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PRE-FEASIBILITY REPORT
Manoharpur and Dip-side Manoharpur Coal Mine Project
ODISHA COAL AND POWER LIMITED Zone-A, Ground Floor, Fortune Towers, Chandrasekharpur, Bhubaneswar – 751023, Odisha
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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Index
Sl. Description Page No.
1. Introduction of the Project: 2
2. Executive Summary: 4
3. End Use Project 6
4. Land Requirement 6
5. Water Requirement and Sources 7
6. Power Requirement and Supply 7
7. Mining 8
8. Manpower 17
9. Project Benefits 19
10. Project Schedule 21
11. Project Cost 21
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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1. Introduction of the Project:
Manoharpur and Dip-side Manoharpur coal blocks were earlier allotted to Odisha
Power Generation Corporation Limited (OPGC) in June 2007. Subsequent to
cancellation of coal blocks by Supreme Court of India, These two coal blocks have
been allotted to Odisha Coal and Power Limited (OCPL) on 31st August 2015 to
supply coal exclusively to the expansion power plants (4x660 MW) of OPGC. These
coal blocks are situated in the IB Valley area of Mahanadi Coalfields Ltd in the
district of Sundargarh, Odisha.
Manoharpur and Dip side of Manoharpur block are contiguous blocks having
common boundary and extension of the Manoharpur coal block. At the time of
allocation Manoharpur block was fully explored and Dip side of Manoharpur block
was regionally explored. In the meantime, the exploration of Dip-side Manoharpur
coal block has been completed and the Geological Report has been prepared by
CMPDI. It is envisaged to start the coal production initially from Manoharpur
coalmine and subsequently from its Dip-side Manoharpur coalmine as an extension
of Manoharpur coalmine. OCPL has obtained all the permits and clearances for
Manoharpur coalmine including Mine Opening Permission. The Mine Operator
appointed by OCPL has commenced the top soil removal engaging its resources.
Requirement of coal has been assessed as 7.6 - 8 MTPA for the expansion power
plants (4x660MW) of OPGC considering the minimum GCV of 3300 Kcal /kg and
90% PLF.
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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2. Executive Summary:
Sl. No. Description Details
1. Name of the Project Manoharpur & Dip-side Manoharpur Coal
Mine Project
2. Name of the Coal Block(s) Manohar & Dip-side Manoharpur
3. Name of the Organization Odisha Coal and Power Limited (OCPL)
4. Name and Address of the
Applicant
Odisha Coal and Power Limited
Zone A, Ground Floor, Fortune Towers,
Chandrasekharpur, Bhubaneswar-751023,
Odisha
5. Location of Mine Village: Manoharpur
Taluka: Hemgiri
District: Sundargarh
State: Odisha.
6. Name of the Coalfield Ib Valley Coalfields
7. Particulars of adjacent
blocks
North Meenakshi – B coal block
South Dulanga coal block
8. End Use Project Expansion Power Plant (4X660 MW) of
Odisha Power Generation Corporation
Ltd.,
9. Net Geological Reserve Manoharpur: 252 MT
Dip-side Manoharpur: 726 MT
10. Mining Lease Area 1781.591 Ha
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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11. Topo-sheet No. with
latitude and longitude.
Topo-sheet No.: F44 R13 & F44 R9
Latitude: 21o 55’52.168”N to
21o 58’16.871”N
Longitude:
83o 44’41.287”E to
83o 47’42.750” E
12. Peak Rated Capacity (PRC) 8MTPA
13. Estimated Cost of the
Project
Approx. 2720 Cr.
14. Nearest Town Sundargarh
15. Nearest Railway Station Hemgir
16. Nearest Airport Jharsuguda
17. Proposed year of start of
Production
2019
18. Proposed year of reaching
PRC
2023
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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3. End Use Project:
4X660MW Expansion power plant of Odisha Power Generation Corporation
limited (OPGC) located at Ib Thermal Power Station, Banharpalli in the district of
Jharsuguda, Odisha.
