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Fuel 275 (2020) 117865

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Fuel
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Full Length Article

Laboratory investigation on underground coal gasification technique with T


real-time analysis
Ranjeet Mandala,b, , Tanmoy Maitya, S.K. Chaulyac, G.M. Prasadc

a
Department of Mining Machinery Engineering, Indian Institute of Technology (Indian School of Mines), Dhanbad 826004, Jharkhand, India
b
Research Education and Social Empowerment Society, Dudhichuwan, Chitra, 815351 Deoghar, Jharkhand, India
c
CSIR-Central Institute of Mining and Fuel Research, Barwa Road, Dhanbad, India

ARTICLE INFO ABSTRACT

Keywords: Energy demand will continue rising in India due to increasing pressure of population; continuing urbanization;
Underground coal gasification significant expansion of better living standards of the middle class peoples; electrification in more and more
UCG villages; and modernization of agriculture, infrastructure and manufacturing sectors. In India, coal is the most
Real-time monitoring of UCG abundant and major fossil fuel which is going to play big role in meeting its energy demand. A major part of this
Syngas
requirement can be met by proper utilization of deep-seated coal. Underground coal gasification (UCG) process
Clean coal energy
is a clean coal technology for utilization of unminable coal. In this article, a novel simple laboratory model of
UCG is developed with advanced real-time control and monitoring. The experimental study is carried out on a
high-ash single coal block for 48 h period. In this experiment, synthesis gases are produced by the gasification of
coal block by using oxygen and steam as the main oxidising agents. Observation and analysis are made on the
characteristic of produced gases, coal-tar, cavity-growth under variable process conditions. This laboratory-
based experimental study will play a vital role for prediction on practically-difficult UCG process for successful
operation in actual field by reducing its complexity.

1. Introduction coal and lignite up to 1200 m depth are 3, 15, 148.81 and 44698.14
million tonnes respectively in the country as on dated 1st April, 2017
Demand of energy is growing at a much higher rate than the growth [5,6]. Table 1 shows the coal resource (up to 1200 m depth) in India
rate of the economy in India. It will continue rising in India due to [7,8].
increasing pressure of population; continuing urbanization; significant As upper layer coal is running out fast, the utilization of deep-seated
expansion of better living standards of the middle class peoples; elec- coal is the clear alternative left for energy security. But it is fraught with
trification in more and more villages; expansion of electrification of many challenges. A major part of this requirement can be met by proper
Indian railways; more demand of electric vehicles; and modernization utilization of deep-seated coal.
of agriculture, infrastructure and manufacturing sectors. According to
an energy demonstrating exercise entitled India Energy Security 1.1. Challenges of mining of deep-seated coal
Scenarios (IESS), 2047, undertaken by NITI Aayog, India, the energy
demand of India is probably going to increase by about 2.7–3.2 times Mining of deep-seated coal seam is neither easy nor economically
between the years 2012 and 2040 [1]. In India, coal is a major fossil viable through conventional mining. The problems associated with
fuel and it is used for electricity generation, steel production and var- mining of coal at greater depths are as follows [9]:
ious other purpose. In India, about 75% of produced coal is consumed in
power sector. As coal is the most abundant and major fossil fuel in this A. By underground methods
country, it is going to play a big role in meeting about 70.87% of energy (i) Strata/roof support problems like coal bumps/rock bursts and
demand of India during 2016–17 where as lignite contributed 3.63% high vertical/horizontal stresses,
[2,3]. In India, coal will remain the most important source of energy till (ii) Emission of hazardous gases inside the underground mine
2031–32 and possibly even further [4]. Geological resource of reserve atmosphere,


Corresponding author at: Department of Mining Machinery Engineering, Indian Institute of Technology (Indian School of Mines), Dhanbad 826004, Jharkhand,
India and Research Education and Social Empowerment Society, Dudhichuwan, Chitra, 815351 Deoghar, Jharkhand, India..
E-mail address: ranjeetmandal145@gmail.com (R. Mandal).

https://doi.org/10.1016/j.fuel.2020.117865
Received 2 January 2020; Received in revised form 2 March 2020; Accepted 13 April 2020
0016-2361/ © 2020 Elsevier Ltd. All rights reserved.
R. Mandal, et al. Fuel 275 (2020) 117865

Table 1
Coal deposits at different depths in India.
Coal deposits at different depth ranges Percentage of total coal deposits

0–300 m 62.74
300–600 m 30.07
600–1200 m 7.19

(iii) Excess temperature and humidity in underground mine gal-


lery, which calls proper ventilation and air-cooling,
(iv) Seepage of water in huge amount and its accumulation in the
underground gallery. It makes necessary to pump out the water
from underground to the surface, and
(v) Low production rate.

