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Project Report
For
Govindpur Ph-II OCP (1.2 MTY)
(East Bokaro Coalfield)
Nominal Capacity : 1.2 MTY Peak Capacity : 1.5 MTY
of
Central Coalfields Limited
DECEMBER’2009 (After CCL Board Approval on 23.12.2009)
Regional Institute-III
Project Report for Govindpur Ph-II OCP, CCL CMPDI
C O N T E N T S
Sl. Chapter Particulars Page No. No. No.
1. Summarised Data i - iii 2. List of Appendices iv List of Drawings v 3. I Introduction Chapter I –1–2 Location, Communication, Topography 4. II Chapter II –1 & Climate 5. III Geology Chapter – III-1–32 6. IV Marketability & Linkage Chapter – IV-1–2 7. V Main Technical Decisions for the Quarry Chapter – V-1–13 8. VI Pumping & Drainage Chapter – VI-1–4 Power Supply, Distribution, 9. VII Chapter – VII-1–11 Communication & Illumination 10. VIII Coal Handling Plant Chapter – VIII-1–4 11. IX Railway Siding Chapter – IX-1 12. X Workshop Chapter – X-1 – 6 13. XI Manpower & Productivity Chapter – XI –1 14. XII Civil Construction Chapter – XII-1 – 2 15. XIII Water Supply & Sewerage Chapter – XIII-1–3 16. XIV Land Chapter – XIV-1 17. XV Energy Conservation Chapter – XV-1–3 18. XVI Economics Chapter – XVI -1–8 19. XVII Safety & Conservation Chapter – XVII -1– 6 20. XVIII Mine Closure & Environment Chapter – XVIII-1–13 21 Appendices 1X – 51X 22. Approval of CCL Board Annexure – I
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER- I
1.0 INTRODUCTION:
Govindpur Phase-II OCP is located in Bokaro District of Jharkhand. It is situated in the north western part of the East Bokaro Coalfield and it is a part of the Kathara Area of Central Coalfields Limited. It lies adjoining to Sawang OCP in the west. This Project Report envisages producing 1.2 MTY of ROM power grade coal (Grade E) from “Geological Report on Coal Exploration Govindpur North Block, East Bokaro Coalfield” prepared in Dec 2001 and the area south of Bermo Seam incrop upto 200m depth line on Seam-VI floor in the south. It is also envisaged to remove both coal and OB departmentally.
1.1 Draft PR of Govindpur Ph-II OCP (0.80 MTY)
Govindpur Opencast is a new mine and a Draft Project Report was prepared in Feb 2008 to produce 0.8 MTY of coal from the Govindpur North sub-block of Govindpur Block in East Bokaro Coalfield. Further reserves from an area to the south of the incrop of Bermo seam has been added to the reserve of Govindpur North Block and the capacity of the PR enhanced to 1.2 MTY.
1.2 Justification for locating the project in the forest area :
Karo group of seams is proposed to be exploited in Govindpur Ph II OCP. It is a huge source of non-coking coal. This reserve of 19.53 MT non-coking coal lies below the patches of forest and non-forest land. Hence, unless the forest land above the coal seams is released, the coal seams cannot be exploited. Mining being site specific it is not possible to divert the operations to non- forest land.
Job No. 340721 Chapter-I-1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
1.3 SCOPE OF THIS PROPOSAL
In this proposal of Govindpur Ph-II OCP (1.2 MTY): a) The reserve from an area to the south of the incrop of Bermo seam was added to the reserve of Govindpur North Block and the capacity of the PR was increased to 1.2 MTY. b) The option proposed in the present PR for Govindpur Ph-II OCP (1.2 MTY). They are detailed as under:
OPTION-I Coal Production Departmental OB removal Departmental Average Grade E CHP Coal size (-) 100mm Evacuation of Pipradih Railway coal Siding
c) The proposal envisages for shovel dumper combination of mining. d) Departmental Coal Handling Plant is proposed. Product size of (-) 100 mm has been proposed.
Job No. 340721 Chapter-I-2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER – II
2.0 LOCATION, COMMUNICATION, TOPOGRAPHY & CLIMATE
2.1 Location The Govindpur North Block covering an area of 1.75 sq km lies between latitudes 23 o48'30" & 23 o49'30" N and longitudes 85 o51'15" & 85 o52'45" E. It is included in the Survey of India Toposheet No. 73E/13. The block lies to the east of Sawang Colliery.
2.2 Communication Govindpur Ph-II OCP is well connected by rail and road. The Gomoh- Barkakana loop line of Eastern-Central Railway is about 2km from the project. Bokaro Thermal Power Railway Station is the nearest railway station. The OCP is about 80km from Hazaribagh. It is about 130km from Ranchi via Ramgarh - Tenughat Dam road. The Sawang colliery was connected to this Project by a seasonal causeway over Konar River, which has been washed away. It is being proposed to construct a bridge over Konar River at the same place.
2.3 Topography The surface topography of the block is shown in Drg. No. RI-3/G/5707. The block is usually slightly rolling with gentle southerly slope. The maximum elevation is 318m above MSL and minimum 231 & 240m along the flanks of Konar River & Montico Nala respectively. The Project lies in the catchment area of Konar River & Montico Nala. The Konar river flows in the south easterly direction and the Montico nala flows in the south direction and joins the Konar River to the south of the block.
2.4 Climate The area experiences semi to extreme climate with day temperature as high as 45 0C during the summer, which falls down to around 5 0C in night during winter. The rainy season lasts from mid June to mid September.
Job No. 340721 Chapter-II -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Chapter-III
Geology of the Block
3.1.1 General: The Gobindpur North OC Block with an area of 1.55 sq km is located in the NW part of East Bokaro Coalfield, and is under the administrative control of Kathara Area of CCL. The OC block is part of the area covered in Geological Report on Gobindpur Block prepared by CMPDI in 1993 wherein it has been designated as ‘Gobindpur North Sub Block’. This is the northern most part of Gobindpur Block where all the Karo group of seams are available. The Upper Karo group of seams are thick with open cast potentiality while the lower Karo group seams have underground potentiality only. The details given in this report are based on the ‘Geological Report on Coal Exploration, Govindpur North Block (Karo Group of Seams)’ prepared by CMPDI in December, 2001.
3.1.2 Location: The Gobindpur North OC Block covering an area of 1.55 sq km lies between the latitudes 23 deg 48’ 30” to 23 deg 49’ 30”and longitudes 85 deg 51’ 15” to 85 deg 52’ 45” and is included in the Survey of India Toposheet no 73E/13. The block lies to the immediate east of Sawang Colliery and some distance to the north of Bokaro TPS of DVC.
3.1.3 Limits of Gobindpur North Block :
North: E-W trending Karharbari/Metamorphic contact South: 200m depth line on floor of Seam-VI (south of Incrop of Bermo Seam) East: Surface trace of fault F16 (near Govindpur –Pichri fault) West: Fault F7 (near Borrea Fault)
Job No. 340721 Chapter-III -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
3.1.4 Communication : The Gobindpur North OC Block is very well connected by rail and road. The Gomoh-Barkakana loop line of EastCentral Railway passes about 2 km south of the southern boundary of the block where Bokaro thermal Power railway station is the nearest railway station. The Hazaribagh-Bermo metalled road passes close to the northern and eastern sides of the block. The block is about 80km from Hazaribagh and 2km from Kathara GM office.
3.1.5 Topography and Drainage : The northern region is extremely hilly on account of outcrops of basal Barakar Formation, which are hard, compact and resistant to weathering. The southern region is slightly rolling with gentle southerly slope. The maximum elevation in the hill region is 331 m above MSL and minimum is 231m and 240m along the flanks of Konar River and Montico Nala respectively. The entire Gobindpur North Block lies in the catchment area of the Konar River, which is a perennial and major tributary of Damodar River.
3.1.6 Climate: The block lies in tropical monsoon region with day temperature during summer rising to as high as 45 0 C and fall down to around 5 0 C in winter. The rainy season lasts from middle June to Mid September.
3.1.7 Previous Work : The IBM (1959), NCDC (1965), CCL and CMPDI (1993 and 2001) explored the area through drilling. The present PR is based on the latest GR of CMPDI on Gobindpur North Block (December, 2001).
3.2.1 Drilling: Drilling in the block was taken up by various agencies at various periods of time :
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Table 3.1 Agency Phase BH Code No of BH drilled Meterage Drilled (A)Within the Block (i) NCDC NCBG 7 659.27m. (ii) CMPDI CMEG 28 1988.25m Total 34 2647.52m
The borehole density comes out to be 22 boreholes per sq km.
3.3.1 Geology of the Block The Gobindpur North OC Block forms a segment of the northern limb of the main synclinal basin of East Bokaro coalfield. It is located in the western part of the coalfield in which rocks of Karharbari and Barakar formations are preserved in a ‘graben’ between ‘Borrea Fault’ in the west and ‘Govindpur-Pichri Fault’ in the east. In this block, rocks belonging to the lower part of the Kargali-Karo stage are lying over metamorphics. The generalized stratigraphic sequence is given below:
Table 3.2 Geological succession of Gobindpur North O/C Block Age Formation Rock Types Recent - Soil & Alluvium Post Gondwana Intrusive Lamprophyres & Dolerite Dykes and sills Lower Permian Barakar Coarse to medium grained arkosic sandstone, carbonaceous shale and coal seams (Karo-V to XI) Karharbari Very Coarse grained sandstone, grits (sometimes siliceous), pebble beds, carbonaceous shale and coal seams(Karo-IV to I) Upper Talchir Shales , shaly and fine grained sand stones, Carboniferous occasional pebble beds. Unconformity Pre-Cambrian Granite-gneiss. Amphibolite and mica schist
Job No. 340721 Chapter-III -3
Project Report for Govindpur Ph-II OCP, CCL CMPDI
3.3.2 Geological Structure As mentioned earlier The Gobindpur North OC Block forms a segment of the northern limb of the main synclinal basin of East Bokaro coalfield. Also that it is located in a ‘graben’ between ‘Borrea Fault’ in the west and ‘Govindpur-Pichri Fault’ in the east. In this block, other faults present in the Block are tabulated below: Table 3.3 Details of faults present in Gobindpur North O/C Block Fault Strike Throw Throw Evidences direction direction Amount F7 NS E 30-40m Omission of seam-VIII in Cmeg-53 F8 NW-SE SW 5-10m Floor level differences F9 NNW-SSE E 5-10m Omission of seam in NCBG-7 F11 NNW-SSE E 30m Floor level differences F12 NW-SE NW 10m Reduction in partings F13 NW-SE NW 10-15m Floor level differences
3.4.1 Sequence of coal seams Following is the stratigraphic sequence of coal seams present in the block: Table 3.4 Details of coal seams & partings, Gobindpur North O/C Block Generalised Full seam Seam Thickness (m) range (m) intersections Minimum Maximum Soil 0.00 6.50 2-4 Strata above 12.57 54.45 30-40 4 Seam-XI NCBG-8 (CMEG-116) Parting 4.48 7.95 7.45 12.52 Seam-X 7-8 7 (CMEG-112) (NCBG-27) Parting 0.36 5.87 0.91 3.79(CMEG- Seam-IX 2-3 9 (NCBG-16) 112) Parting 9.27 31.55
Job No. 340721 Chapter-III -4
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Generalised Full seam Seam Thickness (m) range (m) intersections 20.38 30.05 Seam-VIII 22-23 12 (CMEG-113) (CMEG-99) Parting 10.17 14.57 0.69 7.31 Seam-VII-Top 3-4 22 (CMEG-110) (NCBG-8) Parting 0.31 3.82 1.00 4.38 Seam- VII-Bot 2-4 23 (CMEG-110) (CMEG-65) Parting 0.22 5.93 0.40 3.26 Seam-VI 2-3 21 (CMEG-46) (CMEG-111) Parting 27.58 48.70 0.62 2.48 Seam-V 1.5-2 20 (CMEG-36) (CMEG-112) Parting 19.52 32.62 1.45 3.70 Seam-IV 2-3 22 (CMEG-50) (CMEG-42) Parting 4.91 12.45 0.49 3.30 Seam-III 1.7-3 21 (CMEG-41) (CMEG-78) Parting 10.56 26.76 0.04 0.51 Seam-II 0.30-0.60 5 (CMEG-101) (CMEG-108) Parting 2.57 8.57 0.37 0.61 Seam-I 0.40-0.60 3 (CMEG-107) (CMEG-101)
3.4.2 Description of seams Gobindpur North OC Block is located in an area where only lower stage of Barakar formation and Karharbaris are exposed. Therefore only Karo group of seams starting from Karo-I to Karo-XI have been encountered in the boreholes. Bermo seam and seams above it incrop further down dip to the south of the boundary of the block. Seam VIII is the thickest seam but is highly interbanded. Seam VII Top, VII Bottom and VI form a packet of three distinctly identifiable horizons, which nearly merge with each other at a few places in the block. Seam V, IV and III are comparatively thin and are amenable to underground mining only. Seams II and I are very thin and impersistent.
