PRESENTATION

ON
MINE PLANNING & PROJECT PLANNING

CONCEPTS, CONSIDERATIONS & PROCESSES

OUTLINE OF THE PRESENTATION

PLANNING CONCEPTS AND STAGES

• MASTER PLANNING OF COALFIELDS
• PROJECT PLANNING & MINE PLANNING
• OPERATIONAL PLANNING

COAL MINING METHODS

• UNDERGROUND
• OPENCAST
• HYBRID METHODS

INFORMATION FLOW & PROCESSESS IN PLANNING

OPENCAST MINING
• GEO-MINING CONDITIONS
• TECHNOLOGICAL OPTIONS & MINING METHODS

UNDERGROUND MINING
• TECHNOLOGICAL OPTIONS & MINING METHODS

ISSUES & CHALLENGES

TYPICAL OPENCAST MINE PLANNING LIFE CYCLE
 PLANNING CONCEPTS & STAGES

• MASTER PLANNING OF COALFIELDS

• PROJECT PLANNING & MINE PLANNING AND DESIGN

CONCEPTUAL LEVEL PLANNING

PRE FEASIBILITY STUDY

MINING PLAN (Statutory requirement) INCREASING LEVEL OF CONFIDENCE

FEASIBILITY STUDY

DETAILED PROJECT REPORT

• OPERATIONAL PLANNING (Need based for large capacity opencast mines)

CHOICE OF MINING METHODS

• UNDERGROUND METHODS
• OPENCAST METHODS
• HYBRID METHODS (HIGHWALL MINING)

MOSTLY GOVERNED BY ECONOMIC CONSIDERATIONS &

BREAK EVEN STRIP RATIOS.

STAGE 1
STAGE 2
STAGE 3
CHOICE OF MINING METHOD, TECHNOLOGY AND RATED CAPACITY

OTHER KEY CONSIDERATIONS:

MINE/BLOCK DIMENSION & LAYOUT , SURFACE CONSTRAINTS

GEO-MINING CONDITIONS
• TOPOGRAPHY
• SEAM THICKNESS AND DISPOSITION
• STRUCTURAL COMPLEXITY
• UG WORKINGS/FIRE etc.
• STRIPPING RATIO
• RATE OF ADVANCE & DEEPENING

PRODUCTION REQUIREMENT – QUANTITY & QUALITY AND TIMELINES

LOGISTIC LIMITATIONS

ENVIRONMENTAL CONSIDERATIONS

TECHNO-ECONOMICS AND ECONOMIES OF SCALE

FUND AVAILABILITY
INFORMATION FLOW AND PROCESS IN OPENCAST PLANNING

Geographical Features
Base Geological Report
& Surface constraints

Study of GR &
Surface features in details

Coal seam, Dip, Structural

Features, fault, fold,
Disturbances

Conservation, safety and

Fixation of Mine Boundary economic considerations

Access Trench, Haul Road,

Mining Strategy & Sequence
 Information flow from previous slide

Estimation of Mineable
Reserve

Eqpt. Selection, Calendar plan

Mining Stage Plans, Location of
Dumps, Optimization etc.

EMP related study &

Infrastructure Planning Data generation

CHP, W/S, Electricals & Lighting Baseline data, EMP, R&R,

Pump, Civil, Washery, FBC etc Mine Closures

PR Details, Plans &

Appendices
 Information flow from previous slide

Project Costing/ Investment

Cost sheet/ IRR/ Risk Analysis etc

Scrutiny & Appraisal of PR

Finalization of PR
DATA INPUT FOR TOPOGRAPHICAL DATA
OPENCAST MINE PLANNING •Physiography

•Drainage

•Surface Features
 METEREOLOGICAL DATA
 LAND USE DETAILS

 GEOLOGICAL DATA

•Regional Geology
•Borehole Logs
•Floor Structure (Each Seam)
•Roof Structure (Each Seam)
•Seam Isochores
•Overburden Isopach Maps
•Interburden Isopach Maps
•Geological Structure
•Seam Structure Data/Quality data
 HYDROLOGY & HYDROGEOLOGICAL DATA