4. Land Requirement:
a. Abstract of Land Schedule :
Sl.
No.
Classification of
Land
Area Inside the
block (in Ha.)
Area outside the
block (in Ha.)
Total
( in Ha.)
1 Forest Land 476.230 134.887 611.117
2 Agricultural Land 339.364 163.446 502.810
4 Homestead land 14.032 4.438 18.470
3 Barren Land 429.780 122.204 551.984
5 Grazing Land 51.401 15.820 67.221
6 Water Body 27.078 2.911 29.989
Total Land within
proposed Mining Lease 1337.885 443.706 1781.591
Land for Colony for MO & Owner & other outside mining lease area
1 Agricultural Land 13.483 13.483
2 Barren Land 16.425 16.425
Total Land outside
proposed Mining Lease 29.908 29.908
TOTAL PROJECT AREA 1337.885 473.614 1811.499
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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5. Water Requirement & Source:
a. Water Requirement:
Water is required for various operations such as Domestic for drinking, dust
suppression, mine operation, green belt development and mechanical workshop.
Total raw water requirement for the mine has been estimated at 3780KLD with
recovery including design margin and losses.
b. Source of Water Supply:
Initially water will be met from ground water through boreholes for construction
and portable use. OCPL has received the NOC for ground water abstraction of
720cum/day from Central Ground Water Authority. Further drawal of 5.55 cuses
water from Hirakud reservoir has been received.
Washery to be designed on zero discharge principle. Thus, all waste water has to be
recycled. In that case, water requirement for washery has to be “Top up Water”.
6. Power Requirement & Supply:
Sources and receiving of power: The total power requirement for mines
operation is around 17 MVA. In order to avail this power in an uninterrupted and
continuous manner, OCPL has arranged power from two different sources.
Source-1: From 132/33 KV Remja GSS OPTCL at 33 KV, by constructing a 22 Km
33 KV single circuit line on RS joist poles and a 33 KV switching station at mines
end. This power supply arrangement shall be used for construction activities till the
CHP is commissioned and in the development stage & operation stage of mines till
the permanent power supply arrangement is ready (source-2). After charging of
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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permanent power supply arrangement (source-2), this connectivity shall be used
as a back-up power supply arrangement for mining activities.
Source-2: From 765/132/33 KV substation of NTPC, Darlipali at 33 KV, by
constructing two 132/33 KV 31.5 MVA transformer bays at Darlipali STPP. This
connectivity shall be used as a permanent source of power for mining operation
activities.
7. Mining:
a. Mining Technology:
The proposed mining block represents presence of moderately flat multiple coal
seams with intermediate varying parting. Moderately thick to thin seams occur at
shallow to moderate depth in wide area having power grade coal reserve. So this
will make the project most viable by adopting opencast mining method.
The overburden lying between surface and coal seam roof and the partings between
two successive seams are removed before coal is exposed. Fertile top soil of about
0.3m will be removed separately by using hydraulic backhoe & tipping truck
combination. During initial stage, top soil will be stored at a designated place with
appropriate conditions. When Ex-Pit waste dumps are formed to their final
configurations, top soil will be spread over dumps and stabilized by grass
carpeting/plantation. During later stage, top soil will be carried directly from
excavated area to in-pit waste dumps for spreading.
Below top soil, occurs a layer of weathered mantle comprising mostly of laterite.
This layer may not need blasting and may be excavated directly by shovel. Its
thickness varies from place to place.
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Coal seams may be encountered at the floor of weathered mantle wherever
occurring. Hard layers of sandstone, shale or carbonaceous shale occurring above
coal seams will require drilling and blasting for facilitating them to be loaded by
shovel, transported by rear dumpers and be stacked at designated sites of waste
dumps.
After removing overburden or parting, a coal seam is exposed. Coal will be
loosened/ cut by surface miners and loaded onto dumpers by front end loaders to
transport to receiving hoppers located on surface.