B. By opencast methods
(i) Requirement of huge capital investment for overburden re-
moval and availability of a large land for its dumping,
(ii) Environment pollution, Fig. 1. The schematic diagram of UCG experimental set-up in laboratory scale.
(iii) Problem of rehabilitation and resettlement of the peoples,
and cavity is formed in the underground coal seam. The rate of cavity
(iv) Involvement of long time duration for extraction of coal from growth depends upon the rate of coal gasification and cavity’s size
deep seated seam. depends upon the properties of coal (i.e. ash content in coal)[16].
Perkins and Sahajwalla (2006) [17] showed that the cavity growth rate
1.2. Preferred option for recovery of deep seated coal is a function of working parameters like temperature, cavity pressure,
water influx, and properties and structure of coal, [2,18].
The underground coal gasification (UCG) is a clean coal technology The UCG process involves four steps: drilling, linking, ignition and
for recovery of deep seated coal, the extraction of which is not only gasification. There are various methods for preparing a coal seam for in
difficult but also uneconomical by conventional methods. UCG process situ gasification. The adaptability of UCG methods is dependent on geo-
is an environment friendly, economical and promising clean coal mining conditions such as natural permeability of the coal seam; geo-
technology for utilization of deep seated coal or unminable coal [10]. chemistry of the coal; thickness, depth, width and inclination of coal
By this technology coal/lignite is first converted into syngas below seam [19,12]. The UCG process has been categorized into three phases
ground at high temperature and then it is transported to the above for gasification process in in situ namely, oxidation, reduction and
ground through a borehole [11]. Syngas provide more calorific value pyrolysis zone [20]. This process is a slow and takes long duration for
than coal. Generally, one tonne of coal has potential to produce approx. complete gasification of coal.
2500 m3 of syngas [2]. This gas can be used in pollution free electricity
generation and as a feedstock of several chemical processes, such as 2.1. Important reaction during gasification
production of synthetic natural gas, hydrogen, urea, fertilizers. [12,13].
UCG technology is capable of producing 20 times more energy from a During coal gasification many chemical reactions happen, then coal
similar coal asset than what is possible from coal seam gas or coal bed converting into syngas which is a mixture of carbon monoxide (CO) and
methane [14]. UCG technology has several advantages compared to hydrogen gas (H2 ).
conventional coal mining as well as surface coal gasification. burning
C (s ) + H2 O (g ) CO (g ) + H2 (g )

2. Underground coal gasification process Syngas can be processed to form synthetic natural gas (CH4 ) by
reacting it with additional hydrogen.
The underground coal gasification process involves drilling of sev- CO (g ) + 3H2 (g ) CH4 (g ) + H2 O (g )
eral vertical boreholes in a coal seam. One of them is called injection
borehole through which oxidants (air/oxygen and water steam) are fed Synthetic natural gas can also be produced by heating coal with
into a coal seam. Initially ignition is required for burning of coal at steam.
bottom of injection borehole. During UCG process coal is ignited at 2C (s ) + 2H2 O (g ) CH4 (g ) + CO2 (g )
bottom of the injection borehole (i.e. near the coal seam) by variety of
ways, such as by using electric coils, gas firing [15]. The coal gasification depends on the flow rate of the oxidants to the
After ignition oxygen is provided to the injection borehole for coal seam. The thermochemical efficiency of the process is also de-
continuous combustion of coal. The injected oxidants (oxygen/air) pendent on the ratio of oxygen and steam fed into the cavity, which is
react with coal below ground and to form a mixture of several gases controlled by using different types of flow control valves [21].
which is termed as syngas. It compress combustible gases namely me-
thane, hydrogen and carbon monoxide, and non-combustible gases such 2.2. Major benefits of UCG
as nitrogen and carbon dioxide. The syngas is transported to the surface
through another borehole called production borehole [12,13]. Rest of The major benefit of UCG process is that it does not create the
those vertical boreholes (known as instrumentation boreholes) [as problems of rehabilitation and resettlement of the people because, it
shown in Fig. 1] are used for keeping various types of sensors for requires less area in comparison to opencast mines. UCG has both en-
monitoring of different parameters. The calorific value of the produced vironmental friendly as well as economic benefits such as smaller
gases by UCG process is very low if air injection is used. It is approxi- carbon footprint compared to conventional mining methods and also
mately one-eighth of the calorific value of petroleum gas and doubles surface coal gasification; reduced land compensation and occupancy
this figure if oxygen injection is used [16]. After coal gasification, the time-frame; less pollution (e.g., lower fugitive noise, dust, vehicle