Job No. 340721 Chapter-III -5
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Due to their thickness and occurrence in shallower depth, the seams, Karo-VI and above (upto seam-XI) have been identified for exploitation by open cast methods. Although the coal seams in the block are of coking nature, their ash content is on rather higher side. Therefore the grades of seams are given both on coking and non-coking basis for areas where ash% is more than 35%.
3.4.2 Seam-XI This is the top most seam of Karo Group in the block occurring 5.03m to 5.60 m below Bermo Seam which incrops along the southern limit and 4.48m to 7.95m above underlying Karo-X Seam. The Incrop of Seam-XI occurs in an E-W strike length of 1.5 km. In the southern part of the block, it underlies Seam X/IX with a parting of 23.47m (NCBK-02) to 24.60m (CMEK-95).
The details of borehole intersections of this seam are given below:
Table 3.5 Details of borehole intersections of Seam-XI in Govindpur North Block
1 Floor depth below G.L. (a) Shallowest 14.88m (NCBG-8) (b) Deepest 59.94m (CMEG-68) 2 F.R.L (a)Highest 240.02m (CMEG-110) (b)Lowest 217.00m (CMEG-68 ) 3 No. of BH intersections (a) Unfaulted 5 (b) Faulted / Partially Faulted - c) Burnt - d)Incrop -
Job No. 340721 Chapter-III -6
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Thickness: The thickness of Seam-XI generally varies from 1.70m (CMEG-97&-16) to 2.48m (CMEG –112). However in western part in borehole no NCBG-7 the thickness of the seam has further reduced to 1.22 m. The Thickness is around 2m in rest of the area. Roof and floor The immediate roof of the seam is composed of alternate shale and sandstone, shaly sand stone and occasionally sandy shale. Carbonaceous shale, shale and sandy shale form the immediate floor of the seam. Dirt Bands: Table 3.6 Range of Dirt Bands in Seam-XI Details Minimum Bh No Maximum Bh No Nos CMEG- CMEG- considered Seam 1.70 99,116 2.48 112 11 Thickness i) Including 1.70 99,116 2.48 112 11 dirt bands +NCB ii) Including 1.70 99,116 2.48 112 11 bands (I-30) iii) Ex band 1.70 99,116 2.48 112 11 2)a..Dirt bands >0.05-0.30m A) Number - 110,113 1 110,113 2 B) Thickness 1) Individual 0.07 113 0.25 110 2 2) Aggregate 0.07 113 0.25 110 2 2) b Dirt bands 0.30-1.00m A) Number NIL NIL NIL NIL NIL B) Thickness 1) Individual NIL NIL NIL NIL NIL 2) Aggregate NIL NIL NIL NIL NIL 2) c Dirt bands >1.00m A) Number NIL NIL NIL NIL NIL B) Thickness 1) Individual NIL NIL NIL NIL NIL 2) Aggregate NIL NIL NIL NIL NIL Note: NCB=non combustible bands
Job No. 340721 Chapter-III -7
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Effect of igneous Intrusion: Seam-XI has not been found to be affected by igneous intrusion in any of the boreholes in the block. Quality Table 3.7 Quality characteristics of Seam-XI in Gobindpur North Block
No. of BH considered = 5 Thickness 1.70 (CMEG-99, 116) to 2.48m (CMEG-, 112) Range Proximate Analysis (as analysed basis) Ex band bcs In band M% 1.0 - 1.6 1.0-1.6 1.0-1.6 A% 25.2 – 36.1 29.1 – 36.1 30.9-37.4 VM% 18.1 –23.1 18.2 – 20.8 18.2 – 21.6 CV(K Cal/Kg) 5440 - 5820 5040 - 5620 5040 - 5380 UHV(K 3780 - 5257 3753 - 4719 3601 - 4498 Cal/Kg) Grade (a)Coking --- W-I – W-IV W-III – W-IV W-IV – UG W-IV – UG Range (W-IV) (W-IV) (W-IV) (W-IV) General Grade b) Non-Coking Range D - E D - E D - E General (D) (D-E) (D-E)
Ultimate Analysis As analysed Unit coal basis basis Ex band bcs I VM% 21.1 24.4 24.4-28.7 24.4-29.7 C% 56.38 87.85 H% 3.24 5.05 N% 1.16 S% 0.35 P% 0.107 CO2% 0.53 CV(K Cal/Kg) 8655 8330 8283 Other Tests CI - CT G SI 1
Job No. 340721 Chapter-III -8
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Grade : The above data indicates that the coal from Seam-XI is having low moisture, medium volatile matter and medium to high ash content. The In-band coking grade of the seam is ‘Ungraded’ to Washery grade-IV while the same as per non-coking norms is E to D.
3.4.3 Seam-X Seam –X occurs 4.48 m (CMEG-68) to 7.95m(NCBG-7) below Seam XI and 0.36m(NCBG-27) to 5.87m (CMEG-98) above underlying Karo-IX Seam. The Incrop of Seam-X also occurs in an E-W strike length of 1.5 km in the southern part of the block. The details of borehole intersections of this seam are given below: Table 3.8 Details of borehole intersections of Seam-X in Gobindpur North Block
1 Floor depth below G.L. (a) Shallowest 29.13m (NCBG-8) (b) Deepest 63.08m (CMEG-68) 2 F.R.L (a)Highest 246.66m (NCBG-16) (b)Lowest 195.36m (CMEG-99) 3 No. of BH intersections 12 (a) Unfaulted 7 (b) Faulted / Partially Faulted 2/1 c) Burnt 1 d)Incrop 1
Thickness: The thickness of Seam-X generally varies from 7.45m (CMEG-112) to 12.52m (NCBG –27). Maximum thickness is found around borehole no NCBG-8 and CMEG-70 in central part of the block. The thickness of the seam is around 7 to8m in rest of the area.
Job No. 340721 Chapter-III -9
Project Report for Govindpur Ph-II OCP, CCL CMPDI
However in one borehole ( CMEG-64) in the western part shows a thickness of 11.27m which is an isolated case. Roof and floor The immediate roof of the seam is composed of shale and sandy shale and occasionally alternate shale and sandstone. Sandy shale and occasionally sand form the immediate floor of the seam. Dirt Bands: Table 3.9 Range of Dirt Bands in Seam-X Details Minimum Bh No Maximum Bh No Nos CMEG- CMEG- considered Seam Thickness i)Including 7.45 112 11.27 64 10 dirt bands +NCB ii)Including 7.27 39 10.93 64 10 bands(I-30) iii)Ex band 7.27 39 10.65 64 10 2)a..Dirt bands >0.05-0.30m ( No band in 2 boreholes out of 9 analysed) A) Number 1 64,69,98 5 70 7 B) Thickness 1)Individual 0.07 70,95 0.29 99 7 2)Aggregate 0.11 68 0.77 70 7 2)b..Dirt bands 0.30-1.00m A) Number 1 39,113 2 98 3 B) Thickness 1)Individual 0.32 98 0.40 116 3 2)Aggregate 038 39 0.65 98 3 Non –combustible bands A) Number 1 113 2 64 2 B) Aggregate 0.10 113 0.34 64 2 Thickness Note: NCB=non combustible bands
Effect of igneous Intrusion: Seam-XI has been found to be affected by igneous intrusion in only one of the boreholes (CMEG- (99) in the block where top section of the seam has been devolatalised.
Job No. 340721 Chapter-III -10
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Quality Table 3.10 Quality characteristics of Seam-X in Gobindpur North Block
No. of BH considered = 7 Thickness 7.19 (CMEG-99) to 11.27m (CMEG-64) Range Proximate Analysis(as analysed basis) Ex band bcs In band M% 0.9 – 3.9 0.9 – 3.9 0.8 – 3.9 A% 20.6 – 32.5 26.3 – 34.3 28.3-38.1 VM% 21.0-24.4 19.1 – 22.1 19.1 – 21.0 CV (K Cal/Kg) 5080 - 5740 5190 - 5420 4820 - 5420 UHV 4015 - 5008 3960 - 4629 3449 - 4607 (K Cal/Kg) Grade (a)Coking --- W-I – W-IV W-III – W-IV W-IV – UG Range (W-IV) (W-IV) (W-IV) General Grade b)Non-Coking Range D - E D - E D - E General (D) (D-E) (D-E) Ultimate Analysis As analysed Unit coal basis basis Ex band bcs I VM% - 27.2 – 29.6 25.0-28.0 25.4-28.6 C% 55.75 87.88 H% 3.25 5.15 N% 1.18 S% 0.34 P% 0.116 CO2% 0.62 CV(K Cal/Kg) 8119-8613 8171-8521 8285-8703 Other Tests CI - CT G SI 1
Job No. 340721 Chapter-III -11
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Grade : The above data indicates that the coal from Seam-X is having low moisture, medium volatile matter and medium to high ash content.The In-band coking grade of the seam is ‘Ungraded’ to Washery grade-IV while the same as per non-coking norms is E to D.
Beneficiation Washability studies were carried out earlier on the coal cores from NCBG- 16, the details of which are as follows: Table 3.11 Overall Screen Analysis Cleans at 1.50 Ash% 13mm - 0.4mm (-) 0.4mm (calculated) Wt% Ash% Wt% Ash% Wt% Ash% 36.8% 97.9 37.1 2.1 25.0 29.0 26.6
Some more such studies have been carried out in adjoining Govindpur Block, details of which are available in the G.R. of the block.
3.4.4 Seam-IX Seam –IX occurs 0.77 m (CMEG-113) to 5.87m (CMEG-99) below Seam X and 9.27m (NCBG-7) to 25.29m (CMEG-98) above underlying Karo-VIII Seam. The seam is almost merged with Seam-VIII around borehole CMEG-113. The Incrop of Seam-X also occurs in an E-W strike length of 1.5 km. about 40 to 50m north of incrop of Seam X in the block. The details of borehole intersections of this seam are given below: Table 3.12 Details of borehole intersections of Seam-IX in Govindpur North Block
1 Floor depth below G.L. (a) Shallowest 32.81m (NCBG-8) (b) Deepest 78.75m (CMEG-68)
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
2 F.R.L (a)Highest 256.11m (CMEG-43) (b)Lowest 190.37m (CMEG-99) 3 No. of BH intersections 11 (a) Unfaulted 7 (b) Faulted / Partially Faulted 2/nil c) Burnt nil d)Incrop 2
Thickness: The thickness of Seam-IX generally varies from less than a meter (0.91 in NCBG – 16 only) to 3.79m ( CMEG –112). Maximum thickness is found around borehole no CMEG-112 in the central part and in the eastern most part (CMEG-38) of the block. The thickness of the seam is around 2m in larger part of the block. Roof and floor The immediate roof of the seam is composed of carbonaceous shale followed by fine to medium grained sandstone and occasionally sandy shale/shaly sandstone. The floor of the seam is composed of shaly sandstone and sandy shale and occasionally alternate shale and sandstone.
Dirt Bands: Table 3.13 Range of Dirt Bands in Seam-IX Details Minimum Bh No Maximum Bh No Nos CMEG- CMEG- considered Seam 1.35 39 3.79 112 13 Thickness i)Including 1.35 39 3.59 112 13 dirt bands +NCB
Job No. 340721 Chapter-III -13
Project Report for Govindpur Ph-II OCP, CCL CMPDI ii)Including 1.35 39 3.29 112 13 bands(I-30) iii)Ex band 2)a..Dirt bands >0.05-0.30m ( No band in 5 boreholes out of 13 full seam analysed)
A) Number 1 39,70,113 2 64,98,112 8
B) Thickness 1)Individual 0.05 70,113 0.21 112 8 2)Aggregate 0.05 70,113 0.30 112 8 2)b..Dirt bands 0.30-1.00m
A) Number 1 40 1 40 1
B) Thickness 1)Individual 0.34 40 0.34 40 1 2)Aggregate 0.34 40 0.34 40 1 Non –combustible bands
A) Number 1 39,40,64 1 39,40,64 4
B) Aggregate 0.06 64 0.20 112 4 Thickness
Note: NCB=non combustible bands
Effect of igneous Intrusion: Seam-XI has not been found to be affected by igneous intrusion in any of the boreholes
Quality Table 3.14 Quality characteristics of Seam-IX in Gobindpur North Block
No. of BH considered = 9
Thickness 0.91m (NCBG-16) Range to 3.79m (CMEG-112)
Job No. 340721 Chapter-III -14
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Proximate Analysis (as analysed basis) Ex band bcs In band M% 0.9 – 1.3 0.8 – 1.5 0.9 – 1.5 A% 22.5 – 31.5 22.5 – 38.6 23.6-44.8 VM% 20.1-25.4 17.8 – 22.6 17.2 – 22.6 UHV 4371 - 5671 3463 - 5671 2511 - 5491 (K Cal/Kg) Grade (a) Coking --- W-II – W-IV W-II – UG W-IV – UG Range (W-III – W-IV) (W-III – W-IV) (W-IV-UG) General Grade b) Non-Coking Range B-D B - E C-F General (C-D) (D-E) (D-E) Ultimate Analysis As analysed Unit coal basis basis Ex band bcs I VM% 22.6 25.0 – 31.4 25.0-29.5 25.0-28.0 C% 58.43 88.26 61.47 88.69 H% 3.32-3.55 5.09-6.10 N% 1.10-1.15 S% 0.45-0.55 P% 0.08 CO2% 0.51-0.58 CV(K Cal/Kg) 8410-8556 8407-8589 8296-8543 Other Tests CI - CT F-G SI 1
Job No. 340721 Chapter-III -15
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Grade : The above data indicates that the coal from Seam-IX is having low moisture, medium volatile matter and medium to high ash content. The In-band coking grade of the seam is ‘Ungraded’ to Washery grade-IV while the same as per non-coking norms is E to D.