This process of clearing the top soil, removing overburden and extraction of coal
will be done in layers simultaneously with formation of benches to maintain safe
angle of slope and adequate working width for deployed machineries. These
benches will be aligned along strike of the seam and cut from one end of mine to the
other end. Thus, mine will advance from incrop side of lowest seam to dip side of
the property. Height of bench will be restricted to maximum safe digging height for
excavator deployed in that bench.
As mine progresses towards dip, waste material will be backfilled in de-coaled area.
Thus the opencast excavation will be closed continuously, after providing channels
for transport of coal from face to surface.
Proper planning of transport network, dumps and drainage, adequate lighting and
ventilation are required as the mining progresses beyond depth of 200m. As the
depth and stripping ratio increases, the percentage accommodation of dump within
the quarry will also be limited.
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b. Choice of Technology
For continuous feeding of coal to the OPGC’s thermal power plant, coal quality is to
be regulated within a specified range of GCV. It needs more flexibility in mine
operations to extract coal at different locations from different seams to maintain
that average quality. So, shovel-dumper system is chosen. Draglines could have
been cheaper but mine operations become rigid by deploying dragline. Large size
draglines are highly cost intensive. Its availability, maintenance and utilization
casts a shadow of doubt about projected gains against risks involved. However, the
technical considerations of deploying dragline does not support due to presence of
multiple seams with varying thickness & varying intermittent parting & band.
Shovel-dumper system is very flexible and also offers convenient mining operations
to deal with sudden occurrences of unworkable or poor quality patches and change
of floor position due to varying seam gradient and thickness. It also offers flexibility
for easy transition to any other technology or equipment configuration. The
technology is well known and advantageous to get skilled manpower. So shovel-
dumper mining method is adopted for overburden removal. Medium size electric
hydraulic shovels have been proposed in overburden to achieve high degree
flexibility & reduce pollution.
Coal will mostly be cut by surface miner in windrowing method. There are many
advantages in this technology including the avoidance of drilling, blasting, crushing
of coal and related environmental hazards, improvement in grade of ROM coal by
removing thin bands i.e. selective mining, clean surface for transport etc. It is
estimated that coal at two ends of a bench & comparatively thinner seams (about
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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15%) may have to be extracted by conventional drilling- blasting method and this
will vary according to actual geological and geotechnical conditions.
Part In-pit conveying of coal may be opted in later years for coal transportation from
quarry bottom. Initially Blast free coal from bottom sections will be transported
along benches and then along main haul road along floor upto the receiving hopper
on pit top by rear dumpers. Coal from upper seams will be transported along haul
road on southern or northern slope slope after year7-8 when mine will be developed
along its full strike. This system may continue upto year25. After year 25 as the mine
depth increases beyond 200m there will be extreme shortage of space for
accommodating overburden internally due to higher depth & stripping ratio, during
this period central haul road & haul road on southern slope will be filled up & main
haul road will be developed along northern slope, main conveyor may be aligned
along part of this flank haul road . Then coal will be transported along benches by
rear dumper and the same will be loaded onto inpit conveyor on northern quarry
slope via reclaim feeder. This system will optimize the transport fleet, which in turn
reduce the environmental pollution & savings in fuel & manpower. High angle
conveyor system may also be adopted in future. Decision regarding inpit conveying
or high angle conveyor may be taken at future date.
c. Equipment Selection
Hydraulic shovels have been preferred over rope shovels due to their higher
productivity, faster marching, higher manoeuvrability and ease of maintenance.
They are cheaper but have shorter life than rope shovels.
Choice of excavator size is dictated by optimum utilization of these excavators and
efficiency of loading thin benches up to 3m. In view of that, 10 to 12 cum hydraulic
shovels/ backhoe (175-205 T/950 to 1050 HP) are proposed for overburden
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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excavation and 6-7cum hydraulic shovels/ backhoe (450 to 550HP) are proposed
for comparatively thinner partings. These shovels will also load part coal which will
be drilled and blasted.
Optimum dumper size for larger shovel is 90 to 100 T and that for smaller size
shovel & pay-loaders is 50-60T.
