PRESENTATION ON

5-DAYS EXCURSION AND

TRAINING

AT

CIMFR

PRESENTED BY: Aftab

JamalRajeev KumarAnkit

Agrahari

BCCL block-II Mine

Maithan Hydel Plant SAIL Bokaro

Chandrapura Thermal Plant

BCCL (BHARAT COKING COAL LTD.)- Block II Mine

About BCCL• BCCL meets almost 50% of the total prime coking coal requirement of the

integrated steel sector• Operates 81 coal mines which include 40 underground, 18 opencast & 23

mixed mines.• The Company also runs 6 coking coal washeries, 2 non-coking coal

washeries.• The total manpower as on 01.03.2010 is 72,222..

History of Block II mine of BCCL• The project was envisaged to improve the financial position of BCCL and to

meet the growing demand of Coking Coal in the country.• Block-II Area came into existence in the year 1983-84 primarily for the

production of Coking Coal with the inclusion of the Nudkhurkee OCP, Benedih OCP, Jamunia OCP & the opening of Block-II.

Location• Block-II Area is situated about 40 KM west of Dhanbad & its coordinates

are:• Latitude – 23 º 47’ 30’’ N to 23 º 46’ 30’’ N• Longitude – 86 º 13’ 30’’ E to 86 º 10’ 30’’ E

BCCL (BHARAT COKING COAL LTD.)- Block II Mine

Reserve• Reserve as on 01.04.10 upto 600 Mtr. Depth is 184.753 MMT

Leasehold area• Total leasehold area is 907 Hectares.

Area affected by Fire & subsidence• 1300m X (1200m (East) + 600m (West)) = 1300m x 900m (average) =

1170000 M ² or 117 Hectare. • Area affected by fire is eastern part of Block-II OCP Mine up to No. X

Seam.

Future plans• One Underground Coal mine of 0.45MTY capacity is going to be started in

near future in the Area involving continuous miner technology. One OCP using Surface Miner Technology with a capacity of 2.4 MTY is also going to be started in the Area. One Washery behind the existing Washery is going to be constructed in near future.

Block-II mine coal seams

A (24/96) Rope-bucket dragline used in BCCL block-II mine.

Boom of FEC(Rafier) draglineUsed in BCCL block-II mine.

Bucket of FEC(Rafier) draglineUsed in BCCL block-II mine.

A RECP750 Drill at work in BCCL block-II mine.

Hydraulic Shovels used in BCCL block-II mine.

Reclaimed OB dump

Dust generation due to transportation in mine.

Poor strength of reclaimed land.

• The newly formed national laboratory, the Central Institute of Mining and Fuel Research (CIMFR) Dhanbad, is a constituent laboratory of Council of Scientific & Industrial Research (CSIR) was aimed to provide R&D inputs for the entire coal-energy chain from mining to consumption through integration of the Core Competencies of the two (CFRI & CMRI) premier Coal institution of the country.

• The newly formed entity CIMFR Dhanbad, a constituent laboratory of Council of Scientific and Industrial Research (CSIR) would be the premier organization of the country providing basic research, R & D back up, advisory services and help in technology up-gradation & adaptation to coal and mineral based industries to reach the targeted production with high standards of safety, economy and cleaner environment.

• 4 environmental projects that were going at the time of excursion:1) Utilization of mine water for regain process2) Contribution of mine fire on GHG’s(Green house gases) and defines standards3) How biodiversity controls GHG in mining area4) Steel industry, BCCL and many uses Damodar River water .Effect of these industry

on: Assimilative capacity of water Dilution of the effluent Carrying capacity Supportive capacity

CIMFR (CENTRAL INSTITUTE FOR MINING & FUEL RESEARCH),Dhanbad

MINE FIRE

GALLERY1) Fire is a major hazard

associated with coal mining

2) Fire causes loss of life,

hindrance in coal production and

sealing of a mine area for along

time

3) CIMFR has conducted study to

understand complex phenomenon

of open fire and suitable fire

suppression technique under

various condition.

4) For simulation studies of open fire in

underground gallery, a fire model

gallery of 65 m length and 5.8 sqm

cross section has been constructed.

5) It is equipped with 130 sensors and

2 data loggers to monitor changes in

behavior of fire in terms of

temperature, gas concentration, heat

flux, air velocity and smoke density

during experiment.

4) 3 sets of experiment has been done

with liquid nitrogen, nitrogen foam, and

water mist under varied velocity of 1 ,

1.5, and 2 m/s. In a set of experiment

18 to 20 tons of was used. Study

revealed that water mist can also be

considered to have good potential in

controlling fire economically.

FLAME PROOFING ELECTRICAL EQUIPMENT1) Methane emits while coal is extracted from a mine, and the mixture of methane with air is explosive and has caused large number of explosions killing thousands of persons in underground mines. Similarly, during drilling and subsequent refining, gases emit and form explosive mixture with air.

2) Therefore, in such explosive environment special type of electrical enclosures which are commonly known as flameproof or explosion proof enclosures are employed.

3) These equipment are used in industries like oil refineries, petrochemical, underground coalmines, pharmaceuticals industries, gas-bottling plant etc.

4) Testing and certification of such equipment are required to confirm their design to relevant standards. The motors with sealing box, bolts with shrouding are essential for coalmines and oil mines of India to avoid site-born accidents.

External Ignition Test: 1) The enclosure should be placed in an explosion chamber. The test should be made with the same flammable mixture inside the enclosure and in the explosion chamber.

2) The mixture inside the enclosure should be ignited by spark plug. The test is considered to be satisfactory, if the mixture present in the explosion chamber is not ignited.