3.4.5 Seam-VIII
This is the thickest as well as most prospective seam of Karo Group in the block. It lies 9.27m (NCBG-7) to 31.55 m (CMEK-52) below Seam IX and 4.02m (NCBG- 12) to 14.57m(CMEK-113) above underlying Karo-VII Top Seam. This is a highly banded seam and has been intersected in 31 boreholes. Details of borehole intersections of this seam are given below: Table 3.15 Details of borehole intersections of Seam-VIII in Gobindpur North Block 1 Floor depth below G.L. (a) Shallowest 8.10m (CMEG-36, 102) (b) Deepest 113.80m (CMEG-99) 2 F.R.L (a)Highest 29.64m (CMEG-36) (b)Lowest 137.52m (CMEG-99) 3 No. of BH intersections 27 (a) Unfaulted 20 (b) Faulted / Partially Faulted 1/3 c) Burnt 1 d) Incrop 2
Incrop: The incrop of Seam-VIII also occurs in an E-W strike length of 1.5 km. running parallel to and at about 40 to 50m north of incrop of Seam IX in the block. Thickness: The thickness of Seam-VIII varies from 20.38m (CMEG-113) to 30.05m ( CMEG – 99). However it is generally around 22m to 23m in the area.
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Roof and floor The immediate roof of the seam VIII is composed of carbonaceous shale followed by medium to fine grained sandstone at top. The floor generally comprises of sandy shale and shaly sand stone and occasionally medium to fine grained sandstone. Dirt Bands: As evident from the band-by-band analysis of the seam in 16 boreholes the Seam VIII contains large no of combustible and non-combustible bands.
Table 3.16 Range of Dirt Bands in Seam-VIII
Details Minimum Bh No Maximum Bh No Nos CMEG- CMEG- considered Seam Thickness i)Including 20.38 113 30.05 99 16 dirt bands +NCB ii)Including 15.28 40 26.27 52 16 bands(I-30) iii)Ex band 12.18 40 16.66 52 16 2)a..Dirt bands >0.05-0.30m NIL in two boreholes. (CMEG-40 & 43) A) Number 1 38,41,42,99 11 52 14 B) Thickness 1)Individual 0.07 52,113 0.30 107,109 14 2)Aggregate 0.10 99 1.65 52 14 2)b..Dirt bands 0.30-1.00m NIL in one borehole. CMEG-99 A) Number 1 43,63,98 5 52 14 B) Thickness 1)Individual 0.32 52 0.99 41 14 2)Aggregate 0.37 43 2.57 70 14 2)c..Dirt bands >1.00m NIL in 8 boreholes (CMEG-38,52,63,64,107,110,113,116) A) Number 1 41,70,99,109 5 40 14 B) Thickness 1)Individual 1.04 42 3,27 40 14 2)Aggregate 1.07 70 9.04 40 14
Note: NCB=non combustible bands
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Effect of igneous Intrusion: Seam-VIII has been found to be affected by igneous intrusion in two boreholes (CMEG-70 & 112) in the block. In CMEG-70 only the top most 0.11m section of the seam has been devolatilised, while in CMEG-112 this seam as well as seams below it has been partly burnt.
Quality Table 3.17 Quality characteristics of Seam-VIII in Gobindpur North Block
No. of BH considered = 15 Thickness 20.38 (CMEG-112) to 30.05m (CMEG-99) Range Proximate Analysis(as analysed basis) Ex band bcs In band M% 0.8 - 1.2 0.8-1.3 0.7-1.4 A% 27.7 – 30.2 27.5 – 39.4 33.2 – 43.9 VM% 18.6 –22.0 18.3 – 20.5 16.2 – 18.8 CV(K Cal/Kg) 5480 - 5920 5350 - 5540 4030 - 4860 UHV(K 4567 - 4926 2325 - 4622 2731-3891 Cal/Kg) Grade (a)Coking --- W-III – W-IV UG – W-IV UG-W-IV Range (W-IV) (W-IV) (W-IV) General Grade b)Non-Coking Range D D - F E_F General (D) (D) (F) Ultimate Analysis As analysed Unit coal basis basis Ex band bcs I VM% 23.4-28.3 23.4 – 27.4 23.2-26.6 C% 60.18 88.53 H% 3.43 5.06 N% 1.00 S% 0.40 P% -
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
CO2% 0.5 CV (K Cal/Kg) 8287-8665 8291-8483 7916-8760 Other Tests CI - CT D/E SI 1
Grade : The above data indicates that the coal from Seam-VIII is having low moisture, medium volatile matter and medium to high ash content. The In-band coking grade of the seam is ‘Ungraded’ to Washery grade-IV while the same as per non-coking norms is F to E. Beneficiation Washability studies were carried out earlier on the coal cores from NCBG-16 as well as that from a borehole from borehole NCBG-11 from adjoining block, the details of which are as follows: Table 3.18 Raw coal Screen Analysis Cleans at 1.50 B.H.No. Ash% 13mm - 0.4mm (-) 0.4mm Wt% Ash% Wt% Ash% Wt% Ash% NCBG-16 45.2 98.3 45.5 1.7 30.4 21.3 18.36 NCBG-11 38.7 97.0 39.1 3.0 25.2 31.9 17.6
Some more such studies have been carried out on coal core from borehole no. CMEG-82 and in adjoining Govindpur Block, details of which are available in the G.R. of the block.
3.4.6 Seam-VII Top
Seam-VII Top occurs 10.17 m (CMEG-98) to 14.57m(CMEG-113) below Seam VIII and 0.31m (CMEG -53) to 3.82m (CMEG-113) above underlying Seam-VII Bottom
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The details of borehole intersections of this seam are given below: Table 3.19 Details of borehole intersections of Seam-VII Top in Gobindpur North Block
1 Floor depth below G.L. (a) Shallowest 5.43m (CMEG-78) (b) Deepest CM-99-123.12M 126.45m (CMEG-112) 2 F.R.L (a)Highest 285.16m (CMEG-78) (b)Lowest 123.12m (CMEG-99) 3 No. of BH intersections 22 (a) Unfaulted 19 (b) Faulted / Partially Faulted 1/- c) Burnt 1 d)Incrop 1
Incrop The Incrop of Seam-VII Top is available in an E-W strike from 40 to 50m north of Seam-VIII incrop on ground. But incrops of Seam-VII Top, VII Bottom and VI occur in close proximity to each other due to existence of very thin parting between them.
Thickness: The thickness of Seam-VII Top is very erratic due to development of bands near the roof and floor and their selective inclusion/exclusion from the seam thickness depending on the economic viability. Thickness varies from 0.69m (CMEG-110) in the south-western part to 7.38m (CMEG-50) in the north-eastern part. But generally the thickness lies between 2 to 3m in remaining parts.
Job No. 340721 Chapter-III -20
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Roof and floor The immediate roof of Seam-VII Top is generally carbonaceous shale and occasionally grey shale/sandy shale topped by fine-grained sandstone and occasionally alternate shale and sandstone. Grey shale and sandy shale generally constitute the immediate floor of the seam. Dirt Bands: Table 3.20 Range of Dirt Bands in Seam-VII Top Details Minimum Bh No Maximum Bh No Nos CMEG- CMEG- considered Seam Thickness 0.69m 110 2.38 98 i)Including 0.50 63 2.38 98 30 dirt bands +NCB ii)Including 0.50 63 2.38 50 30 bands(I-30) iii)Ex band 0.50 63 2.31 52 30 2)a..Dirt bands >0.05-0.30m - NIL in 23 boreholes out of 30 analysed for full thickness
A) Number 1 52 1 98 7
B) Thickness 1)Individual 0.12 52 0.30 98 7 2)Aggregate 0.12 52 1.65 98 7 Note: NCB=non combustible bands
Effect of igneous Intrusion: Seam-VIII has been found to be completely burnt by igneous intrusion in only one borehole (CMEG-112) in the block.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Quality Table 3.21 Quality characteristics of Seam-VII Top in Gobindpur North Block
No. of BH considered = 22 Thickness 0.69m (CMEG-110) to 2.31m (CMEG-50) Range Proximate Analysis (as analysed basis) Ex band bcs In band M% 0.5 – 5.2 0.5 – 5.2 0.5 – 5.2 A% 22.6 – 34.4 26.3– 42.2 27.7-46.6 VM% 17.8-26.7 17.8-26.7 17.8-26.7 CV(K Cal/Kg) 4890 - 6000 4890 - 6000 4890 - 6000 UHV(K 3987- 5712 2911 - 5177 2304-4981 Cal/Kg) Grade (a)Coking --- W-II – W-IV W-III – UG W-III – UG Range (W-II-W-IV) (W-III-UG) (W-III-UG) General Grade b)Non-Coking Range D D - F E_F (D) (D) (F) General Ultimate Analysis As analysed Unit coal basis basis Ex band bcs I VM% 18.8 20.9-28.7 22.9– 29.9 22.9-29.9 C% 54.44 88.81 H% 3.02 4.03 N% 0.90 S% 0.43 P% - CO2% 0.58 CV(K Cal/Kg) 7995-8682 7995-8682 7995-8682 Other Tests CI - CT D SI 1
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Grade : The In-band coking grade of the Seam-VII Top is ‘Ungraded’ to Washery grade-III while the same as per non-coking norms is F to G .
3.4.7 Seam-VII Bottom Seam-VII Bottom occurs 0.31 m (CMEG-53) to 3.82m(CMEG-112) below Seam VII Top and 0.22m (CMEG -50) to 5.93m (CMEG-101) above underlying Seam-VI. The Seam-VII Bottom is almost merged with Seam-VII-Top in borehole CMEG-36, 53 and 78 with a parting of grey shale measuring 0.70, 0.31 and 0.52m respectively. The seam is almost merged with Seam –VI in borehole CMEG-50 where the parting is only 0.22m. . The details of borehole intersections of this seam is given below: Table 3.22 Details of borehole intersections of Seam-VII Bottom in Gobindpur North Block 1 Floor depth below G.L. (a) Shallowest 13.52m (CMEG-101) (b) Deepest 136.60m (CMEG-116) 2 F.R.L (a)Highest 282.39m (CMEG-78) (b)Lowest 252.39m (CMEG-115) 3 No. of BH intersections 23 (a) Unfaulted 19 (b) Faulted / Partially Faulted 1/- c) Burnt 2 d) Incrop 1
Incrop The incrop of Seam-VII Bottom is available in an E-W strike on ground and runs in close proximity to incrops of Seam-VII Top and VI due to existence of very thin parting between them.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Thickness: The thickness of Seam-VII Bottom varies from 1.00m (CMEG-110) in the south- western part to 4.38m (CMEG-65). But generally the thickness remains around 2- 4m in remaining parts.
Roof and floor The immediate roof of Seam-VII Bottom is generally shale/ sandy shale and occasionally sandstone. The immediate floor is generally shaly sandstone or fine to medium grained sandstone. Dirt Bands: Table 3.23 Range of Dirt Bands in Seam-VII Bottom Details Minimum Bh No Maximum Bh No Nos CMEG- CMEG- considered Seam Thickness i)Including 1.00 110 5.25 95 23 dirt bands +NCB ii)Including 1.00 110 5.25 95 23 bands(I-30) iii)Ex band 1.00 110 5.25 95 23
Effect of Igneous Intrusives : The seam is partly burnt in CMEG-42 and 113 and is completely burnt in Seam-VII Bottom CMEG- 112.
