sand for stowing-crushed OB, Bottom Ash etc.

• Slow rate of stowing.
• Appropriate method for coal extraction by caving method with controlled
subsidence without having surface right for the mine .
• Development & implementation of Coal To Liquid(CTL) Conversion
165
Technology including Coal Gasification.
What is revealed ?

• A clear indication that appropriate actions are not initiated on time

• Mining Industry must be concerned for improvement in underground
production
• The repeated discussions and intentions of Mining Industry for
enhancing underground coal production is not translated into proper
planning and design or innovative actions.
• With new target given by Government big steps are called for to
improve underground production and productivity in underground
mining.
• Mining Industry must assess its underground mining competency and
take necessary pro-active simultaneous actions

166
 General Information of WCL UG Mines
• No. of producing Mines at present - 33 Nos.(Excluding Murpar) in 8 Areas of WCL except
Majri & Wani Area
• Production target from 34 UG mines for the year 2017-18 (AAP 48.5 Mte.)- 6.00 M.Te
• Production achieved in F.Y.2016-17- 5.367 M.Te
• Overall Capacity utilisation in UG Mines of WCL in 2016-17 - 68.08%
• LHD on Roll working, April,2017- 114
• SDL on roll working, April,2017- 79
• LHD Productivity prog.up to April,2017 -107 TPD
• SDL Productivity prog.up to April,2017 -66 TPD
• Total Manpower deployed in all 41 UG Mines as on 01.04.2017- 24,163
• No. of Mines in Profit -Nil
• No. of Loss Making Operating Mines having loss >Rs.5000/- Per Te. -15
• Ave.Cost of production per ton of coal from all UG mines in FY 2016-17- Rs.5610.979
• Ave. sale value of coal per te.- 2080.325
• Ave loss per te. of coal produced- Rs.3530.65
• Loss from UG Mines in WCL during 2016-17- Rs.1895.10 Cr.
• Ave.OMS achieved in FY 2016-17- 0.93 Te.
• Unviable Mines identified for closure during 2017-18- 10 N0s.

167
 MAJOR CONSTRAINTS IN UNDERGROUND WORKING OF WCL
• Most of the Mines are very old and extensive (long traveling/hauling distance with
high gradient where easy mining areas are exhausted during last several decades
of mining.
• Unfavorable and difficult geo-mining conditions:
• a) Adverse Roof Conditions: In many of the mines, numerous faults and hidden
slips/cleats, bad roof conditions/roof falls with RMR less than 40 in most of the
mines except Pathakhera Area
• (b)Thin-seam workings: Many working sections in Pathakhera Area(in Bagdona
seam at Shobhapur, Tawa-I mines Av. Thickness 1.2-.1.5M) ,Nagpur Area(IV-
Top,Bottom seam,Seam-III
• (c) High Water percolation: Kamptee series is encountered in most of the
underground mines of Wardh Valley field of WCL e.g.Kumberkhani,Murpar, Rajur,
AB incline ,Pipla.
• (d) Soft floor : Soft floor, in addition to high water percolation generates large
volume of muck & slurry. e.g Kumberkhani,Murpar, Rajur UG.,AB incline.
• Existence of Fiery Seams: The only thick seam available in Wardha coalfield is
prone to fire and spontaneous-heating. In almost all the mines of Chandrapur, &
Ballarpur Areas, dealing with spontaneous-heating is a regular phenomenon. In
Pench and Kanhan Areas due to existence of basalt rock in the roof, regular caving
in depillaring is impeded, resulting in crushing of pillars and finally occurrence of
fire/heating

168
 Continue-

• (f) Steep gradient: Very steep gradient of 1:3 t0 1:4 at Chattarpur-II, Hindustan Lalpeth
Colliery No. 1, AB incline, Silewara, Patansaongi limit scope of mechanization & affect
productivity.
• (g)Thick seams: About 16-17m thick seam at Chandrapur & Ballarpur necessitate multi-
lift system of working with stowing which impedes production rate, extraction rate as
well as additional cost.
• (h) Contiguous Seams: Coal seams with parting less than 9.0m at Pench & Nagpur Area
pose additional problem of adverse roof & strata control in mines.

• Limited Coal reserves and balance reserves on deeper horizons beyond 200 M depth in
some areas with additional problems of poor roof and water.

• Non-availability of cavable reserves due to presence of overlying water bearing Kamptee

series. Kamptee series is encountered in most of the underground mines of Wardha
Valley field of WCL which results in high water percolation.