3) After the test, the mixture in the chamber is deliberately ignited to confirm that outside atmosphere of the equipment is hazardous.

4) At least five tests should be made. The mixture in the enclosure and if necessary, in the explosion chamber, being renewed for each.

UNIVERSAL TESTING MACHINE

TORSION TESTING MACHINE FOR WIRE

TENSILE TESTING MACHINE

COAL DUST COLLECTING AND BRIQUETTING SYSTEM

FUME TEST CHAMBER

Maithan Hydel Power Project

1) DVC(Damodar Valley Corporation) is the first-ever multipurpose river valley project of independent India which came into being on July 7, 1948 by an act of Constituent Assembly.

2) DVC has its command area of approx 24,235 km² spreading across the Damodar basin. The upper valley consists of two entire districts (Dhanbad and Bokaro) and eight districts partly in the state of Jharkhand. The lower valley on the other hand consists of five districts partly (Burdwan, Hooghly, Bankura, Howrah and Purulia) in the state of West Bengal.

1) Maithon Hydel Power Station (MHPS) is located on the river Barakar about 12.9 km above its confluence with the Damodar near the border of Dhanbad & Burdwan districts of the states of Jharkhand & West Bengal respectively. .

2) The dam's mission comprises:• flood Control• promotion & operation of

schemes for irrigation• water supply for domestic

& industrial use• navigation & drainage• generation, transmission &

distribution of electrical energy.

1) The lake is spread over an area

of 65 km². It is 15,712 ft (4,789

m). long & 165 ft (50 m). high

The unique feature of this is that

it is located underground in the

left bank of the river and is the

first of its kind in India.

2) The power station has a total

generating capacity of 60 MW

with 3 turbines(francis) of 20 MW

each at 176.5 rpm for 4 hrs per

day. It has 3 manhole.

Flood warning

• The Indian Meteorological Department(IMD), Kolkata, transmit the rainfall

forecast for the next 24 hours for the entire Damodar Valley region to Maithon. A

computer model at the Flood Forecasting Unit(FFU) at Maithon estimates the

inflow into the reservoirs based on the real time data & rainfall forecast of IMD.

• Before releasing the water from dam's spillway gates, necessary warning is

communicated to district authorities, affected downstream industries,

municipalities and others including senior administrative officials of Burdwan,

Bankura, Purulia; IOW Dept. Govt.of WB; EE, DHW, Durgapur; Member(RM); CWC,

New Delhi. Whenever there is a discharge from Maithon and Panchet dams

exceeding 1,132 cu ft/s (32.1 m3/s), special arrangements are broadcast through

DOORDARSHAN and AIR regional news bulletins. DOORDARSHAN, Kolkata also

telecasts daily weather forecasts with probable rainfall in the Damodar Valley.

SAIL (STEEL AUTHORITY OF INDIA LTD.), Bokaro

The fourth integrated plant in the Public Sector Spread in an area of 17000 acres

VARIOUS PLANTS

Raw Materials & Material Handling PlantCoke Ovens & By-product PlantBlast FurnacesSteel Melting ShopsContinuous Casting ShopSlabbing Mill

Raw Materials & Material Handling Plant

9 MT of different raw materials viz. Iron ore fines and lumps, Limestone (BF and SMS grade), Dolomite lumps and chips, hard Coal and Manganese ore are handled here every year.

Iron ore and fluxes are sourced from the captive mines of SAIL situated at Kiriburu, Meghahataburu, Bhawanathpur, Tulsidamar and Kuteshwar. Washed coal is supplied from different washeries at Dugda, Kathara, Kargali and Giddi, while raw coal is obtained from Jharia coalfields.

Coke Ovens

Converts prime coking coal into high quality coke for the Blast Furnaces

By-products: Anthracene Oil, Benzene, Toluene, Xylene, Light Solvent Naphtha, Ammonium Sulphate and Extra-hard Pitch in the process

Coke Oven battery has 8

batteries with 69 ovens each

1 oven has volume of 27 M3

480 ovens coke in a day

Silos

Coal Storage Coal tower-for supply of coal

Operation room

Blast Furnaces: Five 2000-cubic metre Blast

Furnaces that produce molten iron - Hot Metal - for steel making.

The process of iron-making is automated, using PLC Charging System and Computer Controlled Supervision System

Waste products like Blast Furnace slag and gas are either used directly within plant or processed for recycling / re-use.

Slabbing Mill Transforms ingots into slabs

by rolling them in its 1250 mm Universal Four-High Mill

Rolling capacity of the Mill is 4 MT per annum

Chandrapura Thermal Power Plant

Located at Bokaro district in the State of Jharkhand

Key features:

An installed capacity of 390 MW 3 units of capacity 130 MW each Three stage turbine Fly ash arrested by EP Reheat & re-impulse turbine Capacity addition of 2 x 250 MW is

under execution

Fly Ash Utilization:

A large amount of fly ash received from ESP is utilized in brick-making process

A view of bricks formation from fly ash

Ash dyke:

Approx. 90% of the ash is

disposed to the ash dykes in

the form of slurry.

Decant water is reused from

ash dyke which is collected in

near pond.

ESP:

The ash generated in CTPP are present as bottom ash(20%) in Boiler and fly ash(80%) in ESP.

Fly Ash is separated in dry form from ESP.

The flue gases leaving the

boiler passes through the

Electrostatic Precepitator

(ESP). Finally, they are

drawn by the Induced

Draught (ID) Fan into the

main flue and to the

chimney.

220 Meters tall chimney

provided for dispersion of

emissions & minimize the

Ground Level Concentration

THANK YOU