Quality
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Table 3.24 Quality characteristics of Seam-VII Bottom in Gobindpur North Block
No. of BH considered = 27 Thickness 1.00m (CMEG-110) to 4.38m (CMEG-65) Range Proximate Analysis (as analysed basis) Ex band bcs In band M% 0.6 – 3.3 0.5 – 3.0 0.5 – 2.4 A% 24.3 – 39.2 27.4– 44.0 26.8-58.6 VM% 17.8-22.3 17.0-21.5 17.8-21.5 CV(K Cal/Kg) 5110-6930 4280 - 5610 2860 - 5610 UHV(K 5106-3904 4746-2704 4525-2048 Cal/Kg) Grade (a)Coking --- W-III – UG W-III – UG W-III – UG Range General (W-III-W-IV) (W-IV) (UG) Grade b)Non-Coking Range C-E D - F D-UG (D) (D-E) (E-F) General Ultimate Analysis As analysed Unit coal basis basis Ex band bcs I VM% - 20.9-28.7 22.9– 29.9 22.9-29.9 C% 57.87-58.96 88.12-88.39 H% 3.29-3.37 5.03-5.04 N% 0.92-1.15 S% 0.31-0.33 P% 0.123-0.126 CO2% 0.16-0.57 CV(K Cal/Kg) 5610-6930 7717-8598 7717-8598 7916-8598 Other Tests CI - CT F-D SI 1 Ash fusion Temp deg C IDT HT FT >1400 >1400 >1400
Job No. 340721 Chapter-III -25
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Grade : The In-band coking grade of the Seam-VII Top is ‘Ungraded’ to Washery grade-III while the same as per non-coking norms is ‘Ungraded’ to D .
3.4.8 Seam-VI
Seam-VI occurs 0.22m (CMEG -50) to 5.93m (CMEG-101) below Seam VII Bottom and 57.58m (CMEG -109) to 48.70m (CMEG-52) above underlying Seam- V. The Seam-VI is almost merged with Seam-VII-Bottom in borehole CMEG-36 and 50 with a parting of grey shale measuring less than 1m. The details of borehole intersections of this seam is given below: Table 3.25 Details of borehole intersections of Seam-VI in Gobindpur North Block 1 Floor depth below G.L. (a) Shallowest 8.60m (CMEG-121) (b) Deepest 138.90m (CMEG-99) 2 F.R.L (a)Highest 278.04m (CMEG-48) (b)Lowest 118.77m (CMEG-99) 3 No. of BH intersections 23 (a) Unfaulted 15 (b) Faulted / Partially Faulted 4 / - c) Burnt 3 d)Incrop 1
Incrop Due to existence of very thin parting between them, the incrops of Seam-VI and Seam-VII Bottom run in close proximity to each other and are available in an E-W strike on ground.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Thickness: The thickness of Seam-VII Bottom varies from 0.40m (CMEG-46 to 3.26m (CMEG-111). In the west central part, around BH no CMEG-46, 101,65, 42 and 99 the seam thickness has been reduced to 1m or less due to development of carbonaceous bands. But generally the thickness remains around 2 to3m in most of the area.
Roof and floor The immediate roof of Seam-VII Bottom is generally shaly sandstone or fine to medium grained sandstone. The immediate floor is generally sandy shale, shaly sandstone and occasionally fine grained sandstone.
Dirt Bands : Table 3.26 Range of Dirt Bands in Seam-VI
Details Minimum Bh No Maximum Bh No Nos CMEG- CMEG- considered Seam Thickness i)Including 0.45 36 3.26 111 21 dirt bands +NCB ii)Including 0.45 36 3.26 111 21 bands(I- 100) iii)Ex band 0.45 36 3.26 111 21 2)a..Dirt bands <1m NIL in 13 boreholes out of 28 boreholes A) Number nil 36,37,41,43,46,103,109,115 3 52 15 B) Thickness 1)Individual 0.09 107 0.92 63 15
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
2)Aggregate 0.14 123 0.72 52 15 2)b..Dirt bands >1m A) Number nil nil nil nil 15 B) nil Thickness 1)Individual nil nil nil nil 15 2)Aggregate nil nil nil nil 15 3) Non-combustible Bands A) Number 1 54,111 1 54,111 15 B) Thickness 1)Individual 0.05 54 0.06 111 15 2)Aggregate 0.05 54 0.06 111 15 Note: NCB=non combustible bands
Effect of Igneous Intrusive : The seam is completely burnt in and around CMEG-42, 65 and 112. Quality Table 3.27 Quality characteristics of Seam-VI in Gobindpur North Block No. of BH considered = 21 Thickness 0.40m (CMEG-46) to 3.26m (CMEG-111) Range Proximate Analysis (as analysed basis) Ex band bcs In band M% 0.9 – 1.3 0.6 – 1.3 0.5 – 1.3 A% 28.3 – 30.7 29.5– 43.8 24.2-47.8 VM% 19.4 15.8-20.0 15.2-20.4 CV(K Cal/Kg) 5760 4250 - 5760 4110-4950 UHV(K 3040-4870 2745-4691 2193-4691 Cal/Kg) Grade (a)Coking --- W-IV UG UG Range General (W-IV) (UG) (UG) Grade
Job No. 340721 Chapter-III -28
Project Report for Govindpur Ph-II OCP, CCL CMPDI b)Non-Coking Range D E-G D-F General (D) (E-F) (E-F) Ultimate Analysis As analysed Unit coal basis basis Ex band bcs I VM% - 24.4-27.1 22.4– 28.3 21.5-28.3 C% - 88.12-88.39 H% - 5.03-5.04 N% - S% - P% - CO2% - CV(K Cal/Kg) - 8655 8336-9236 8283-8812 Other Tests CI - CT - SI - Ash fusion Temp deg C IDT HT FT >1400 >1400 >1400
Grade : The In-band coking grade of the Seam-VI is ‘Ungraded’ while the same as per non-coking norms is E to F .
3.5.1 Geological coal reserves The total geological reserves of coal in larger Govindpur block (as per March 1993 G.R. of CMPDI) are tabulated below: Table 3.28 Seam–wise & Sector wise net ‘proved’ coal reserves in Gobindpur block (as per GR, 1993) Seam Proved Indicated Total Jarangdih 9.282 9.282 Jarangdih New 5.627 5.627 Jarangdih 6' 3.147 3.147 Jarangdih 'A' 2.530 2.530
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Seam Proved Indicated Total Sawang 'C' 5.815 5.815 Kathara 7.636 3.814 11.450 Uchitdih 'A' 1.909 1.053 2.962 Kargali Top 22.119 6.127 28.246 Kargali Bot 19.109 9.718 28.827 Bermo 44.250 8.529 52.779 Karo-XI 4.545 4.190 8.735 Karo-X 18.233 16.762 34.995 Karo-IX 4.954 4.277 9.231 Karo-VIII 50.772 37.422 88.194 Karo-VII/VI 5.739 6.107 11.846 Karo-IV 5.478 6.500 11.978 Karo-III 4.968 6.000 10.968 Total 216.113 110.499 326.612
The area of that block was much larger than ‘Gobindpur Phase-II OC’ and extended from incrop of Seam-III in the north, to the Borrea Fault and Railway line in the south, and from Borrea Fault in the west, to Govindpur - Pichri Fault in the East. The coal seams covered in the GR of 1993, included, in addition to Karo group of seams, upper seams from Bermo to Jarangdih seams also.
In the year 2001 another geological report of Gobindpur North block, encompassing only Karo Group of Seams and covering area lying to the north of Bermo Seam incrop - upto Seam-III incrop in the north, was prepared by CMPDI. In that area - only Seams XI, X, IX, VIII, VII-Top & VII Bottom and VI were found to be having quarriable potentiality while the lower seams being thin and occurring after thick parting interval were not considered for OC mining. The Sector wise net in situ quarriable reserve in the entire Gobindpur North block (Sectors- A, B & C) have been summarised below.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Table 3.29 Seam–wise & Sector wise net ‘proved’ coal reserves in Gobindpur North block (G.R. 2001) (Figures in Tonnes)
SEAM Av.Grade SEAMS SECT-A SECT-B SECT-C TOTAL Coking Non Coking XI 73440 378754 298467 750661 W-IV E X 363168 1499427 1556928 3419523 W-IV D IX 118296 311447 372960 802703 W-IV D VIII 2274192 4963433 4495212 11732837 Ungraded F VII 757789 1986057 1523060 4266906 W-III E VI 379195 637740 776628 1793563 Ungraded F TOTAL 3966080 9,776,858 9,023,255 22766193 Ungraded
The limits of the various sectors in the GR are defined as follows: Sector-A: Area lying between eastern bank of Konar River in the west, fault F7 in the east, Seam VI incrop in the north and incrop of Bermo Seam in the south. This sector is highly disturbed by a number of sets of faults . The seam incrops are also not in continuity with adjoining Sector -B of OC and have shifted to a considerable distance southward where coal has already been quarried out . Therefore this sector has not been included in the present OC. Sector-B: Area lying between fault F7 in the west and F11in the east, Seam VI incrop in the north and incrop of Bermo Seam in the south. Sector-C: Area lying between faults F11 in the west and F13 in the east, Seam VI incrop in the north and incrop of Bermo Seam in the south. Sector-D: Area lying between faults F13 in the west and F16 in the east, Seam VI incrop in the north and incrop of Bermo Seam in the south. As the sector has insufficient strike length due to presence of faults , and the coal reserves belong to “indicated “ category due to paucity of boreholes data, this sector also could not be included in the present OC . Sector-E: Area south of Bermo Seam incrop in down to 200m depth line on Seam-VI floor in the south, bounded on the east by Montico Nala and on
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the west by Borrea Fault (F7-F7). This is a sector not covered in the geological report of Gobindpur North block (2001), and has now been defined for including additional reserves south of the original limits of Gobindpur North block. Thus only sectors B, C and E have been considered in the PR of present OC. The in-situ reserves in the Govindpur Phase-II OC Block are summarised below: Table 3.30 Seamwise & Sector wise net ‘proved’ coal reserves in Gobindpur Phase-II OC block (Fig in Tonnes) Av.Grade Seam SECT-B SECT-C SECT-E Total Coking Non Coking XI 378754 298467 497120 1174341 W-IV E X 1499427 1556928 2081300 5137655 W-IV D IX 311447 372960 521820 1206227 W-IV D VIII 4963433 4495212 5903820 15362465 Ungraded F VII 1986057 1523060 938340 4447457 W-III E VI 637740 776628 879840 2294208 Ungraded F TOTAL 9,776,858 9,023,255 10,822,240 29,622,353 E Note: 1. The figures are as per “Geological report on Gobindpur North block, East Bokaro Coalfield, CMPDI” in 2001. 2. Additional OC reserves of 526082 te are present in part coal/part jhama zone in sector –B in Seam-VIII (454,784 te) and Seam-VI (71,298 te). 3. A deduction of 10% has been made from the gross reserves to provide for geological loss for unforeseen factors like occurrence of minor faults / burning and thinning.
Out of a total of 29.622 mt in the OC, Sector-B has 9.777mt (33%), while Sector-C & D have 9.023 mt (30%) & 10.822 mt (37%) of total coal reserves. The Seam Karo-VIII constitutes 52%, followed by Seam-X (17%), VII (15%), VI (8%), IX (4%) and XI (4%) respectively. The quarried out area (as was existing in 2001) has been fully excluded while calculating the reserves for the OC block.
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CHAPTER IV
4.0 MARKETABILITY AND LINKAGE
4.1 Demand Liberalisation of power sector by Govt. of India has generated wide spread interests for Private and Public sector investments in different industries. As such, there is an appreciable increase in the number of upcoming new industries in both Private and Public Sectors. This has resulted in a sharp increase in the demand of coal in CCL. The Govindpur Ph-II OCP (1.2MTY) is therefore, proposed with a view to fulfil the above indicated growth in demand.
4.2 Availability The availability and demand from CCL is given in Table-4.0 below: Table No. 4.0
COAL DEMAND AND AVAILABILITY OF CCL (Basis : Chairman CIL's letter to Secy. Coal in Sep '09)
Sl No. Coal Consuming Sectors Coal Demand (MT)
2009-10 2010-11 2011-12 2016-17 A. TPPs Existing TPSs (that came 1 up prior to XIth Plan) 29.21 29.21 29.21 29.21 XI Plan TPSs (including 2 IPPs) 11.23 15.32 27.35 49.17 TOTAL for TPPs 40.44 44.53 56.56 78.38
B. Captive Power Plants (CPPs) # 4.03 4.03 4.03 4.03 TOTAL COMMITMENT FOR POWER SECTOR 44.47 48.56 60.59 82.41
C. Cement Plant # 0.42 0.42 0.42 0.42
D. Steel* 3.60 3.96 4.35 9.25
E. Fertilizer 1.00 1.00 1.00 1.00
F. Sponge Iron # 2.63 2.63 2.63 2.63
G. E-Auction @10% of production 4.60 5.00 5.50 8.30
Chapter -IV-1
H. Others i.e, CPSU, State Agencies, Bricks etc. 2.77 2.77 2.77 2.77 TOTAL Commitment on CCL 59.49 64.34 77.26 106.78
PRODUCTION 46.10 50.00 55.00 83.00
-13.00 -14.00 -22.00 -24.00 GAP
th The availability figures till end of XI plan period (2011-12), as shown in the above table, have been obtained from CCL. The gap in demand and availability of coal justifies implementation of this project.