 OTHER DATA

•Accessibility

•Power

•Water
 OPENCAST PROJECT AND MINE PLANNING

 DEPOSIT APPRAISAL
 DELINIATION OF MINE BOUNDARIES
 ESTIMATION OF MINEABLE RESERVES
 ESTIMATION OF OB AND AV. STRIPPING RATIO
OPENCAST
 METHOD OF MINING & SEQUENCE OF MINING MINE PLANNING & DESIGN
 EQUIPMENT SELECTION & SCHEDULING
 PRODUCTION SCHEDULING
 DUMP & RECLAMATION PLANNING
 ANCILLARY EQUIPMENT PLANNING
 MINE UTILITIES & FACILITIES PLANNING (MATERIAL HANDLING, POWER, WATER)
 LAND REQUIREMENT & CIVIL CONSTRUCTION PLANNING
 ENVIRONMENTAL MANAGEMENT PLANNING AND MINE CLOSURE
 SAFETY AND CONSERVATION
 MANPOWER PLANNING
 PROJECT IMPLEMENTATION SCHEDULE
 CAPITAL & OPERATING COST ESTIMATES
 FINANCIAL ANALYSIS & SENSITIVITY ANALYSIS
OPENCAST METHODS

ADVANTAGES:

• HIGHER % OF RECOVERY OF COAL.

• SAFER OPERATIONS.
• EARLY EXTRACTION & QUICK RETURN OF CAPITAL.
• LARGE OUTPUT POSSIBLE.
• HIGH MANPOWER PRODUCTIVITY.
• HIGH DEGREE OF MECHANIZATION POSSIBLE.

CHALLENGES:

• ENVIRONMENTAL ISSUES.
• WEATHER AFFECTS ON OPERATIONS.
• LAND ACQUISITION.
• REHABILITATION & RESETTLEMENT.
• EXTERNAL DUMP SPACE.
• ENVIROMENTAL & FORESTRY CLEARANCES.
• INCREASED DEPTHS (> 300 m) OF MINES IN FUTURE).
OPENCAST METHODS

CHOICE OF OPENCAST MINING METHODS CAN BE CLASSIFIED

BASED ON TECHNOLOGY & EQUIPMENT TYPES, LAYOUT &
DISPOSITION OF COAL SEAMS, GEO-MINING CONDITIONS AND
CONSTRAINTS.

VARIOUS TERMINOLOGIES USED WITH OPENCAST MINES ARE:

STRIP MINING
OPENPIT MINING
CONTOUR MINING/MOUNTAIN TOP REMOVAL
STRIKE MINING VRS DIP-RISE MINING
TERRACE MINING
HORIZONTAL SLICING
INCLINED SLICING
BACKFILL MINING
 OPENCAST METHODS
GEO-MINING CONSIDERATIONS

