Jha Indian Coal-sector

7/30/2019 Jha Indian Coal-sector

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2nd MEETING OFINDIA-EU WORKING GROUP

ONCOAL & CLEAN COAL

TECHNOLOGIES

29th November 2006

BRUSSELS


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AN OVERVIEW OF

INDIAN COAL SECTOR


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Energy Scenario

Coal continues to be the major source of primary energy worldwide.Share of coal in worlds energy consumption is 28%.

Coal and lignite in India support about 55% of the primary commercial

energy.Fuel-wise Break-up of Primary Energy Consumption (in %)

100

6

6

28

2436

WORLD

100

5

10

21

2341

OECD

100Total

6Hydro-Electric

1Nuclear Energy

55Coal

8Natural Gas30Oil

INDIAConsumption by Fuel

Source: BP Statistical Review of World Energy, June 2006.


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Mode - wise Electricity Generation

Wind, 1%

Nuclear, 3%

Gas, 10%

Diesel, 1%

Coal, 69%

Hydel, 16%

Coal

Hydel

GasDiesel

Nuclear

Wind


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World Coal Resources

PROVED COAL RESOURCES OF THE WORLDPROVED COAL RESOURCES OF THE WORLD (Coal & Lignite)(Coal & Lignite)

Total Proved Resources (Coal & Lignite)Total Proved Resources (Coal & Lignite) -- 909 BT909 BT

USA 27%

Russia 17%China 13%

India 10%

S.Africa 5%

Others 19%

Australia 9%

Source: BP Statistical Review of World Energy, June 2006Source: BP Statistical Review of World Energy, June 2006


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Key Players in Indian Coal Sector

407 MtesTotal (During 2005-06)

27.5 Mtes

(7%)

Captive Producers - (Steel & Power)

36.1 Mtes

(9%)

Singareni Collieries Company Ltd.

(SCCL) - (AP St. Govt. & Govt. of IndiaJt. Venture)

343.4 Mtes(84%)

Coal India Ltd. (CIL)- (A Govt. of IndiaEnterprise)

ProductionCoal Producing Companies


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TOTAL RESOURCE 253 Billion Tonnes

COKING 32 Bt

NON-COKING 221 Bt

INDIAN COAL RESOURCES - 2006


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COAL RESERVES IN INDIA

253.337.7119.895.8Total

221.235.6106.379.3Non coking

1.70.21.000.5Blendable/

Semi Coking

25.11.911.811.4Medium

Coking Coal

5.30.000.74.6Prime Coking

TotalInferredIndicatedProvedType of Coal

(Billion Tones)

(As on 1.1.2006)


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DEMAND SUPPLY GAP (Projected)DEMAND SUPPLY GAP (Projected)

51.10

10.2540.85

680.00

652.35

27.65

731.10

662.60

68.50

11-12

181

12556

1086

1037#

49

1267

1162

105

24-25DEMAND AT 8%GDP GROWTH

25.80COKING COAL

41.68TOTAL

15.88NON COKING COALGAP

432.50TOTAL

414.60NON COKING COAL

17.90COKING COALAVAILABILITY

474.18TOTAL

430.48NON COKING COAL

43.70COKING COAL

DEMAND

06-07SECTORDEMAND/SUPPLY/ GAP

# Includes 25 Mt Coal equivalent of CBM-UCG

(Million Tonnes)

Source: Draft Report of WG on Coal & Lignite for XI Plan & VisiSource: Draft Report of WG on Coal & Lignite for XI Plan & Vision Coal 2025on Coal 2025


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COAL AVAILABILITY IN INDIA

1086

25

1061

57

175

47

782

24-25

(Proj.)

680.0

-

680.0

-

118.7

40.8

520.5

11-12

(Proj.)

432.5

-

432.5

-

31.2

37.5

363.8

06-07

(Antic.)

407.0

-

407.0

-

27.5

36.1

343.4

05-06

(Actual)

Grand Total

Coal equiv. of

CBM-UCG

Total Coal Production

Unblocked Areas

Others including Captive

SCCL

CIL

( in Mt)

Source: Draft Report of WG on Coal & Lignite for XI Plan & VisioSource: Draft Report of WG on Coal & Lignite for XI Plan & Vision Coal 2025n Coal 2025


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Thrust AreasThrust Areas

To introduce stateTo introduce state--ofof--art mining and beneficiationart mining and beneficiationtechnologiestechnologies

To harness coal resources with due regard toTo harness coal resources with due regard toenvironmental and social issuesenvironmental and social issues

To promote exploration and exploitation of CBM,To promote exploration and exploitation of CBM,CMM & AMMCMM & AMM

To promote underground coal gasification and coalTo promote underground coal gasification and coalliquefactionliquefaction

ToTo modernisemodernise mining practices through IT drivenmining practices through IT drivenprocess control and managementprocess control and management

To promote research and development in Coal SectorTo promote research and development in Coal Sector


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Coal Movement in India

Bulk of coal (47%) is transported by well

developed railway network Pit-head consumers by dedicated MGR rail

link(23%)

Coastal consumers in Southern India by rail-cum- Sea Route.