4.3 Linkage
Basket Linkage is proposed for the coal from this mine.
Chapter -IV-2 Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER – V
5.0 MAIN TECHNICAL DECISIONS FOR THE QUARRY
5.1 PRESENT STATUS This proposal has been prepared as a new project . This report proposes to exploit the upper Karo Group of seams (Seam VI to XI) based on the “Geological Report on Coal Exploration Govindpur North Block, East Bokaro Coalfield” prepared in Dec 2001 and the area south of Bermo Seam incrop upto 200m depth line on Seam-VI floor in the south, bounded on the east by Mantico Nalla and on the west by Borrea Fault (F7-F7). This is a sector not covered in the geological report of Gobindpur North block (2001), and has now been defined for including additional reserves south of the original limits of Gobindpur North block.
5.2 Boundaries of Mining Block The Plan showing the quarry boundary is given vide Drg. No. R3-OCM-000456. The mine boundary has been fixed as follows: -
Northern Boundary The northern floor boundary has been fixed along the in-crop of Seam VI.
Southern Boundary The southern floor boundary has been fixed along 180m-depth line on the floor of Seam-VI.
Eastern Boundary The eastern floor boundary has been fixed leaving a surface barrier of 50m against existing course of Montico Nalla at the quarry surface.
Western Boundary The western floor boundary has been fixed along the major fault F7, which has a throw of about 50 - 70m. The area on the west of this fault is the up thrown side and is highly geologically disturbed being dissected by number of faults. This
Job No. 340721 Chapter-V -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI area has already been worked in patches. And as such, in this PR the area on the west of the fault F7 has not been considered for working.
5.3 Rated Capacity The rated capacity of the mine has been determined as 1.2 MTY on the basis of the following factors: a) Coal reserves and stripping ratio and b) Mining & Technical capacity of the mine.
The quarry boundary has been maximized to the extent possible and mining upto Seam VI has been considered. The extractable reserve has been estimated as 19.53 MT of coal. The life of the mine has been estimated as 20 years. There is further coal reserve available on the dip side in the south. However, to exploit this reserve Mantico Nalla flowing north to south on the eastern side has to be diverted. Without diverting this Nalla the working area becomes very narrow and beyond a depth of 180m, it will be very difficult to work in this narrow patch.
5.4 MINING RESERVES – VOLUME OF OBR – STRIPPING RATIO
The mineable reserves have been estimated from the iso-chore plans of the different seams. A loss of 10% has been taken as geological losses. In addition to the geological losses, 15 cm of coal thickness has been left in the roof and the floor of every seam to estimate the mineable reserves of coal. The total volume of OBR has been estimated from the total iso-excavation plan. The partings wise volume of OBR has been estimated from the cross-sections.
The total mineable reserves are estimated as 19.53 M.tes with a corresponding volume of OBR of 28.66 Mm 3 at an average stripping ratio of 1.47 m 3/te. The break-up of the seam wise coal reserves and total volume of OB/partings are given in Table 5.1.
Job No. 340721 Chapter-V -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Seam wise Mineable Reserve
Table No.5.1 Sl. No. Particulars Mineable Reserve (MT) A SEAMS 1 Seam VI 1.57 2 Seam VII B 2.00 3 Seam VII T 0.99 4 Seam VIII 9.77 5 Seam IX 0.80 6 Seam X 3.64 7 Seam XI 0.76 Total Mineable reserves 19.53 Total Net geological reserves 29.62 B Total Volume of Partings/OB 28.66 C Average Stripping Ratio 1.47
5.5 Geological & Mining Characteristics
The geological & mining characteristics of the proposed Govindpur Ph-II OCP (1.2 MTY) mine are given in Table 5.2. Total 7 numbers of coal seams are occurring within the quarriable area. Out of these, Seam VIII is the thickest and most prominent seam, which contains dirt bands. The coal seams are dipping at a gradient of 16 0-23 0 towards the south.
Job No. 340721 Chapter-V -3
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Table No.5.2 Mining & Geological Characteristics of the Quarry
Sl. THICKNESS Average Particulars Unit No. RANGE Value 1. Seam Thickness A Seam VI M 2 - 3 2.5 B Seam VII B “ 2 - 4 3 C Seam VII T “ 1 – 2 1.5 D Seam VIII “ 22 – 23 22.5 E Seam IX “ 2 – 3 2.5 F Seam X “ 7 – 8 7.5 G Seam XI “ 1.7 – 2.5 2 2. Seam Gradient Degree 16 - 23 - 3. Specific Gravity of the seams Te/m 3 1.62 4. Excavation Category of coal Assumed III 5. Parting/Overburden Thickness A Seam VI and Seam VIIB M 0.2 – 6 3 B Seam VIIB and Seam VIIT “ 0.3 – 3.8 2 C Seam VIIT and Seam VIII “ 10.2 – 14.6 12 D Seam VIII and Seam IX “ 9.3 – 31.5 20 E Seam IX and Seam X “ 0.4 – 5.9 3 F Seam X and Seam XI “ 4.5 – 8 6 6. Excavation Category of OB Assumed 50% Cat.III+50% Cat (IV) 7. OB Volume weight Te/m 3 2.40 (approx.) 8. Strike length of the quarry Km 1.50 9. Maximum depth of the quarry M 180 10. Quarry surface area Ha. 76.42
Job No. 340721 Chapter-V -4
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Mining and Technical Capabilities :
The targeted capacity of 1.2 MTY is proposed to be achieved by 4 th year of mining operation. The time to achieve target production has been fixed on the basis of: a) Estimated schedule of delivery and erection of main HEMM - capacity build up. b) Time required for opening of strike length. c) Construction period required for coal handling plant, evacuation system and other infrastructure development. d) Land acquisition.
5.6 Design Criteria
The following design criteria have been adopted for the mining operation of the quarry: - (i) No. Of annual working days : 330 (ii) No. Of daily shifts : 3 (iii) Duration of each shift : 8 hours.
Annual 330 working days has been calculated considering following assumptions: Calendar days per annum - 365 Less- Public Holidays - (-) 8 Unscheduled delays - (-) 5 Bad weather effect - (-) 22 Working days per annum with Sunday working: - 330
The opencast mine would be worked on the above 3 shift/day basis and 7 days/week schedule and the number of working days / year are adopted as 330, considering annual public holidays, unscheduled delays and bad weather effect particularly in rainy season.
Job No. 340721 Chapter-V -5
Project Report for Govindpur Ph-II OCP, CCL CMPDI
5.7 Life of the Mine For the rated output of 1.2 MTY of ROM coal and with the mineable reserves of 19.53 MT the life of the opencast mine is estimated as 20 years. The mine will achieve the targeted production in the 4th year of operation.
5.8 Opening of the Quarry For the quarry two openings have been proposed. One opening has been proposed in the northwest, from the incrop of Seam VI near borehole no CMEG 100 at an FRL of +243. To develop the full strike length of the mine for the gainful deployment of HEMM and to achieve the targeted production earlier, another quarry opening has been proposed in the northeast. Here also the opening is from the incrop of Seam VI near fault F11 and an FRL of +280m. This opening will also facilitate the early starting of internal dump on the eastern part of the quarry, upto fault F11.
5.9 Mining System The mining and geological conditions of the mine are as follows: - (a) Multiple seams to be worked (b) Steep gradient of 16 – 23 degree of the coal seams. (c) Variable thickness of OB/Partings.
Considering the above mining and geological conditions, shovel-dumper mining system with horizontal slicing has been envisaged for working this OC mine.
5.10 Calendar Programme of Excavation
The Summarised Calendar Programme of Excavation is given in Table No.5.3 which has been formulated based on adopted sequence of opencast mine field development at optimum conditions of mining operations for the entire life of mine. The total mineable reserves have been estimated as 19.53 MT corresponding to a volume of OBR of 28.66 MM 3 at an average stripping ratio of 1.47 m 3/te. The rated output of 1.2 MTY would be achieved in 4 th year after the sanctioning of the PR. The production built-up would be for a period of 4 years.
Job No. 340721 Chapter-V -6
Project Report for Govindpur Ph-II OCP, CCL CMPDI
As may be seen in the table, the peak OB workload is 2.10 Mm 3 in the 7 th year of quarry operation. The detailed calendar program is given in Table 5.4.
Summarised Calendar Programme of Excavation
Table-5.3 Year Coal OB S.R. 1 0.00 0.90 -- 2 0.40 1.22 3.05 3 0.80 1.57 1.97 4 1.20 1.88 1.57 5 1.20 1.88 1.57 6 1.20 1.87 1.56 7 1.20 2.10 1.75 8 1.20 1.87 1.56 9 1.20 1.83 1.53 10 1.20 1.73 1.44 11 1.20 1.55 1.29 12 1.20 1.49 1.24 13 1.20 1.39 1.16 14 1.20 1.39 1.16 15 1.20 1.39 1.16 16 1.20 1.39 1.16 17 1.00 1.14 1.14 18 0.75 0.89 1.19 19 0.60 0.71 1.19 20 0.38 0.46 1.19 TOTAL 19.53 28.66 1.47
Job No. 340721 Chapter-V -7
Project Report for Govindpur Ph-II OCP, CCL CMPDI
DETAILED CALENDAR PROGRAMME OF EXCAVATION Table No.5.4
COAL YEAR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Total COAL 0.00 0.40 0.80 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.20 1.00 0.75 0.60 0.38 19.53 XI 0.00 0.00 0.00 0.00 0.04 0.04 0.00 0.03 0.05 0.05 0.06 0.07 0.07 0.07 0.07 0.07 0.06 0.04 0.03 0.02 0.76 X 0.00 0.00 0.00 0.00 0.18 0.18 0.02 0.17 0.26 0.26 0.29 0.31 0.31 0.31 0.31 0.31 0.26 0.20 0.16 0.10 3.64 IX 0.00 0.00 0.00 0.00 0.04 0.04 0.01 0.04 0.06 0.06 0.06 0.07 0.07 0.07 0.07 0.07 0.06 0.04 0.03 0.02 0.80 VIII 0.00 0.03 0.25 0.70 0.72 0.72 0.77 0.64 0.56 0.56 0.57 0.58 0.58 0.58 0.58 0.58 0.49 0.36 0.29 0.19 9.77 VIIT 0.00 0.08 0.11 0.10 0.05 0.05 0.09 0.07 0.06 0.06 0.05 0.04 0.04 0.04 0.04 0.04 0.03 0.02 0.02 0.01 0.99 VIIB 0.00 0.15 0.23 0.22 0.10 0.10 0.18 0.14 0.12 0.12 0.10 0.08 0.08 0.08 0.08 0.08 0.06 0.05 0.04 0.02 2.00 VI 0.00 0.14 0.21 0.18 0.07 0.07 0.13 0.11 0.09 0.09 0.07 0.05 0.05 0.05 0.05 0.05 0.04 0.03 0.03 0.02 1.57 OB YEAR 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Total OB 0.00 0.68 1.46 1.84 1.82 1.90 2.63 2.20 1.92 1.92 1.67 1.46 1.46 1.46 1.46 1.46 1.22 0.91 0.73 0.47 28.66 TOP OB 0.00 0.41 0.59 0.41 0.48 0.50 0.54 0.57 0.59 0.59 0.41 0.27 0.27 0.27 0.27 0.27 0.23 0.17 0.14 0.09 7.06 XI-X 0.00 0.00 0.00 0.00 0.09 0.09 0.00 0.09 0.14 0.14 0.13 0.13 0.13 0.13 0.13 0.13 0.10 0.08 0.06 0.04 1.60 X-IX 0.00 0.00 0.00 0.00 0.02 0.02 0.01 0.05 0.08 0.08 0.07 0.07 0.07 0.07 0.07 0.07 0.06 0.04 0.03 0.02 0.81 IX-VIII 0.00 0.00 0.06 0.40 0.69 0.74 1.28 0.88 0.61 0.61 0.55 0.50 0.50 0.50 0.50 0.50 0.42 0.31 0.25 0.16 9.47 VIII-VIIT 0.00 0.13 0.54 0.80 0.44 0.44 0.59 0.45 0.36 0.36 0.36 0.36 0.36 0.36 0.36 0.36 0.30 0.23 0.18 0.12 7.12 VIIT-VIIB 0.00 0.05 0.08 0.07 0.05 0.05 0.08 0.07 0.06 0.06 0.05 0.05 0.05 0.05 0.05 0.05 0.04 0.03 0.02 0.01 0.95 VIIB-VI 0.00 0.09 0.19 0.16 0.06 0.06 0.12 0.10 0.08 0.08 0.08 0.09 0.09 0.09 0.09 0.09 0.07 0.05 0.04 0.03 1.65 S.R. - 3.05 1.97 1.57 1.57 1.56 1.75 1.56 1.53 1.44 1.29 1.24 1.16 1.16 1.16 1.16 1.14 1.19 1.19 1.19 1.47
Job No. 340721 Chapter-V -8
Project Report for Govindpur Ph-II OCP, CCL CMPDI
5.11 Coal Winning and OB removal
OB Removal To remove the overburden, two 4 cum diesel hydraulic shovel with 35T Rear Dumpers have been proposed. The peak OB workload is 2.10 Mm 3.