MINERAL DEPOSITS

NON-STRATIFIED
STRATIFIED
IRON
COAL/LIGNITE/PHOSPHATE
ORE/BAUXITE/GOLD

HORIZONTAL INCLINED VEIN TYPE MASSIVE

MODERATELY STEEPLY NARROW WIDE

INCLINED INCLINED

THICKNESS OF THICKNESS OF THICKNESS OF STRUCTURAL CIRCULAR

OB PARTINGS SEAM DISTURBANCE IRREGULAR

DEVELOPED PRESENCE OF DUMP SPACE MINE

WORKINGS DIRT BANDS AVAILABILITY LAYOUT

STRATA PRESENCE OF
CONDITIONS AQUIFERS

BACKFILLED BY BACKFILLED BY
DIRECT CASTING TRANSPORT
ROUND THE PIT
OPENCAST METHODS

TECHNOLOGICAL
OPTIONS

TRANSPORTABLE NON-TRANSPORTABLE

SHOVEL-DUMPER COMBINATION

ROPE SHOVEL HYDRAULIC SHOVEL DRAGLINE, DIRECT SIDE

FRONT END/BACKHOE CASTING

SCRAPER OPERATION

BWE – BUCKET WHEEL EXCAVATOR D/L & SHOVEL-DUMPER

HYBRID SYSTEM
CONVEYOR TRANSPORT IN MINE

SURFACE MINER APPLICATION

HYBRID TRANSPORT SYSTEM

OPENCAST METHODS

DISPOSITION OF COAL SEAMS

MULTIPLE THICK SEAMS – NEARLY FLAT (UPTO 4 DEGREES)
MOST OF THE MINES IN NCL/SECL
OPENCAST METHODS

DISPOSITION OF COAL SEAMS

STEEPLY INCLINED SEAMS – GRADIENTS BETWEEN 30 TO 60 DEGREES
MOST OF THE MINES IN NEC, ALSO IN PARTS OF BCCL

08/03/20 16
13 0 0 N

- 7 90 0E

140 0 N

15 0 0 N

16 0 0 N

170 0 N

18 0 0 N

19 0 0 N

2 0 0 0N

2 10 0 N

22 00 N

2 3 0 0N

24 0 0 N

25 00 N

2 6 0 0N

2 7 0 0N
OPENCAST METHODS

2800N

2 9 0 0N

3 0 0 0N

3 10 0 N

3 200N

3 3 0 0N

34 0 0 N

3 5 0 0N

3 6 0 0N

37 00 N

3 800N

3 9 0 0N

40 0 0 N

4 10 0 N

4 2 0 0N

43 00 N

- 8 0 0 0E

4 400N
MINES IN TALCHER COALFIELD

4 5 0 0N

46 0 0 N
DISPOSITION OF COAL SEAMS

4 700N
MULTIPLE SEAMS, MODERATELY INCLINED (7-15 DEGREES) AND STRUCTURALLY DISTURBED
 OPENCAST METHODS

DISPOSITION OF COAL SEAMS & STRUCTURAL COMPLEXITY

K O N A R K B L O C K

SECTOR-L

SECTOR-K SECTOR-J

SECTOR-H SECTOR-I
SECTOR-G

SECTOR-F

SECTOR-E

SECTOR-D

SECTOR-C

GOPALPRASAD WEST
GOPALPRASAD EAST
& EASTERN PART OF

BLOCK
SECTOR-B

SECTOR-A

NATARAJ BLOCK

DIGITAL MODEL OF THE SEAM FLOOR FLOOR CONTOUR

TECHNOLOGICAL OPTIONS (EQUIPMENT TYPES)

DRAGLINES (LIMITED APPLICABILITY, FLAT GRADIENT REQUIREMENT)

SHOVEL (VERY FLEXIBLE SYSTEM)

ROPE SHOVELS
HYDRAULIC SHOVELS
FRONT SHOVELS
BACKHOES
HIGH CAPACITY FRONT END LOADERS

TRUCKS/DUMPERS
DIESEL
DIESEL ELECTRIC
TROLLEY ASSISTED

SURFACE MINERS (FLAT GRADIENTS, SELECTIVE MINING)

DOZERS WITH RIPPER ATTACHMENTS (THIN SEAMS, PARTINGS)

INPIT CRUSHING & CONVEYING

BUCKET WHEEL EXCAVATORS

HIGHWALL MINERS
PLANNING OF UNDERGROUND (UG) MINES

 OPENING OF MINE ENTRIES

 METHOD OF MINING TO EXTRACT COAL FROM UG

UNDERGROUND
 COAL EVACUATION SYSTEM MINE PLANNING & DESIGN

 COAL HANDLING ARRANGEMENT

 MINE SUPPORT

 MINE VENTILATION

 MINE PUMPING

 POWER SUPPLY & ILLUMINATION

 SAFETY & CONSERVATION OF COAL

 EMP & MINE CLOSURE

TYPICAL MECHANISED UG MINE
UNDERGROUND MINING METHODS & TECHNOLOGICAL OPTIONS

• Bord and pillar method • Longwall method

• Manual • Individual support

• Semi-mechanized longwall
• Side Discharge • Powered support
Loader (SDL) longwall
• Load Haul Dump
(LHD) • Special methods
• Mechanised
• Continuous Miner • Blasting Gallery using
technology • Remote controlled
LHDs & Jumbo Drills
• Jankowice for inclined
seams
• Hydraulic mining, etc.
 GEO-MINING PARAMETERS
FOR
UNDER GROUND MINING TECHNOLGY SELECTION