Limited Aerial Ropeway and belt conveyors


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Coal Preparation As per GoI stipulation, power houses situated

beyond 1000 kms from pitheads, load centers andspecified areas must use


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Largest Equipment Size

-2.20m - 3.70m

0.3m - 0.6m

SURFACE MINER

Cutting Width

Cutting Depth

-24/96DRAGLINE

42 cum20 cumROPE SHOVEL

PROPOSED TOBE INDUCTED

AT PRESENT

16 cum11.8 cumHYDRAULIC SHOVEL

DOZER

RBH DRILL

REAR DUMPER

770 hp

311 mm

170 T

850 hp

381 mm

250T


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Technology-wise Break-up of Underground

Coal Production

62.75TOTAL

2.61Other methods

2.87Mechanized Longwall

0.14Conventional Longwall

34.40Mechanized Bord & Pillar

22.74Manual Bord & Pillar2005 06 (MT)Method of mining


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Future Trends : (Underground Mining)

Phasing out of manual mining

Adoption of higher level of mechanisation

Powered Support Longwall

Continuous miner

Blasting Gallery

High wall mining


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Underground Coal Mining-

Thrust Areas Extraction of coal locked in pillars/ below

developed seams

Strata control, particularly Hard Roof Management

Mining of Thick seams

Mining of moderately inclined seams ( 150 to 250) Mining of steeply inclined seams ( more than 250)

Fast drivage of Inclines / Shafts

Communication Technology allowing controlroom operation of UG mines


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CMM Demonstration ProjectCMM Demonstration Project

CBM Recovery and CommercialCBM Recovery and Commercial UtilisationUtilisation

Being implemented jointly by BCCL and CMPDIL inBeing implemented jointly by BCCL and CMPDIL in

SudamdihSudamdih andand MoonidihMoonidih mines of BCCLmines of BCCL Fund provided by GoI/GEF/UNDPFund provided by GoI/GEF/UNDP

The aim of the project is:The aim of the project is:

To acquire exposure in CBM production fromTo acquire exposure in CBM production fromvirgin area and working mine by drilling fromvirgin area and working mine by drilling from

surface and undergroundsurface and underground

UtilisationUtilisation technique of extracted CBMtechnique of extracted CBM

The gas is likely to be available from 2007The gas is likely to be available from 2007--08 for08 for

utilisationutilisation


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Thrust Areas for Research ActivitiesThrust Areas for Research Activities Development of mining methods for steep and thick seamsDevelopment of mining methods for steep and thick seams

Development of hard roof management technique like HydroDevelopment of hard roof management technique like Hydrofracturing or safe blasting etc.fracturing or safe blasting etc.

CBM / CMM resource assessment and recovery techniquesCBM / CMM resource assessment and recovery techniquessuitable for Indian conditionssuitable for Indian conditions

InIn--situ gasification of identified coal/lignite seamssitu gasification of identified coal/lignite seams

Detection and mapping of old and unapproachable undergroundDetection and mapping of old and unapproachable undergroundworkingsworkings

Application of I.T for detection of trapped miners in the eventApplication of I.T for detection of trapped miners in the event ofofdisastersdisasters

Cost effective beneficiation of LVHR coalsCost effective beneficiation of LVHR coals

Improved fine coal recovery techniques for coking coalImproved fine coal recovery techniques for coking coalwasherieswasheries

Conversion of coal to Liquid hydroConversion of coal to Liquid hydro--carbons/surface gasificationcarbons/surface gasification


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Development of miningmethods for winning steep

and thick coal seams


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Extraction of Steep & Thick Coal Seam

STATEMENT OF THE PROBLEM

- STEEP SEAM EXTRACTION IN NEC

NEC is a unit of Coal India Limited in North East India.