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R. Mandal, et al. Fuel 275 (2020) 117865

fumes) from site operations; easily and economically power generation investigation on the this technique in a practical scenario is necessary.
through UCG-integrated gasification combined cycle (IGCC); no surface Monitoring system plays vital role for successful operation of UCG
gasifier required for production of methanol, synthetic natural gas, process and reduces its complexity [28,29]. For this purpose an ex-
hydrogen, fossil fuel, chemical, ammonia, fertilizer; no coal washing perimental set-up has been established at Indian Institute of Technology
and fines disposal required at mine sites; low risk of surface water (Indian School of Mines), Dhanbad in India. In this experiment, design
pollution; easily carbon dioxide (CO2 ) capture and remove; capital and and developed a monitoring system for the purpose of studies on UCG
operating costs are lower than in traditional mining; product gas process in a laboratory scale, which is shown in Fig. 1. The main ob-
(syngas) can be directly transported to the end user through pipe [22]. jective of this experiment is to produce gasification data for Indian coals
at the laboratory scale by using developed UCG experimental set-up. In
3. Importance of laboratory experiment of UCG UCG process, some additional vertical boreholes are drilled on the coal
seam, which are called instrumentation boreholes [Fig. 1]. Inside the
Underground coal gasification is a complex process as it depends on instrumentation boreholes various sensors such as thermocouples,
many factors such as geological and geohydrological analysis of strata, pressure transducer, geophones, are placed for monitoring of operating
physical and chemical properties of coal, process parameters, seismic parameters. The process instrumentation plays important role in UCG
events, analysis of produced gases in real time, [11]. Coal chemistry i.e. process for monitoring of various parameters. The main function of
the properties of coal are most important factors, those influence the monitoring unit is to control and monitors all sensors and process in-
underground coal gasification process. Lignite or lowrank coals are strumentations such as thermocouples, data logger, solenoid valves,
preferable for UCG process because its reactivity is more and due to this air/oxygen injecting unit, and gas analyzing unit automatically. The
require less capital cost. The lignite and low-rank coal has high process instrumentation and control unit receives updated information
moisture content and because of this the bed temperature drops and the as developed UCG technique and also provide logical control to UCG
flow of molten slag may be stopped. Coals with low sulphur contain laboratory experiment.
lowers ground water contaminants and build-up better quantity gasi-
fication. Again, the low-ash coal (LAC) and medium-ash coal (MAC) 4.1. Methodology
generate a higher surface area (i.e. cavity) for reactants and led to ef-
ficient gasification. In high ash coal (HAC), CO2 may be used with O2 With a view to providing the importance of laboratory-scale study
and steam as oxidants for production of high quality syngas through on underground gasification technique before its implementation in the
UCG process [23]. field, a UCG model was prepared on a coal block collected from Santhal
UCG process is conceptually very simple but its implementation in Pargana Coal Mines of ECL at Chitra, Deoghar in India. The dimension
actual field is difficult. Before actual implementation of UCG tech- of coal block was 45 cm in length, 35 cm in width and 28 cm in height.
nology at a site, it is necessary to have selection of appropriate site, The properties of the coal block used in this experiment are described in