TECHNOLOGY/ BORD & PILLAR BORD & PILLAR POWERED SUPPORT

PARAMETER CONTINUOUS MINER/ SIDE DISCHARGE LONG- WALL
BOLTER MINER/ LOAD LOADER
HAUL DUMPER
GRADIENT FLATTER THAN 1 IN 6 UPTO 1 IN 4 UPTO 1 IN 2
SEAM 1.5 M TO 5 M 1.5 M TO 5 M 1.5M TO 6M
THICKNESS
FAULTED MAY BE USED MAY BE USED NOT RECOMMENDED
PROPERTY/
INCONSISTENT
SEAM
THICKNESS
DEPTH UPTO 500M DEPTH UPTO 500M DEPTH UPTO 1500M DEPTH

Note:

For extreme geo-mining parameters like thick seams or steeply inclined seems,
special mining method such as blasting gallery, Longwall Top Coal Caving, Sub
level caving etc. are considered.

To support overlying structures, Bord & Pillar (With SDL or LHD) and sometimes
Longwall methods are used with sand stowing
GENERAL LAYOUT OF AN UNDERGROUND MINE

LAYOUT SEAM-VII(BOT +B1)

UNDERGROUND MINING

ADVANTAGES

 Minimal environmental Impact

 Minimal dilution in coal quality
 Minimal effect of weather
 Deep seated reserve can also be worked

CHALLENGES

 Low Recovery
 Hazards of gas, fire, inundation, etc
 High Specific investment
 Higher cost of production
OPENCAST MINING – ISSUES AND CHALLENGES

 TECHNO-ECONOMIC CONSIDERATIONS
DEEPER MINES WOULD ENTAIL HIGHER STRIPPING RATIOS.

QUALITY/PRICE OF COAL AND STRIPPING RATIO NOT PERMITTING

DEEPER OPENCAST PROJECTS.

 AVAILABILITY OF EXPLORED AREA/PROVED RESERVES, BOTH

ON ADJACENT AND DIP SIDE AREA.

 LOGISTICS - COAL EVACUATION LIMITATIONS.

 ACQUIRING LAND AND R&R ISSUES MAKING MINING A HIGH RISK BUSINESS.

 SURFACE AREA CONSTRAINTS (HABITATION, FOREST, NALLA/RIVERS, ROADS,

RAILWAYS, UG WORKINGS, ADJOINING MINES/BLOCKS).

 INTERNALIZING THE MITIGATING EFFECTS OF THE EXTERNALITIES INVOLVED

IN THE PLANNING PROCESS.

 TECHNICAL CONSTRAINTS: PIT BOTTOM ACCESSIBILITY, NON AVAILABILITY OF DUMP SPACE

WHY, PROJECTS NOT PLANNED FOR OPTIMUM CAPACITY
RIGHT IN THE BEGINNING? 5 MTY…10MTY……20 MTY…..????

REASONS:

IN THE 80’S AND 90’S, THE CAPACITY OF THE MINING PROJECTS WERE
PLANNED/CONSTRAINED BASED ON

LIMITED EXPERIENCE IN PLANNING AND OPERATING

LARGE OPENCAST PROJECTS.

MARKETABILITY/ OVERALL DEMAND SUPPLY SCENARIO /

CAPACITY/EXPANSION OF LINKED POWER PROJECTS.

FUNDING CONSTRAINTS INCLUDING FOREIGN EXCHANGE LIMITATIONS.

 RISK OF COST OVERRUN IN PROJECTS WITH LONG GESTATION.

WHY, PROJECTS NOT PLANNED FOR OPTIMUM CAPACITY
RIGHT IN THE BEGINNING? 5 MTY…10MTY……20 MTY…..????