Surface miners having 3.8m drum width with engine power of 900-1100HP are
proposed for coal cutting in windrowing method. Loose coal will be heaped & loaded
on to 50-60 Tonne dumpers by 6-7 cum front end loaders.
250mm diameter drills are proposed for thick partings and top overburden while
160 mm diameter drills are to be deployed for other partings and coal which need
to be blasted.
Crawler dozers of 850HP with ripper attachment are proposed for pre-mining land
preparation and loosening of bands and partings below 3m where good
fragmentation is not expected with 160 mm drills.
Supporting equipment like crane, grader, water sprinkler, tire handler, compactors
etc. of suitable sizes have been provided. However if required, in coal & in inseam
band/ parting smaller size eqyuipment may be deployed for operational efificiency.
The application of In-Pit Crushing and Conveying (IPCC) of coal can be introduced
during the later part of the mine life of the project after conducting the detailed
viability studies. Introduction of any new technology at a future date may be studied
at that time for improved performance, productivity and safety in the mine.
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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d. Production:
Production Program: The year wise Coal and OB Production Schedule are as
follows:
YEAR
COAL OB Stripping Ratio
(in Mt) (in Mcum) (in cum/t)
Cons(Year-1) - - -
P1(Year-2) 1.00 3.32 3.32
P2(Year-3) 2.50 6.27 2.51
P3(Year-4) 5.00 13.83 2.77
P4(Year-5) 8.00 18.44 2.31
P5(Year-6) 8.00 18.44 2.31
P6(Year-7) 8.00 18.44 2.31
P7(Year-8) 8.00 18.44 2.31
P8(Year-9) 8.00 18.44 2.31
P9(Year-10) 8.00 18.44 2.31
P10(Year-11) 8.00 16.78 2.10
P11(Year-12) 8.00 16.78 2.10
P12(Year-13) 8.00 16.78 2.10
P13(Year-14) 8.00 16.78 2.10
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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P14(Year-15) 8.00 16.78 2.10
P15(Year-16) 8.00 16.78 2.10
P16(Year-17) 8.00 16.78 2.10
P17(Year-18) 8.00 16.78 2.10
P18(Year-19) 8.00 16.78 2.10
P19(Year-20) 8.00 16.78 2.10
P20(Year-21) 8.00 16.78 2.10
P21(Year-22) 8.00 16.78 2.10
P22(Year-23) 8.00 19.73 2.47
P23(Year-24) 8.00 19.73 2.47
P24(Year-25) 8.00 19.73 2.47
P25(Year-26) 8.00 19.73 2.47
P26(Year-27) 8.00 19.73 2.47
P27(Year-28) 8.00 19.73 2.47
P28(Year-29) 8.00 19.73 2.47
P29(Year-30) 8.00 19.73 2.47
P30(Year-31) 8.00 18.07 2.26
P31(Year-32) 8.00 18.07 2.26
P32(Year-33) 8.00 21.02 2.63
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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P33(Year-34) 8.00 23.97 3.00
P34(Year-35) 8.00 23.97 3.00
P35(Year-36) 8.00 23.97 3.00
P36(Year-37) 8.00 23.97 3.00
P37(Year-38) 8.00 23.97 3.00
P38(Year-39) 8.00 23.97 3.00
P39(Year-40) 8.00 23.97 3.00
P40(Year-41) 8.00 23.97 3.00
P41(Year-42) 8.00 23.97 3.00
P42(Year-43) 8.00 23.97 3.00
P43(Year-44) 8.00 23.97 3.00
P44(Year-45) 8.00 26.92 3.37
P45(Year-46) 8.00 26.92 3.36
P46(Year-47) 8.00 26.92 3.36
P47(Year-48) 8.00 26.92 3.37
P48(Year-49) 8.00 26.92 3.36
P49(Year-50) 8.00 26.92 3.36
P50(Year-51) 8.00 28.58 3.57
P51(Year-52) 8.00 28.58 3.57
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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P52(Year-53) 8.00 28.58 3.57
P53(Year-54) 8.00 28.58 3.57
P54(Year-55) 8.00 28.58 3.57
P55(Year-56) 8.00 28.58 3.57
P56(Year-57) 8.00 28.58 3.57
P57(Year-58) 8.00 28.58 3.57
P58(Year-59) 8.00 28.58 3.57
P59(Year-60) 8.00 28.58 3.57
P60(Year-61) 8.00 28.58 3.57
P61(Year-62) 8.00 28.58 3.57
P62(Year-63) 8.00 25.63 3.20
P63(Year-64) 8.00 25.63 3.20
P64(Year-65) 8.00 25.63 3.20
P65(Year-66) 8.00 22.68 2.84
P66(Year-67) 8.00 22.68 2.84
P67(Year-68) 8.00 22.68 2.84