study on technical possibility, prediction on growth rate of cavity, Table 2. On this coal block, three vertical boreholes were created and
economical feasibility, safety aspect for successful operation [24–26]. they were linked to each other by horizontal borehole of these three
The main problems are accuracy in seam drilling with linking between vertical boreholes, are was intended for use as injection borehole, an-
injection and production boreholes, controlling the reaction within the other as production borehole and rest was instrumentation boreholes
coal seam, controlling parameters of geohydrology and heat mass [Fig. 2(a) and (b)]. The depth of each vertical borehole was 10 cm and
losses, producing high-quality syngas, and its derivative, from the sur- the length of horizontal borehole was 32 cm. The production borehole
face. is actually vertical, but in this experiment the horizontal borehole was
Laboratory experiment of UCG process plays a vital role for pre- used as the production borehole. The prepared UCG model was placed
diction on UCG process which is helpful for successful operation in on a platform of recalcitrant brick and it was covered with clay slime
actual field and reduces its complexity. The others important process over the outer surface which is shown in Fig. 3.
parameters involved during in situ gasification, such as flow rate of An oxygen gas cylinder and a mini steam generator were connected
oxidants feed to the injection well; temperature of inlet, outlet and to the injection borehole through the inlet pipes and a T-junction. In
reaction zone; cavity pressure; seismic event; subsidence of overburden oxygen flow line a regulator, a gas flow meter and a non-return valve
and coal seam; hydrogeology of coal seam; analysis and quality of (NRV) and a ball valve were connected to control the flow rate of
produced gases. The UCG process cannot continue without the supply oxygen. Similarly, in steam flow line another non-return valve (NRV)
of oxidants (i.e. oxygen/air, steam) in certain ratio. Therefore, in UCG and a ball valve were connected. Non-return valves were used on both
technique above process parameters to be required continuously mon- sides for prevention of reverse flow. As temperature control is essential
itoring for successful operations in actual field. Ideal UCG temperatures to maintain the temperature in the gasifier. Two K-type thermocouples
(greater than 1000 °C ) are similar to those of conventional surface coal namely, TC1 and TC2 were put inside the vertical instrumentation
gasification. Achieving the ideal temperature of UCG process depends boreholes of coal blocks at a distance of 10 cm separated from one
on control of the water influx and oxidants flow rate [20,27]. Gasifi- another for measurement of temperature at different points of
cation temperature is normally estimated before beginning of the op-
eration by considering the input of certain oxidants, and it is monitored Table 2
continuously during the operation. The temperature of gasification Properties of the coal block sample.
zone as well as surrounding strata is a most important process para-
Parameter Value
meters which required continuously monitoring for successful opera-
tion in both actual filed as well as laboratory experiment. During and Moisture 9.1 %
after gasification of coal in underground, there may be changes in strata Ash 10.0 %
Volatile matter 23.9 %
conditions due to cavity formation. The seismic event may also occur
Fixed carbon 57.0 %
due to rock fracturing and propagation of transient dynamic waves Carbon 67.0 %
through the surrounding rock mass. So, it is also essential to monitor Hydrogen 3.4 %
strata conditions and seismic events during in situ coal gasification. Nitrogen 1.5 %
Sulphur 0.3 %
Carbonate CO2 0.08 %
4. Description of the experimental set-up
Phosphorus 0.012 %
Gross calorific value 6340 K cal/kg
Before starting the UCG process at the site, a laboratory scale