REASONS:

IN ADDITION, IN YEARS BEYOND 2000, THE CAPACITY OF THE MINING PROJECTS

WERE PLANNED/CONSTRAINED ALSO BECAUSE OF

TECHNO-ECONOMIC CONSIDERATIONS
DEEPER MINES WOULD ENTAIL HIGHER STRIPPING RATIOS.

QUALITY/PRICE OF COAL AND STRIPPING RATIO NOT PERMITTING

DEEPER OPENCAST PROJECTS.

COST PLUS PROJECTS APPROVED ONLY IF CONSUMERS WERE

WILLING TO PAY AN AGREED HIGHER PRICE.

AVAILABILITY OF EXPLORED AREA/PROVED RESERVES, BOTH

ON ADJACENT AND DIP SIDE AREA.

LOGISTICS - COAL EVACUATION LIMITATIONS.

WHY, PROJECTS NOT PLANNED FOR OPTIMUM CAPACITY
RIGHT IN THE BEGINNING? 5 MTY…10MTY……20 MTY…..????

STAGE 1
STAGE 2
STAGE 3

ADDITIONAL REASONS FOR STAGE-WISE EXPANSION OF PROJECTS

ACQUIRING LAND AND R&R ISSUES MADE MINING A HIGH RISK BUSINESS.

SURFACE AREA CONSTRAINTS (HABITATION, FOREST, NALLA/RIVERS, ROADS,

RAILWAYS, UG WORKINGS, ADJOINING MINES/BLOCKS).

RESERVES NOT UNDER PROVED CATEGORY ALONG STRIKE OR DIP SIDE AS

EXPLORATION COULD NOT BE CARRIED OUT DUE TO ABOVE CONSTRAINTS.

TECHNICAL CONSTRAINTS: ACCESSIBILITY, DUMP SPACE AVAILABILITY,

TECHNOLOGICAL CONSIDERATIONS
 TYPICAL OPENCAST MINE PLANNING LIFE CYCLE

FREEZING MINE BOUNDARY:

KEY CONSIDERATIONS

BLOCK DIMENSION & LAYOUT

EXPLORATION STATUS

INITIAL PLANNED MINE GEO-MINING CONSIDERATIONS:

Reserves : 200 Mt
Final Depth : 220 m STRUCTURAL COMPLEXITY
ACCESSIBILITY
SR : 3 cum/t SAFETY ASPECTS
CAPACITY : 10 Mty CONSERVATION ISSUES
LIFE : 25 YEARS RESERVES & QUALITY
AVAILABLE DUMPING SPACE
TECHNOLOGICAL CONSIDERATIONS

SURFACE CONSTRAINTS:

EXISTING MINES
ROADS/RAILWAY/POWERLINES
HABITATION AREAS
WATERBODY/NALLA/RIVERS
FLOOR BOUNDARY FIRE/UG WORKINGS etc.

TECHNO-ECONOMICS
SURFACE BOUNDARY
STAGE 1
 TYPICAL OPENCAST MINE PLANNING LIFE CYCLE

INITIAL PLANNED MINE

Reserves : 200 Mt
Final Depth : 220 m
SR : 3 cum/t
CAPACITY : 10 Mty
LIFE : 25 YEARS

EXTRACTED : 100 Mt IN 13 YEARS

FLOOR BOUNDARY

SURFACE BOUNDARY
STAGE 2
 TYPICAL OPENCAST MINE PLANNING LIFE CYCLE

INITIAL PLANNED MINE EXPANSION MINE

Reserves : 200 Mt Reserves : 200 +150 Mt
Final Depth : 220 m Balance Reserves : 350 – 100= 250 Mt
SR : 3 cum/t Final Depth : 350 m
CAPACITY : 10 Mty SR : 4.5 cum/t
LIFE : 25 YEARS CAPACITY : 15 Mty
BALANCE LIFE : 18 YEARS
EXTRACTED : 100 Mt IN 13 YEARS

EXTENDED FLOOR BOUNDARY

FLOOR BOUNDARY

SURFACE BOUNDARY
STAGE 3
EXTENDED SURFACE BOUNDARY