• Surface constraints due to built up areas.

• Non-availability of surface land for depillaring e.g. mines of Wani-North area & Saoner-
group mines of Nagpur Area.

169
 Continue-

• Large reserves of coal developed in the past and standing on pillars for
non-availability of surface land, non-availability/shortage of sand for
stowing & waterlogged due to fire/adverse roof conditions.

• Shortage of sand in stowing mines: Presence of thick seams necessitate

multi-lift system of working with stowing but due to restricted supply of
sand for stowing in UG mines of Chandrapur,Ballarpur, and Nagpur Area,
depillaring operations are forced to be restricted, badly affecting the
productivity of SDLs.

• Most of the Mines in the Company are producing less than 2 L.Te/annum
i.e. below the economic limit and incurring heavy losses.

• Less sale value of coal due to poor quality of coal

170
STATUS OF UG MINES OF WCL AS PER PRODUCTION POTENTIAL
DURING 2016-17

PRODUCTION NO. OF MINES

MINES
< 1 L.T./Year 15 HLC-I, Nandgaon, Mana, CRC, MKC, B&C3&4Pit,
Kumbharkhani, Patansaongi, Murpar, Chattarpur-
II, Ambara,Vishnupuri-I,Vishnupuri-II Ganpati,
Mahadeopuri
1-2 L.T./Year 12 DRC RPR, Sasti RO, Rajur RO, Silewara PH-I, A-B
Incline, Saoner-III, Shobhapur, Sarni,
Mouri(Mohan), Jharna, Tandsi, Mathani
2-3 L.T./Year 02 Adasa, Saoner-II
3-4 L.T./Year 02 Saoner-I Expn., Nehariya UG
4-5 L.T./Year 02 Tawa- PH-II, Chattarpur-I

> 5 L.T./Year 01 Tawa PH-I

171
Options of Improvement of production from UG
mines

From
Existing UG mines
New / virgin blocks
Below ultimate depth of OC mines

172
 Measures taken to improve the underground coal production.
A) Addition of New UG Projects:
In order, to augment underground coal production in the subsidiary
company, it is proposed to commission 06 New UG mines having total
capacity of 8.23 Mty. by the year 2019-20, which will serve as replacement
projects to exhausting UG mines and also as additional to the existing
capacity, which are tabulated as under:

•
Sr.No. Area Mines Capacity(Mty.)

1 Pench Jamunia 0.840

2 Nagpur Waghoda 0.390

3 Pench Dhankasa 1.000

4 Pathakhera Gandhigram 2.000

5 Wani north Borda 2.000

6 Umrer Murpar Expansion 2.000

173
 (B) Introduction of Continuous Cutting Technology:
Three upcoming mines have been identified for introducing Continuous
Miner by 2020 and the process for introduction of CM on hire basis in
Tawa-II Expansion Mine of PKD Area is going on-
Sr.No. Name Annual
Capacity(Mty.)
1 Jamunia 0.840
2 Dhankasa 1.000
3 Gandhigram 1.000
4 Tawa-II Exp. 0.360

© Introduction of Mass Production Technology

WCL has planned to introduce Mass production technology (Longwall) in two

upcoming projects Borda and Murpar Enpansion with capacity @ 2.00
Mty. each.

174
 D) Addition / Replacement of UG equipments / Auxiliary equipments in existing UG
mines to improve productivity.

• Timely procurement and providing reliable loading machines i.e. SDLs and LHDs
against new requirement and against survey off machines in UG

• Elimination of manual drilling and enhancement of drilling efficiency by

providing more No. of UDMs and Hydraulic as well as pneaumatic drill machines.
The aforesaid drilling machines along with resin capsules provide better anchorage
to support poor roof condition.