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R. Mandal, et al. Fuel 275 (2020) 117865

Fig. 2. Preparation of coal blocks for UCG laboratory model (a) Coring at Rock Specimen Preparation Laboratory, (b) after coring of coal block.

calorific gases and reducing greenhouse gas emission. The molar feed
ratio of the feed gases was controlled by using a rotameter. A rotameter
was used for measurement of the volumetric flow rate of oxidants
feeding to the injection borehole. The ignition front was found to spread
in both axial and radial directions liberating heat for the progress of
gasification reactions. After coal combustion gas accumulated inside
the borehole and started coming out through production well and goes
to gas chamber. This gas is known as syngas. The production borehole
was connected to the gas chamber via a stainless steel pipe hose for
transportation syngas to gas chamber. During the experimental period,
gas samples may be collected on individual vacutainers at a fixed time
interval for off-line analysis by using a gas chromatograph.

4.3. Observation

4.3.1. Temperature
The duration of experiment has 48 h including 3 h ignition time (ti )
and 15 h quench time (tq ). During ti only oxygen is fed for the com-
bustion and during tq oxygen is stopped to feed. The temperature re-
corded by high range K-type thermocouples (TC1 and TC2) at gasifi-
cation zone. The two thermocouples TC1 and TC2 measured
temperature data of oxidation and reduction zones respectively. The
temperature variation at gasification zone during experiment is re-
presented in Fig. 4. In this experiment the gasifier’s temperature was
Fig. 3. Pictorial view of UCG experimental set-up in laboratory scale. also analysed by using thermal imaging camera at different time period,
two of them are shown in Fig. 5(a) and (b). From Fig.5(a) and (b) it is
gasification zones during coal burning/gasifying. These thermocouples clear that the temperature of oxidation zone is greater than reduction
were connected to a temperature indicator for continuous display ga- and pyrolysis/draying zones.
sification zone’s temperature (in degree Celsius). A stainless steel pipe
hose of 25 mm diameter was used for connection between production 4.3.2. Produced gases
borehole and gas chamber. Fig. 3 shows pictorial view of UCG labora- The injected oxidants react with coal to form a product gas, which is
tory experiment in pilot scale. subsequently brought to the surface, cleaned and used as a fuel or
chemical feedstock. The final product gas consists mainly of hydrogen,
carbon monoxide, carbon dioxide, methane and nitrogen. The produced
4.2. Investigation gases are passed through and analyzed in real time (during gasification)
by a developed gas analysing unit. Concentration of hydrogen, me-
First, combustion was initiated by placing a piece of camphor inside thane, carbon monoxide, oxygen, and carbon dioxide gases were mea-
the injection borehole. After that, end of injection borehole was sealed sured in real time with the help of respective gas sensors, which were
by mud and then oxidants (oxygen) were continued to supply into the mounted over the gas chamber. The developed sensor board for gas
injection well to sustain gasification process. The pure oxygen (O2 ) was analysis is shown in Fig. 6. Five sensors are used to measure the re-
used for oxidizing of coal at below ground. Then steam was used as for spective gases simultaneously with sampling period of 10 s controlled
increasing CO/H2 ratio of product gas, conversion of solid fuel into by a microcontroller and displaying through a data-management

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R. Mandal, et al. Fuel 275 (2020) 117865

Fig. 4. Graphical representation of temperature variation at gasification zone during experiment.

software. The flow chart of this gas monitoring process is presented in


Fig. 7. During analysis of the produced gases, the gas components found
were mainly H2 , O2 , N2 , CO, CH 4 and CO2 . Fig. 8 represents the gra-
phical view of the variation of produced gases concentration during the
first 40 h of experiment (till the starting of quenching period). The
figure also shows the oxygen and steam feed during this period. It is
observed from the variation in the figure that concentration of pro-
duced gases change when feed ratio of oxidants to the injection bore-
hole change.
The produced gases used in electricity generation, chemical and
fertilizer industry by separation its components or increase its con-
centration with the help of gas treatment and conversion units between
gasifier and gas usage. One of the popular and important techniques for
gas separation is the use of membranes. Some of the types of mem-
branes are polybenzimidazole meniscus membranes, CO2 – selective
membranes, hydrogen-selective membranes, hybrid membranes-con-
densation process, higher H2 /CO2 selective membranes [30].

Fig. 6. Gas chamber with gas monitoring unit.


4.3.3. Coal tar
Coal tars and un-reacted water vapour were also come out through
production borehole during gasification. Produced coal tar was also
analysed by FTIR (Fourier Transfer Infra-red) spectroscopy method by present in produced coal-tar during coal gasification. In this waveform,
using the Agilent Technologies make FTIR Spectrometer (Cary 600 four different peaks are found at different wave numbers. These peaks
series). In this technique, an absorbance spectra of the coal-tar sample is of absorbance vs wave number graph show different functional groups
created which provides information about the unique chemical bonds present in the produced coal tar, which are indicated against the cor-
and molecular structure of the material. responding wave number [31]. Fig. 9 shows that the produced coal tar
The Fig. 9 is the graphical representation of organic molecules contain mainly alcohol (both polymeric and H-bonded).

Fig. 5. Body temperature of coal block by measuring thermal imaging camera (a) After 22.75 h (during gasification time), (b) After gasification (during quench time).

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Fig. 7. Flow chart of gas monitoring unit.

Fig. 8. Graphical view of concentration of produced gases against oxidants feed.