Presently working 3 UG mines and 2 Open Cast mines

Tertiary Coal Low ash, high sulphur, caking in nature

All seams are of Deg III gassiness ( >10m3 CH4/te ofcoal produced)

Coals are friable, soft and prone to spontaneous heating

Soft roof and soft floor Roof & floor consists of clay, shale, mudstone & siltstone

Highly acidic mine water due to presence of sulphur


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Evergreen tropical forestVegetation

Humid but short summer, prolonged rainy

season and fairly cold winter

Climate

Hilly rugged terrain having steep slopes

with elevations ranging from 175m - 500mabove mean sea level in Tipong Block and160m - 360m above mean sea level inLachitkhani Block

Topography

GENERAL FEATURES


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Upto 500mUpto 400mUpto 560mUpto 450mExploreddepth(m)

15m to 50m15m to50m

15m to50m

15m to 50mIncropdepth

250 to 400 in southern &

250 to 300 in thenorthern side

550 to 750 in eastern part& 400 to 550 in westernpart

Gradient

5.4 19.24.05-9.007.84-19.83.93 8.62Thickness(m)

60ft seam20 ft seam60ft seam20 ft seam

LACHITKHANI BLOCK(LEDO)

TIPONG BLOCKParticulars

TECHNICAL PARAMETERS OF 20 ft & 60 ft SEAMS


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60ft seam60ft seam

LACHITKHANI BLOCK( LEDO)

TIPONG BLOCKParticulars

20 ft seam20 ft seam

27.2258.38Grand Total(Mt)

20.266.9643.6714.71Total (Mt)

3.68(New)

2.03(T)

14.55(B)

1.43 (T)

3.84(B)1.68(T+B)

32.63

(west)11.03(East)

8.08 (West)

6.629 (East)

Reserve

(Mt)

COAL RESERVES



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78776650*35% of extraction

within panel

135210220175*150Avg. Prod(TPD)

450 to 550Above 600400 to500

250 to 350Above

380Seam Gradient

4 to 4.55 to 66 to 96 to 93 to 11Seam

Thickness (m)

CKShield

SectionalShield

Rigid DescendingShield Method

Flexible

Roofing

ScaperAssisted

Chamber

TipongParticulars

UG METHODS OF WORK APPLIED IN NEC



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Present Method

Tipong mine: Modified Tipong Method

Ledo mine: Scraper assisted chamber method. Methods tried earlier

Flexible roofing:The net used for flexible roofing got punctured

resulting in deterioration of qualityAs total coal could not be evacuated, it led to fire

Descending shield method:Non availability of thick timber required in this method.

Uneven roof and floor surface creating difficulty inshield sliding.Variation in seam thickness did not allow the shield todescend.

METHODS OF WORK USED IN TIPONG & LEDO



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270003000030000LEDO

443006480056500TIPONG

03-0404-0505-06MINE

PRODUCTION ACHIEVED (te)



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OBJECTIVE OF CO-OPERATION

To achieve improved productionperformance and extraction percentage ofthe steep seam higher value coal by utilizingimproved mining technology.

Explore alternative mining methods availablein the member countries to the uniquecharacteristics of the coal bearing strata of

the North Eastern Region.



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Study on Coal Quality ManagementSystem in India - Beneficiation

of Coking and Thermal coals


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INDIANINDIAN COALSCOALS -- CHARACTERISTICSCHARACTERISTICS

FAVOURABLE

Low sulphur content [around 0.5 %]

Less trace elements

More environment friendly due to above

UNFAVOURABLE Contain high percentage of inorganic impurities (due

to Drift origin); 65% of non-coking coal belongs to

high ash category (grade E and below)

Contain high percentage of Near Gravity Materials

(NGM)


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CONSUMERSCONSUMERS COAL QUALITY NEEDCOAL QUALITY NEED

< 34Power Sector

20-25Cement Sector

About 15Coal Dust Injection (CDI)

About 25Heat Intense Industries

20-25Corex Technology for Steel

About 25Sponge Iron Technology

17+0.5Steel Sector

Acceptable limit of

Ash%

Coal Consumers


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COAL BENEFICIATIONCOAL BENEFICIATION2025 (Projection)2025 (Projection)

1061Grand Total

1012Total Non-Coking

810Inferior Grade

202Superior Grade

Non-Coking

13LVHR

36Coking

2025 (in Mt)Quality of Coal

The entire production of coking & low volatile high rankcoal and most of the inferior grade non-coking coal willneed beneficiation.


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COAL BENEFICIATION (cont.)COAL BENEFICIATION (cont.)

Most of the existing washeries have outlived theirlives and require replacement.

New plants have to be erected to cater to theadditional production of coking and LVHR coal

The capacity of non-coking coal washeries needto be greatly increased considering that around

40-45% of the inferior grade non-coking coalwould require beneficiation.


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Beneficiation of Coking Coal fromV/VI/VII/VIII lower seams ofJharia coalfields


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Typical Characteristics

Thick seams with number of bands spreading over approximately30 km stretch along the strike direction.

General characteristics of these coals are Low in Volatile Matter content (15 to 20%)

High ash content ( 30 to 35% or even more),

These coals posses unique petrographic characteristics as

follows:

Mean vitrinite reflectance varies between 1.25 and 1.45%showing desirable maturity of coal.