• .Installation of Man-riding System- In order to eliminate long , arduous travelling

and to provide comfort to miners for increase safety and efficiency , man – riding
system has already been installed and is under operation at 10 UG mines viz.
Tandsi, Maouri, Saoner-I, Shobhapur-II, Ballarpur 3&4 Pit, Tawa-I, chattarpur-I,
Kumbharkhani Adasa & Neharia UG mines.
• Man-Riding system is proposed to be introduced further in 08 UG mines namely
• 1)Saoner-II (2) Saoner-III (3) Rajur (4) Silewara (5) Shasti (6) DRC (7) Tawa-II
8) Chhatarpur-I(02 more sets)
• Extension of MRS proposed in Chhatarpur-I & Saoner-I

175
 (E) Mechanized Drivage of Drift / Incline:-
• In order to facilitate faster drivage of inclines/drifts & for early start of coal
production ,NIT for mechanized means for its drivage is under preparation for
two mines:
(1) Dhankasa (2) Gandhigram

Measures adopted for reducing the losses from UG Mines-

• Closure of highly loss making unviable mines of WCL -5 mines closed in 2016-17-
HLC-3,DRC-6,7,8, Thesgora,Rawanwara Khas & Pipla
10 Mines proposed for closure during 2017-18-Mahakali, CRC, HLC-I,
Vishnupuri-I, Vishnupuri-II, Ganpati, Ambara, Mohan/Mouri, AB Incline and
Kumbharkhani
• Stoppage of production in rest days and PH
• Restriction on deployment of man power in OT
• Deployment of surplus MP in mine development activities for their effective
utilization
• Reduction in power consumption by re-arranging transport & pumping layout of
UG mines
▪ Action is being initiated for 7 days working in UG Mines
176
177
 Suggestive Measures
• Estasblishing of sound monitoring mechanism at Apex level to ensure
timely start of approved UG Projects without delays.
• Finding scope of improvement in low producing mines by analysing all
systems & sub-systems for identifying bottle-necks
• Serious consideration of introducing Continuous Minor in all UG Mines by
replacing or alongwith LHDs in a time bound manner as the required geo-
mining conditions for both LHDs & CMs are the same.
• Switching over from man power intensive,time consuming & cost-
ineffective cyclic operation of coal preparation by blasting method to cost
effective continuous coal cutting technology in order to improve TPD of
existing LHD Machines.
• Amalgamation and reorganisation with a strict focus on priority basis on
either increasing profit or controlling of incurred losses on time bond
basis.
• Considering of stringent measures for reducing cost of production and
where substantial cost reduction does not appear feasible for any
reason,taking hard decision for closing down of highly loss making mines.
178
• Existing manpower and getting them for adoption of new technology takes time.
• In the situation the available method of mass production by continuous miner
without blasting if practicable can be adopted with less time span.
• The mines to be adopted with advance technology to be identified by individual
companies with the help of a special team and mine-wise economically operative
technological option to be decided so that the method remains viable at least for
next 10years.

Technology adoption needed in underground

mining.
• Blasting free mining:
✓Low capacity and low cost continuous
miner (LCCM) on Hire Basis.

179
Measures for incentivizing underground operation
Financial measures-
• Reducing the minimum financial IRR to 8% at 85% level of production (from
existing IRR of 12% at 85% level) for assessing the viability of underground
projects.

• Levying of suitable additional charge on sales realization of opencast

production of CIL as cross-subsidy to compensate for higher cost of operation
of underground mining for achieving sustainable growth of coal production so
as to ensure long term energy security of the country.

• To consider relaxation in duty structure on imported underground mining

machinery and spares for next 10 years.

• To introduce some forms of financial incentives to the members of underground

mine development and construction team for timely commissioning of
underground projects/ schemes. 180
Technological measures:

•Thrust on indigenous manufacturing of mining equipment and spares required for

mass production from underground coal mines along with testing facilities by
rejuvenating the closed state owned mining machinery manufacturing company
through joint venture route.

• Funding for first time introduction of proven technologies like in-seam methane
drainage for highly gassy mines, high speed backfilling etc. from R&D fund of
CIL.

Organisational measures-

• Development of specialized cadres of executives, supervisors and

workers with special pay structures for operation and maintenance of mass
production technology in underground mines.

• Introduction of all men all job system for the above specialized cadre
workers.

181
 ADMINSTRATIVE MEASURES

RESTRUCTURING: HUMAN RESOURCES:

• Break up CIL in UG & Surface Divisions to have focused approach.

• Different Cadre Scheme for UG & OC.

• Differential Pay Structure for UG & Faster Career Development to motivate people to
work in UG.

• Performance should not be judged only on Production, but on Other Critical Mine
Development Parameters as well.

• Shaft Sinking (m)

• Incline Drivage (m)
• Dyke Crossing (m)
• Fault Crossing (m)
• Project Milestones achieved.
• Land Acquisition
• Statutory Clearances/Approvals Received (e.g. EC, FC etc.)

182