Coal Winning 4 cum diesel hydraulic shovel with 35T Rear Dumpers have been proposed for mining of 1.2 MTY of coal. The dumpers from the face to the CHP installed on the surface would transport the coal.
Some major system parameters for both coal winning & OB removal are given below: - 1. Mining Benches a) Maximum Bench Height • 4 Cum Elec Hyd shovel bench - 8-10m b) Minimum Bench Width Working Bench Width for 4 cum Elec Hyd Shovel - 40m Non-working Bench width for 4 cum Elec Hyd Shovel - 25m 2. Width of the permanent haul road - 30 m. 3. Width of the temporary transport ramp - 20 m. 4. Usual height of the spoil dump bench - 30 m. 5. Bench Slope (working) O.B. bench - 70 0 Coal bench - 70 0 Dump bench - 37 0 Overall pit slope - 37 0.
5.12 Annual Productivity of Main HEMM The annual productivity of shovels and dumpers have been calculated on the basis of the following: (a) Excavation Category: Coal : Cat. III OB : 50% Cat. III + 50% Cat. IV.
Job No. 340721 Chapter-V -9
Project Report for Govindpur Ph-II OCP, CCL CMPDI
The materials having compressive strength between 125 to 250 kg/cm2 is classified as Cat. III and between 250 to 1250 Kg/cm2 as Cat. IV
(b) Standard Utilization of Shift Hours For Elect. Hyd. Shovel: 61% For Dumpers 67%
The main mining and transport equipment would be operating on 3 shifts/day and 7 days/week operating schedule. The number of operating days/year has been adopted as 330. Based on the above operating conditions, the estimated annual productivity of the proposed shovels as per the prevalent norms is given below: - The requirement of dumpers for the transportation of OB and coal has been calculated based on (a) annual workload (b) annual productivity of dumpers (c) hauling distanced from the face to the receiving pit/dump site etc. (Table no.5.6). The annual productivity of dumpers for a lead of 1.0 to 4.5 km is given in following table: -
Lead Annual Productivity of Dumpers (in M cum) (in km) 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 For OBR 35T Dumper 0.1879 0.1571 0.1389 0.1268 0.1146 0.1054 0.0980 0.0921 +4 m 3 Elec. Hyd Shovel For Coal 35T Dumper 0.2245 0.1888 0.1674 0.1532 0.1387 0.1276 0.1189 0.1119 +4 m 3 Hyd Shovel
5.13 Equipment configuration
The detailed list of HEMM proposed for Govindpur Ph-II OCP 1.2 MTY is given in Table 5.5 below:
Job No. 340721 Chapter-V -10
Project Report for Govindpur Ph-II OCP, CCL CMPDI
YEARWISE POPULATION OF HEMM Table 5.5
Year 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Coal
Hyd. Shovel 4 Cum 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Rear Dumpers 35T 2 3 5 5 5 5 5 5 5 5 5 5 5 5 5 4 3 3 2
Drill 160 mm 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Dozer 410 HP 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
OB
Hyd. Shovel 4 Cum 1 1 1 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1
Rear Dumpers 35T 8 10 13 16 16 17 17 17 17 17 15 15 15 14 14 14 11 9 7 5
Drill 160 mm 1 1 1 2 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1
Dozer 410 HP 1 1 1 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1
Common Hyd. Shovel (with 1.2 Cum 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 backhoe) Wagon Drill 100- 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 (Diesel) 120mm Grader 280HP 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
RT crane 20T 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Mobile Crane 8T 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Front End Loader 5-6 Cum 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Tyre Handler 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Water Sprinkler (wide spray 28 KL 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 system) Wheel Dozer 460 HP 1 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Fuel trucks 16KL 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Fire Truck 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Reclamation
F E Loader 5-6Cum 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 Water Sprinkler (wide spray 28 KL 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 system) Dozer 410 HP 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Job No. 340721 Chapter-V -11
Project Report for Govindpur Ph-II OCP, CCL CMPDI
5.14 Drilling and Blasting Operations
160mm diameter drills are envisaged for drilling in Top OB / partings as well as in coal seams.
5.15 Spoil Dump
The final stage dump plan showing external dump has been given vide Drg. No. R3-OCM-000457. As the gradient of the quarry is very steep, internal dumping could not be proposed during the quarry operation. However, an area in the east of the proposed quarry has been identified for internal dumping (marked as Internal Dump ‘B’) after its exhaustion in the 4 th year. The total volume of O.B to be removed is estimated as 28.66 M.cum. 24.00 M.cum of O.B is proposed to be placed at the external OB dump ‘A’ and the rest OB of 4.66 M cum is to be placed as internal dump ‘B’. In the absence of external dump nearby, the external OB dump ‘A’ has been earmarked in the North of Konar River in the north-western side of the proposed OC. The same is marked as ‘Open scrub’ in the Survey of India Topo sheet no 73E/13. The top RL of the proposed external dump ‘A’ is +300m. The area of dump ‘A’ is 87.00 Ha. The internal dump B is proposed to be done in the eastern part of the quarry, upto Fault F11. The top RL of internal dump ‘B’ is +270m.
5.16 HFL Detail
The Konar River flowing from north to south in the west of the proposed quarry has an HFL of 232.07m as on 01.10.1978. The surface RL ranges from 240m to 252m in the west. On the other hand north-south flowing Montico Nalla on the east of the proposed quarry has an HFL of 234.95m as on 08.10.2003 whereas the surface RL ranges from 240m to 252m in the east.
Job No. 340721 Chapter-V -12
Project Report for Govindpur Ph-II OCP, CCL CMPDI
5.17 Quarry Extension in dip side
The proposed PR has considered the reserves of Govindpur North block and the area south of Bermo Seam incrop upto 180m-depth line on Seam-VI floor in the south. Further extension of the project in the dip side is possible only after the diversion of Mantico Nalla.
5.18 Product Mix Quality :
Although coal seam, parting and overburden just above coal seam will be worked separately having separate benches, yet, there is a chance of deterioration in quality of coal due to admixtures from roof and floor of the seam and by the inclusion of bands within the seam. It is envisaged that the roof of the seam is properly cleaned before blasting. A proper organization and strict quality control measures are necessary to maintain the quality of coal at faces with all precautions for quality control to reduce contamination at each contact point of coal & OB or parting. The quality of coal has been worked out to be ‘Grade –E’ for the Project Report. The Coal Quality may be improved further by adopting beneficiation measures.
Job No. 340721 Chapter-V -13
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER – VI
6.0 PUMPING AND DRAINAGE
6.1 The proposed PR of Govindpur OCP of CCL has been planned for targeted production of 1.20 MTY. The planning of dewatering the mine has been done in such a way that the working faces and haul roads in all quarries will remain dry as far as possible. The layout of the quarry provides suitable gradient along the quarry floors and the benches to facilitate self-drainage of water to the sump at the lowest level of the quarry. It is proposed to provide garland drain around the quarry boundary to arrest water flowing into the mine from area beyond excavation. During the heavy monsoon period, the work in lower most bench may have to be stopped as it will not be possible to pump out the entire make of water on the wettest day. Therefore, it is proposed to drown a part of the lower-most bench, which would, then act as sump. Water accumulated in the sump will be pumped out to the surface and discharged into the nallah flowing outside the quarry and it will finally join to nearby river Konar/ montico nallah. It is proposed to create a sedimentation lagoon by constructing a series of check dams across the nallah. Water overflowing the check dams would join Konar river. The lagoon will help to separate the suspended solids from the mine water.
6.2 GENERAL CONSIDERATIONS
The pumping requirement has been calculated on the basis of the following general considerations: - - The geographical location of the opencast working. - Meteorological data from the area concerning rainfalls.
Job No. 340721 Chapter-VI -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
- Life of the mine and percentage probability of maximum rainfall in one day during the life of the mine. - Surface feature of the area surrounding the opencast working. - Catchment area: Mined out area and area beyond excavation, and dumped area. - Run-off characteristics of the area. - Depth of the quarry. - Inflow to the quarry of UG & seepage water from Konar river. - Desired location at the surface where the quarry water can be discharged. - Surface drainage system. - Effective working hours – 20 hours/day for pumping calculation, but in monsoon period pumping will be done round the clock. - Proximity of Konar River.
6.3 BASIC DATA The following data has been taken into consideration for arriving at the size of the pumps: -
(a) Maximum depth of the mine : 180 m (b) Percentage probability of maximum : 5 rainfall for entire mine life (c) Probable maximum rainfall in a day : 160 mm in monsoon period from the probability curve (d) Run-off Co-efficient considered : (i) For mined out area = 0.9 : (ii) For area beyond excavation =0.1 : (iii) For internal dump Area =0.15 (e) Inflow of water to the quarry due to : 20% of probable water seepage and underground accumulation due to rainfall & precipitation of River Konar. Konar river. (f) The rainfall data has been adopted : IMD, Hazaribag as recorded at
Job No. 340721 Chapter-VI -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
6.4 PUMPING CALCULATIONS
The calculation has been done taking into consideration the entire area of the mine :-
(a) Approximate Area of excavation of the : 0.764 Sq.Km. mine quarry (b) Approximate Area beyond excavation : 0.04 Sq.Km.
(c) Approximate dump Area in the quarries. : 0.17 Sq.Km. (d) Probable water accumulation on the day of maximum rainfall : 97972 Cum. (e) Taking 20% for seepage and underground precipitation the total water accumulation : 117566 Cum. (f) Assuming 20 hours pumping per day, pumping capacity required to pump out the total make of water in six days. : 979 Cum./hour (271 lps)
6.5 SELECTION OF PUMPS On the basis of the calculation and considering standby pumping capacity, the following pumps have been provided: - Main Pump Four nos. of 300 Cum / hr (82 lps) x 200 m head and two nos. of 150 Cum / hr (42 lps) x 200 m head pumps have been provided. Out of which one no. of each pump have been proposed as standby. Two nos. of 150 Cum./hr x 100 m. head pumps have also been provided to dewater the quarry during initial period of mining. These low head pumps may also be used as intermediate stage pumping.
Job No. 340721 Chapter-VI -3
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Diesel Pumps One number of 300 Cum/hr (82 lps) x 200 m head diesel pump has been provided for emergency requirement. Face Pumps and Slurry Pumps Two Nos. of Face Pumps of 50 Cum/hr. (14 lps) x 45-60 m head and two no. of Slurry Pump of 80 -150 Cum./ hr x 45 m head capacities have been provided to pump out the water & slurry respectively accumulated near the working faces.
6.6 SELECTION OF DELIVERY RANGES The delivery ranges have been selected on the basis of the pumping capacity during probable maximum rainfall and velocity of flow within the reasonable limit. The delivery ranges for different capacity of pumps have been selected for nominal diameters as 250mm, 200mm, 150mm and 100mm for the pumps as per manufacturer’s standard.
6.7 ESTIMATED CAPITAL COST The details of cost estimate along with the phased requirement have been given in Appendix-A.3.3 of pumps, pipes and fittings.
Job No. 340721 Chapter-VI -4
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER – VII
POWER SUPPLY, DISTRIBUTION, ILLUMINATION & COMMUNICATION
7.1 Power Requirement
The estimated connected loads; maximum demand and energy consumption at optimum production level for the Govindpur Ph-II Opencast Project for various options are as summarized below :-
S N Particulars Values 1 Connected Load (in kW) 2164 2 Load in Operation (in kW) 1522 3 Maximum Power Demand (in kVA) 918 4 Annual Energy consumption 7.27 (in kWhr x10 6) 5 Energy Consumption per tonne of coal 6.06 production (in kWhr/te) 6 Cost of Energy per tonne of coal 20.60 production (in Rs)
Table VII (i) indicates the detailed of power requirement and energy consumption.