P68(Year-69) 8.00 22.68 2.84
P69(Year-70) 8.00 21.02 2.63
P70(Year-71) 8.00 21.02 2.63
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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P71(Year-72) 8.00 21.02 2.63
P72(Year-73) 8.00 21.02 2.63
P73(Year-74) 8.00 21.02 2.63
P74(Year-75) 8.00 21.02 2.63
P75(Year-76) 8.00 21.02 2.63
P76(Year-77) 6.00 14.34 2.39
P77(Year-78) 4.68 8.69 1.86
TOTAL 595.18 1656.35 2.78
8. Manpower:
The development of the Manoharpur Mine will take place during the first three to
four years of operation. During year-1 to year-2, the mine will not reach at its rated
production, and the larger size equipment will not be deployed. Accordingly, the
manpower builds up as production increases, and the full equipment fleet is
commissioned. The mine will be developed and operated by the Mine Operator, it
is envisaged that the required manpower shall be engaged by the Mine Operator for
the development and day to day operation of the mine, coal handling plant
including other allied activities.
Departmental manpower has been assessed by OCPL for the mining operation
which is summarized below:
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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Manoharpur Manpower (Departmental) for MO Mode
Exe. Non-Ex. Total
Co. Office 18 3 21
Site 73 36 109
TOTAL 91 39 130
The company has prepared a statutory and non-statutory requirement of manpower
taking into consideration lead time for training and external hiring.
Company will also have 15 persons for the initial 3 years of CHP construction &
operation for the supervision (2 years construction & 1-year operation on
contractual basis). After initial two years of operation of CHP, the Mine Operator
will operate & maintain the CHP.
Coal extraction, loading, transport, overburden drilling & blasting, excavation and
transportation and other auxiliary activities in the mine will be done by the Mine
Operator. Assessment of same will widely vary as per contract and Mine Operator.
However, a tentative assessment of operation manpower for the above activities
have been done by OCPL and are summarized below:
Mine Operator’s Manpower
OBR Operations 300
Coal Operations 175
Common Operations 275
TOTAL 750
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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Security & Canteen Services will be outsourced.
*N.B: These figures are indicative only and may vary as per actual requirement.
9. Project Benefits:
The proposed project is expected to bring significant socio-economic and
environmental benefits both at local and global level as listed below:
1. Infrastructural Improvement
2. Employment Potential
3. Revenue Generation
4. Indigenous People Development Plan (IPDP)
5. Peripheral Development Plan (PDP)
a. Providing Job Opportunity
b. Vocational Training to Local Youth
c. Providing Medical Assistance
d. Education
e. Infrastructure Development
f. Social Afforestation
g. Games, Sports & Culture.
6. Other Benefits: Beside above, indirect benefits have also accrued to the
region by way of increase in agricultural and industrial production.
Overall there will be positive impact in socio0economic area due to increased
economic activities, creation of new employment opportunities, infrastructural
development, better educational and health facilities.
Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project
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10. Project Schedule:
The coal production will start from April 2019 onwards and will reach the rated
capacity in the year 2023.
11. Project Cost:
The total project cost is approximately Rs. 2720Cr.