High inertinite content (60-70%, sometimes even more) whichare intimately mixed with inorganic micro components aswell as with vitrinite, which gives a high percentage of neargravity material (50-60%) at the desired specific gravity of cut.

T l h d


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Typical Characteristics (Contd...)

Due to intimate mixing of microcomponents, these coals have extremely

poor liberation characteristics when raw coal is progressively crushed

from 75 to say, 13 or 6 or even 3 mm, the

yield of cleans at 17.5 + 0.5 % ash variesbetween 30 and 35% only.

Existing coking coal washery circuits arenot capable to beneficiate such coaleconomically.


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LVC Coal :

Projected production programme

Projected production programme by the year 2011-12

is as follows :

Presently usedfor Powergeneration

Nil13Low Volatile HighRank (LVHR), i.e.,high ash Coking

coal

RemarksExistingWashing

Cap, mty

ProjectedProduction

mty

Type of Coal

O CT O CT


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In the context of fast depleting reserves of prime cokingcoal it has become necessary to utilize low volatilecoking coal (LVCC) for coke making for use in blastfurnace after proper blending.

To develop/ establish a suitable technology forbeneficiation of high ash difficult-to-wash Coking coalfrom V/VI/VII/VIII seams coal of Jharia coal field

To set up a Demonstration Plant of capacity around 0.5 1 Mty of raw coal for washing of V/VI/VII/VIII seamcoal of Jharia coal field to obtain: Metallurgical grade coking coal (Ash % ~ 18 + 0.5) as

Cleans Power grade coal (Ash < 34)

Low Carbon Rejects

PROJECT OBJECTIVE


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Capacity creation inresource assessment of

CBM/CMM/AMM

D l t fD l p nt f C lb dC lb d M th i I diM th n in Indi


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Development of CBM from deep seated coal

deposits (VCBM) has made considerableprogress.

26 CBM blocks have so far been allotted withprognosticated resource of 1.45 tcm in 13591 Sq.Km area.

The production potential from the allotted blocksis 38 MMSCMD.

Development ofDevelopment ofCoalbedCoalbed Methane in IndiaMethane in India

C l i M hC l i M h


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Development of CMM/AMM has been visualised through aconcept paper and steps are being taken in this regard.

A CMM demonstration project is under implementation jointlyby BCCL and CMPDI in Sudamdih and Moonidih mines of

BCCL with GoI/GEF/UNDP funding

The surface drilling has started.The gas is likely to be available from 2007-08 for

utilisation.

CMM resource of 150 BCM has been tentatively assessed for 5coalfields viz Jharia, Raniganj, Bokaro (East & West) and S.

Karanpura. This resource would, however, require firming up.

Coalmine MethaneCoalmine Methane

C l i M th


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The development of CMM/AMM in India is not at par withVCBM as it is constrained on account of various reasons.

Constraints in development of CMM/AMM9 Capacity is lacking in resource modeling of de-stressed coal

seams and determination of techno-economic feasibility of

CMM project9 Legal/safety frame work for CMM exploitation

9 Ownership issues

9 Lack of infrastructure for cost effective transportation &

utilisation of recovered methane.

Coalmine Methane

C l i M th


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Assistance and Collaboration Area

Resource modelling of coal seams under

de-stressed condition by experts in the field

Development of a model project with well

defined functional areas of each stake

holders

Economic analysis of the project conceived

Coalmine Methane


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Insitu Coal Gasification


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In India, UCG was taken up as a National Project in early 80's.

The Pilot Scale Project at Merta Road could not be taken updue to apprehension of contamination of ground water, onwhich the local population is dependent.

With the thrust on clean coal technology and advancement insupportive technologies, there is a renewed interest in UCG.

Keen interest is being shown by several agencies in Public andPrivate sector.

Headway is being made by the national coal & lignitecompanies in association with ONGC and SIM Russia in UCG.

Underground Coal Gasification



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Proposed collaboration area

Technology transfer for pursuing UCG in followingareas

Site selection initially for a pilot scale studies

Taking up pilot scale studies in an collaborative

regime for establishing techno-economics

If found feasible pursuing a commercial project

with CO2 sequestration under a collaborative

regime



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Capacity creation in assessingCarbon Credit benefits related to

CBM/CMM/UCG etc.

Capacity creation for Carbon Credit


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Development of CBM/CMM/UCG is priorityarea of GoI

To accrue full benefit of clean coal technologiessuch as CBM,CMM,UCG etc, we need to

develop expertise in formulating relevantprojects in these areas qualifying carbon credit

mechanism

Capacity building for carbon credit is identifiedas an area of cooperation

Capacity creation for Carbon Credit


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Thank you

Documents

Jha Indian Coal-sector