7.2 Existing Power distribution Arrangement Presently the Govindpur Ph-II O/C Project substation (1x3 MVA, 11/3.3 kV) is receiving power at 11 kV through one no. independent single feeder with ACSR Conductor from Kathara Regional Substation (1x10 MVA, 33/11 kV). This Substation is situated near Kathara o/c Project at a distance of 12.0 Km (approx.).
Job No. 340721 Chapter-VII -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
7.3 Proposed Power Supply Arrangement It is proposed to install another 2 MVA 11/3.3 kV Transformer for additional electrical equipments and loads. Power shall be distributed from this sub-station to various additional electrical equipment and load points.
7.4 Distribution and Utilisation Voltage The distribution and utilization voltage for the project are summarized below:- (i) Shovel (4 M 3) - 3.3 kV (ii) Pumps as & above 110 kW - 3.3 kV (iii) Pumps below 110 kW - 440 V (iv) Workshop - 3.3 kV (v) C.H.P. - 3.3 kV (vi) Lighting (Mining Area) - 230 V (L- L) (vii) Office - 230 V
7.5 System of Power Supply For all the utilization voltages in the project, the system of power supply shall be restricted earthed neutral.
7.6 Substation Capacity To meet the power requirement of the project, substations with following transformer capacity has been envisaged:- (i) Substation: - 1x3 MVA; 11/3.3 kV (Existing) 1x2 MVA; 11/3.3 kV (Proposed) The transformer capacity of existing Substation is 3 MVA, 11/3.3 kV. This transformer will feed power to O.B, coal winning equipment (existing), W/S, colony and other lighting loads. 2 MVA; 11/3.3 kV transformer is proposed to be installed for feeding power to the additional load of HEMM deployed for O.B. removal and coal winning and pumping loads.
Job No. 340721 Chapter-VII -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
7.7 Quarry Distribution Two Nos. of 3.3 kV O.H.T.L. with ACSR ‘DOG’ conductors are proposed to be erected along the quarry edge of the project. Power to the electrical equipment shall be tapped from O.H.T.L. through armoured PVC cable. Sufficient provision of field switches have been made for feeding power to 4 m 3 shovels at 3.3 kV. Also sufficient Nos. of field switches has been provided for operation of H.T. pumps. For operation of L.T. Pumps at 440 Volt, 3.3 /0.440 kV, 630 kVA & 250 kVA step down transformers have been provided.
7.8 Metering Arrangement For the purpose of proper allocation of energy charge, 11 kV breaker as well as 3.3 kV breakers are provided with metering facilities.
7.9 Quarry Illumination Quarry illumination has been provided by groups of 400W & 250W, 250V HPSV lamps mounted on 15m high towers, distributed along the quarry edge. 5 kVA 3.3/0.230 Kv (L-L), lighting transformers have been provided to feed power to lamps mounted on towers.
The haul road of the mine is proposed to be illuminated by High Pressure Sodium Vapour lamps of 250 W mounted on poles of suitable height. Adequate Nos. of 10 kVA, 3.3/0.230 Kv (L-L) lighting transformers have been provided to facilitate haul road illumination. Provision have been made in the estimate towards general and spoil dump illumination of the mine and industrial areas.
Inverter type emergency lighting sets would be installed at important locations for use at the time of general power supply failure. Over and above, one no. of 10 kVA generator set has also been provided to meet the emergency lighting requirement.
Job No. 340721 Chapter-VII -3
Project Report for Govindpur Ph-II OCP, CCL CMPDI
7.10 Colony Illumination The power supply to colony will remain unchanged. Provision of Transformer, 440V OHTL and other electrical accessories has been made for colony illumination & electrification both.
7.11 Power Supply to CHP Proposal has been made to feed power to CHP at 3.3 KV from the project Substation of the mine. The CHP will have its own incoming power arrangement & distribution network.
7.12 Power Supply to Workshop The project Substation will feed power to the workshop at 3.3 kV through independent feeder. The Workshop-substation will step down the voltage as per requirement and will feed its loads accordingly.
7.13 Improvement of Power Factor Static capacitors with automatic p.f. correction relays have been provided in the substation to improve the power factor to about 0.98 lagging. Capacity of capacitors required to improve power factor to the above stated value has been estimated as 508 kVAR for Option I & II and 424 kVAR for Option III at 3.3 kV.
7.14 Power Cost Based on current DVC tariff, the annual power bill would be of the order of Rs.247.24 lakhs at the rated coal production and OB transportation.
Job No. 340721 Chapter-VII -4
Project Report for Govindpur Ph-II OCP, CCL CMPDI
7.15 Communication For effective management of different production, service units and for ensuring safety, the following communication facilities have been envisaged for Govindpur Ph-II OCP (1.20 MTY). - Surface Mine Communication System - Internet with LAN
Surface Mine Communication EPABX (ISDN) Exchange In order to cater to the need of surface communication and Integrated Service Digital network exchange of 50 lines, is proposed for facilitating voice, data and video communication between various offices, residential buildings and other strategic points within the mines, at higher speed. A variety of devices can be connected to a single ISDN line including ISDN Digital telephone, faxes modems and data transmission facility (E1 support) with LAN port.
ISDN exchange shall utilise pulse code modulation based on fully distributed microporcessor and dual architecture. Exchange shall be based on 32 bite processor having distributed control logic and switching control. Important interfaces like analog PSTN interface and ISDN-BRI/RI shall be provided. Audio conferencing, video conferencing, Data interface along with CTS support shall be provided.
Integrated Services Digital Network Exchange provides the transmission and reception of voice, data and video at higher speed of current modems. A variety of devices can be connected to a single ISDN line, including ISDN digital telephone, faxes and modems. Features as caller ID, advice of charge, disk top conferencing, computer network connectivity and fast Internet access are important advantages of ISDN exchange.
Job No. 340721 Chapter-VII -5
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Digital ISDN exchange with 50 lines and expandable upto 200 lines, complete with PC based operator console with Pentium PC should be provided.
The proposed EPABX exchange should have the following main features. (i) The inbuilt Data switching facility will be used to transmit data between two exchanges (the other exchange may not have ISDN features) upto a speed of 19.2 Kbps. (ii) The system will have DID (Direct Inward Dialing) and E&M two/four wire facility. (iii) The system will be interfaced with a broad variety of voice mail system. (iv) The system will support 3-way conferencing by allowing a third party to enter in an existing call between stations/trunks. (v) The system will continuously performs tests on itself and diagnoses the results for maintenance reporting purposes. (vi) The system will record automatically all the incoming and outgoing calls in its temporary memory for billing, identification, cal type used and it can be programmed also. Accessories (i) Maintenance console with printer. (ii) Float cum Battery charger (iii) Battery back up. (iv) Earthing.
External P&T Telephone Communication System Besides the existing facilities of communication system of the project five additional telephone sets with a EPABX interface have been provided for P&T communication and access to public communication grid. These telephone sets would be located in the residences and offices of key personnel of the project, sub-station, workshop, etc.
Job No. 340721 Chapter-VII -6
Project Report for Govindpur Ph-II OCP, CCL CMPDI
EDP System Facilities along LAN and Internet It is proposed to deploy electronic data processing facilities for production planning, control and project management etc. The system envisages to play a key role in establishment of highly effective Data Base Management System (DBMS) and Management Information System (MIS) etc.
The type of computer would be small business computer with broad facilities and also have specific facilities to carry out: - Pay rolls - Financial accounting - Inventory control - Material management - HEMM utilisation, breakdown analysis, idle time analysis etc. - Production, despatch schedule and variances. - Accident records etc. - Resource utilisation & MISD.
Before initiating action for installation and implementation of the above EDP system, a detailed system study would have to be carried out, with clearly defined system objectives for identifying the data processing needs and management information system needs of the project. Based on the results and findings of the study, the system configuration and specification have to be decided.
LAN Facility A Local Area Network having 2 PCs in operation is proposed for this project. The proposed network structure shall have 1 server for catering to all the clients which shall be primarily connected with the server. This server will serve as main file and print server. This server shall preferably be Pentium D core 2 Duo based PC with 1 GB RAM, 120 GB HDD running at 2.4 GHz min.
Job No. 340721 Chapter-VII -7
Project Report for Govindpur Ph-II OCP, CCL CMPDI
The NOS will be Windows NT 4.0 with a required No. of user licenses. The backbone cabling will be of fibre optic cable.
Internet Facility An internet connection is proposed for the project to cater to the needs of information gathering, file transfer and speedy correspondence by E-Mail. The main internet link will be provided by VSNL/BSNL by means of leased lines/dial-up modems. The main server unit will be a Pentium D core 2 Duo based PC with 1 GB RAM, 120 GB HDD running at 1.7 GHz minimum.
Software The Network Operating Software will be Windows NT 4.0 with the required No. of user license. For simultaneous Internet access from multiple client MS Proxy Server 2.0 will be installed on top of Windows NT 4.0. In this way a private local network along with Internet gateway can be built up.
7.16 Capital Investment for Plant & Machinery – Electrical The total capital investment for this Project for electrical power supply, distribution, illumination, colony lighting, communication and EDP facilities etc. have been estimated and is given in Appendix-A.3.7.
Job No. 340721 Chapter-VII -8
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER – VIII COAL HANDLING PLANT
8.0 Introduction The PR of Govindpur Open cast Project is being prepared for a rated capacity of 1.20 MT of ROM coal / annum. The Coal Handling Plant for this project has been envisaged to handle total production of coal from this mine. The coal produced from the mine will be crushed and dispatched by tipping trucks to nearby Washery / Rly. siding for onwards dispatch to customers. For this size of coal handling plant other supporting infrastructures and suitable repair facilities have also been provided. The coal handling plant will operate on 3 shifts/day and 7 days per week basis round the year like the mine.
8.1 Location The plan showing the location of CHP is given in drg. No. R3/E&M/002357. As can be seen from the plan the terrain is rugged. The CHP has been planned keeping in view the rugged terrain. The following factors have been considered in finalizing the location of CHP. (a) Mine boundary (b) Mine entry (c) Topography (d) Availability of free space (e) Overall economy of the system
8.2 Basic Data Details 8.2.1 Production capacity of the mine : 1.20 MTY 8.2.2 No. of working days / Year : 330 8.2.3 No. of working shifts/day : 3 8.2.4 Effective working hours/shift : 5 8.2.5 Feed size of coal in (mm) : (-) 1200 8.2.6 Product size of coal in (mm) : (-) 100 8.2.7 Consumer : Power Station & others
Job No. 340721 Chapter-VIII -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
8.2.8 Mode of despatch : By Tipping truck to near by siding or to customer. 8.2.9 Loading hours/day : 365 days / Round the clock
8.3 System Capacity System capacity of the CHP has been selected to match with the mine production. Hence for the mines rated capacity 1.20 MTY, the overall handling capacity of CHP has been envisaged to be 1.20 MTY.
8.4 Description of CHP
8.4.1 Receiving and Crushing of ROM Coal A receiving platform of suitable size has been planned for the coal handling plant. The maximum size of ROM coal received from the quarry will be of (-) 1200 mm size. The ROM coal will be discharged by the rear discharge dumpers to the feeder breaker hopper and it will be crushed to (-) 200 mm size. Two nos. of feeder breakers of capacity 500 tph each have been provided out of which one will be in operation at a time and other will work as standby.
8.4.2 Secondary Crushing The crushed coal of (-) 200 mm size from the feeder breakers will be collected by a short conveyor and fed into a roll crusher of 500 tph capacity for crushing coal up to (-) 100 mm size.
8.4.3 Conveying System The crushed coal from secondary crusher will be discharged onto an elevating cum tripper conveyor for storage of crushed coal in overhead hoppers. The width & capacity of conveyors have been considered as 1200 mm and 500 TPH capacity respectively.
8.4.4 Storage & Reclamation Provision has been made to store crushed coal in overhead hoppers. The crushed coal will be fed to overhead hoppers (4X200 Te Capacity) by a short
Job No. 340721 Chapter-VIII -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
elevating conveyor. There will be provision of ground stock of crushed coal after the hoppers. Below the hoppers motorized flap/hydraulic gate have been provided in each of the hopper opening for loading the coal into truck.
8.4.5 Loading and Despatch Each opening of the overhead hoppers will be fitted with motorized flap /hydraulic gate which may be activated for loading as and when the tipping truck will be positioned underneath the opening. Thereafter, coal will be dispatched to nearby washery / Railway siding. Provision for weighment of coal / trucks has also been envisaged.
8.4.6 Pollution control and Fire Fighting Necessary arrangements have been provided for dust suppression and fire fighting. Dust suppression arrangements have been provided at following locations: a) Receiving platform of Feeder Breakers b) Discharge end of Feeder Breakers c) Crusher top d) Loading points.
Suitable nos. of dry type portable fire fighting equipment has been provided to protect the plant from fire hazard.