4.3.4. Cavity growth operation and control of the gasification process from the surface. In
The cavity formed inside the coal block is assessed after the com- this paper, a laboratory based UCG model is designed, developed and
pletion of gasification process. A probe camera is used to get the inside experiment was conducted with real-time advanced monitoring of
view of the cavity formation and is presented in Fig. 10(a). An optical syngas characteristic, temperatures, cavity formation, coal-tar through
pictorial view of the same cavity is obtained after breaking the coal monitoring software and instruments. The simple experimental set-up
block and is presented in Fig. 10(b). The dimensions of the cavity are was made by using a single-piece coal block from an Indian mine.
also measured. It is observed that the rate of cavity formation and it’s The main motivation for moving toward UCG technique as future
size depend on the rate of gasification (feed molar ratio of oxidants) and energy security and utilization of deep-seated coal is the economic,
ash content in the coal respectively. As long as the coal gasification environmental and other benefits over the conventional mining
process continues the cavity formation by this process also keeps methods. UCG technique has extended the scope for gasifying coal di-
growing [32]. It is observed that during cavity formation cracks are also rectly from a coal seam. This experimental study is helpful for assess-
generated in the coal block that helps boosting of the gasification rate. ment of the behaviour of process parameters for adoption of UCG
technology. It is observed that the rate of gasification depends upon
5. Conclusions feed molar ratio of oxidants (i.e. oxygen and steam ratio) into the in-
jection well. When water steam slightly increases to the injection
The implementation of the UCG technique in the actual field re- borehole, the productions of CO and H2 gas increase. This laboratory-
quires knowledge of different scientific field such as coal geology, geo- based UCG process study can now forecast on the sustainability and
mining, automation, chemical, and process engineering. Significant standardisation before the actual field implementation.
investment is necessary to build the complete real system for successful

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R. Mandal, et al. Fuel 275 (2020) 117865

Fig. 9. Graphical representation of functional group presents in produced coal tar.

Fig. 10. Pictorial view of coal block after gasification for cavity analysis (a) By using a probe camera, (b) After braking of coal block.

Declaration of Competing Interest the context of underground coal gasification. J CO2 Util 2017;21:177–90.
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assessment of underground coal gasification [Ph.D. thesis]. Virginia Tech; 2012. programme.
[28] Kačur J, Laciak M, Durdán M. Remote monitoring and control of the UCG process.
In 12th International Carpathian Control Conference (ICCC), 2011. IEEE; 2011. pp. Dr. Swades Kumar Chaulya has been working as a scientist since 1993 at a national
176–180. laboratory, presently known as CSIR-Central Institute of Mining and Fuel Research (CSIR-
[29] Kostúr K, Sasvári T. Research of lignite underground gasification. Acta Montanistica CIMFR), Dhanbad under the aegis of Council of Scientific and Industrial Research (CSIR),
Slovaca 2010;15(2):121–33. Ministry of Science and Technology, Government of India. He has published 37 research
[30] Merkel TC, Zhou M, Baker RW. Carbon dioxide capture with membranes at an igcc papers in international cited journals, 41 papers in national journals, about 80 papers in
power plant. J Membrane Sci 2012;389:441–50. various conferences. There are 13 national and international patents in his credit, and
[31] Shearer GL. An evaluation of fourier transform infrared spectroscopy for the most of which have been commercialized.
characterization of organic compounds in art and archaeology [Ph.D. thesis].
University of London; 1989.
Dr. Girendra Mohan Prasad is working as a Senior Principal Scientist in Central Institute
[32] Najafi M, Jalali SME, KhaloKakaie R, Forouhandeh F. Prediction of cavity growth
of Mining and Fuel Research (CSIR-CIMFR), Dhanbad, India. His areas of research are
rate during underground coal gasification using multiple regression analysis. Int J
studies of various electrical and electronic properties of semiconductor materials, optical
Coal Sci Technol 2015;2(4):318–24.
fiber communication, fiber-optic sensor development and communication system for
mining and allied industries. He has published 14 research papers in international jour-
Ranjeet Mandal is working as Secretary in Research Education and Social Empowerment nals, 6 papers in national journals, and presented 23 papers in International/National
Society, Dudhichuwan, Chitra, Deoghar, Jharkhand, India. He has completed in B. Tech conferences.
(EIE), P.G. Diploma (Industrial Automation) and pursuing part-time Ph.D in Department
of Mining Machinery Engineering, Indian Institute of Technology (Indian School of

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