8.4.7 Power supply, control and internal communication All the electrical equipment will be suitable for successful operation at the ambient temperature prevailing at site. Power distribution system with all protections and measuring facilities, Centralised sequence control, signaling and instrumentation, Interlocking, Emergency stopping and Illumination etc. have been provided.
8.4.8 Other Facilities Two nos. 50 Te capacity truck weighbridges have been envisaged for Weighment of trucks. Safety switches shall be provided like pull chord switch,
Job No. 340721 Chapter-VIII -3
Project Report for Govindpur Ph-II OCP, CCL CMPDI
belt sway switch at suitable intervals along the length of conveyors for stopping of conveyors and training of belts in case of emergency.
Description of CHP
A receiving platform of suitable size has been planned for the coal handling plant. The maximum size of ROM coal received from the quarry will be of (-) 1200 mm size. The ROM coal will be discharged by the rear discharge dumpers to the feeder breaker hopper and it will be crushed to (-) 200 mm size. Two nos. of feeder breakers of capacity 500 tph each have been provided out of which one will be in operation at a time and other will work as standby.
Conveying System The crushed coal (200 mm) will be discharged onto an elevating cum tripper conveyor for storage of crushed coal in overhead hoppers. The width & capacity of conveyors have been considered as 1200 mm and 500 TPH respectively.
Storage, Reclamation & Loading Storage, Reclamation, Loading and other facilities have been envisaged as described above for variant –I & II.
8.5 Estimated Capital Cost
The estimated capital expenditure for the coal handling plant as envisaged for handling the capacity of 1.20 MTY coal is given in the Appendix: A.3.4.0.
Job No. 340721 Chapter-VIII -4
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER – IX
RAILWAY SIDING
9.0 Introduction The proposed Govindpur opencast project in East Bokaro Coalfield has been planned for targeted production of 1.20 MTY of coal. Railway siding is not available nearby to dispatch the proposed production of coal from this mine. As such a railway siding has been proposed at the abandoned Pipradih railway siding of CCL for dispatch of coal from this Project. Provision for loading of coal through wharf wall loading with pay-loader system at the proposed siding for dispatch of coal produced from Govindpur Ph-II OCP.
9.1 Yard Layout The yard has been planned for a full rake siding of 58 Box N wagon with wharf wall facilities (one empty receiving line only) suitable for semi- mechanised loading.
9.2 Take Off-Point It is assumed that the proposed railway siding will be taken off from the Gomio Railway Station of main Gomoh-Barkakana rail line. The length of the proposed railway siding will be about 0.8 Km to accommodate a rake of 58 ‘N’ wagons.
9.3 Characteristic features of the proposed Railway siding are as follows: (a) One empty receiving line for a full rake length of 58 box N wagons. (b) Wharf wall loading of wagons. (c) Environmental measures (dust suppression, fire fighting, plantation etc.) (d) Weighment of wagons / rakes.
9.4 Estimated Cost of the Railway Siding The details of cost estimate of proposed Railway Siding including Yard portion has been given in Appendix-A.5.
Job No. 340721 Chapter-IX -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER – X
WORKSHOP & STORE
10.0 Introduction Govindpur PH-II OCP is a new mine of Central Coalfields Limited. This project report has been prepared for a targeted production of 1.20 MTY. So, a new unit workshop has been proposed. This unit workshop is envisaged to cater the need of daily maintenance, schedule maintenance, lubrication, routine inspection, minor/medium repair and replacement of parts/sub-assemblies of HEMM such as- Dumpers, Dozers, Shovels, and Drills etc. Minor repair of assemblies and sub-assemblies of pumps, CHP equipment, electricals etc. deployed in the project will also be performed in this workshop. Any major overhaul of equipment and manufacturing of spares on large scale are beyond the scope of this workshop. These works will be carried out in Regional Repair Shop or Central Workshop, Barkakana. This unit workshop will have two parts – Excavation and E&M workshops. Apart from this, Project store and other common facilities have been provided. A schematic layout plan of the workshop is shown in drawing No. R 3 E&M 002378.
10.1 Excavation Workshop This part of workshop will have the facilities for attending to schedule maintenance, minor and medium repair or replacement of parts/sub- assemblies of face and transport equipment such as – Shovels, Drills, Dozers, Dumpers, Graders, Crane and other miscellaneous equipment used for mining operation. All dumpers and dozers coming to workshop for their daily as well as schedule maintenance will be first washed at the washing stations provided in the workshop and then brought to the respective maintenance
Job No. 340721 Chapter-X -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
shop like daily maintenance shop and schedule maintenance (lubrication & Inspection) shop as per their schedule. In daily maintenance shop, the equipment will be checked for lubrication, tyre inflation, oil levels etc. The equipment for scheduled preventive maintenance as per recommended schedules of the manufacturers will be directed to schedule maintenance shop where their complete lubrication will be taken care along with diagnosis of their technical state. After evaluation of the condition, they will be sent to the Dumper Repair shop for medium repair and/or to Regional Repair Shop, Central Workshop for major repairs. The equipment, which experience incidental problem in the field and require medium repair will also be directed to Dumper/Dozer repair shop.
Maintenance of Shovels, drills and minor repairs will be carried out at the site. The components/assemblies requiring further repair will be dis- assembled from the machine and the dis-assembled components will be brought to the Repair shop. In case of major repair, these will be sent to central workshop. Broadly this workshop will have the following functional shops:
i) Machine shop ii) Electrical Repair shop iii) Smithy shop iv) Dumper Repair shop v) Dumper Daily Maintenance shop vi) Schedule Maintenance (Inspection and lubrication) shop vii) Dozer Repair shop viii) Welding Shop ix) Washing Station x) Stores & common facilities
Job No. 340721 Chapter-X -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
i) Machine shop This shop will have the necessary machine tools for restoration of worn-out parts and manufacture of small non-complicated spare parts, which are in short supply and required for repair of HEMM.
ii) Electrical Repair shop This shop will have the facilities for carrying out the minor and medium repairs of the electrical components of the mining equipment. The repair facilities have been limited to the parts replacement and repair of self-starter, Dynamo, Battery charging etc.
iii) Smithy shop This shop will deal with the manufacture of small hand forging components required for the repair need of HEMM equipment. It is located in one side of the workshop.
iv) Dumper Repair shop This shop will cater to the need of repair/replacement of parts/components of the dumpers needing repair after their proper inspection & diagnosis of defects in the Schedule Maintenance shop. The dumpers, which experience incidental problem in the field and require minor & medium repair will also be attended in this shop. All dumpers coming for repair must be first washed at the washing station before entering this shop. There is a common 15/5T floor operated EOT crane, which will serve dumper repair shop as well as other shops.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
v) Dumper Daily Maintenance shop Checking of water and oil levels, greasing of lubrication points, checking of air pressure of tyres, brake testing etc. will be performed in this shop.
vi) Dumper Schedule Maintenance (Lubrication and Inspection shop) The schedule maintenance (lubrication and Inspection) of the dumpers as per schedules recommended by the manufacturers will be done in this shop. For this purpose pressurised lubrication system has been provided.
vii) Dozer Repair shop This shop is meant for carrying out the maintenance and repair of dozer. The repairs will be done mainly by the replacement of parts, units and sub-assemblies. The entrance & exit of dozers will be from one side only.
viii) Welding shop This shop will take-up the welding of buckets of shovels and other jobs of dumpers etc. It will also under take other non standard welding works.
ix) Washing Station High-pressure water and steam jet washing unit for dumper and dozer have been envisaged for washing.
x) Stores & Common facilities A small store is provided for storage of 10 days consumption of spares & consumables required for repair & maintenance of HEMM & other mining equipment. The different repair shops will draw day-to-day requirement of spares & other consumables from this store. Job No. 340721 Chapter-X -4
Project Report for Govindpur Ph-II OCP, CCL CMPDI
A fully equipped fuelling station is also provided for fuelling the vehicles and transport equipment.
10.2 E&M Workshop Considering the nature of repair and maintenance of E&M equipment, which is different from the HEMM, a separate E&M workshop has been envisaged. This part of the workshop will have the facilities for schedule maintenance, day to day maintenance and minor & medium repair by parts/unit replacement method of all E&M equipments deployed in the project such as- pumps, electrical equipment, CHP equipment etc. Broadly this workshop will have the following functional shops: i) Machine shop, ii) Mechanical Repair shop, iii) Electrical Repair shop
i) Machine shop This shop will undertake machining and reconditioning of spares. It will also manufacture small spares, which are in short supply and required for the repair of E&M equipment.
ii) Mechanical Repair shop The equipment like pumps and pumping installation experiencing incidental problem in the field and requiring minor repairs will be brought to this shop where they will be inspected and repaired. Apart from this the normal maintenance/repair of the pumps & CHP equipment will be done in this shop.
iii) Electrical Repair shop This shop will deal with the testing and minor repairing of electrical components of CHP equipment, pumps, switchgears etc.
Job No. 340721 Chapter-X -5
Project Report for Govindpur Ph-II OCP, CCL CMPDI
10.3 Project Store This workshop will have a project store to meet the total requirement of proposed workshop as well as additional requirement of the project. Only day-to-day requirement of spares and consumables will be kept in the workshop store for smooth functioning of workshop.
10.4 Working Schedule This workshop will work mainly in two shifts of 8 hrs. duration but a group of technical personnel will also be provided in the third shift to look after the field repairs of mining equipment deployed in this shift.
10.5 Capital Investment The details of P&M provided for the workshop along with their estimated cost have been given in Appendix-A.3.2.
Job No. 340721 Chapter-X -6
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER - XI
MANPOWER & PRODUCTIVITY
11.1 The manpower requirement for Govindpur Ph-II OC mine for a rated production of 1.2 MTY of coal has been estimated as 426 (upto target year i.e., 4th year) for Option-I & III, resulting in an overall OMS of 10.67 Te. The manpower includes 10 persons for land reclamation/EMP. Earning per man shift (EMS) is estimated as Rs. 1584.01.
The skill wise break-up of workers (upto target year) is given below: -
Sl. Particulars Category Nos. Percentage of No. total worker 1. Unskilled I 25 8.4 2. Semi-skilled II, E 27 9.0 3. Skilled C, D, III, IV, V, VI 116 38.8 4. Highly Skilled A, B 131 43.8 Total 299 100
The break-up of total manpower in groups i.e. Workers, monthly paid staff & officers are given below; Sl. Particulars No. Percentage of No. total manpower 1. Workers 299 70.2 2. Monthly Paid Staff 104 24.4 3. Officers 23 5.4 Total 426 100
The manpower would be posted from the internal resources of the company. The unskilled/semi-skilled manpower may be trained to make them skilled/highly skilled in order to avoid additional recruitment.
Job No. 340721 Chapter-XI -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER – XII
CIVIL CONSTRUCTION
12.1 INTRODUCTION
The life of this project has been estimated as 20 years. For service and welfare buildings permanent type of construction has been proposed. The cost estimate for civil construction has been prepared based on the cost index. The cost index has been worked out as 2082 with respect to 100 base at Delhi as on 01.10.1976. The details have been given in Appendix- A.2.3.
12.2 BUILDINGS
12.2.1 RESIDENTIAL BUILDINGS
For residential buildings 55% housing satisfaction has been provided. The manpower provision for this project upto target year is 426 and 235 houses of different type would be required. There are sufficient existing quarters, so no additional provision for residential buildings has been made. The details of number of houses are given in Appendix A.2.1.
12.2.2 SERVICE BUILDINGS
Almost all service and welfare buildings exist there. Provision has been made in this report for construction of site office, Excv. and E&M workshop, sub station and some statutory buildings. Details of service buildings and statement showing capital investment have been given in Appendix- A.2.2.
Job No. 340721 Chapter-XII -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
12.3 ROADS & CULVERTS
12.3.1 APPROACH ROAD TO PROJECT Provision for 1.0 km. long approach road to project has been made. Details have been given in Appendix-A.8.2.1 . 12.3.2 HAUL ROAD Provision for 3.5 km. long haul road has been made. Details have been given in Appendix- A.8.2.2.
12.3.3 BRIDGE Provision for a permanent bridge over Konar River has been made. Details have been given in Appendix- A.8.2.2.
Job No. 340721 Chapter-XII -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER - XIII
WATER SUPPLY & SEWERAGE
13.1 WATER DEMAND The potable and industrial water requirement for the project has been assessed up to target year as follows:
(i) Portable Water Demand 0.0019 MGPD (ii) Industrial Water Demand 0.0500 MGPD
13.2 INDUSTRIAL WATER SUPPLY Details of industrial water supply scheme alongwith the estimated capital expenditure has been furnished in appendix-A.8.3.1
13.3 INDUSTRIAL SEWERAGE Estimated capital expenditure for industrial sewerage scheme and details has been indicated in Appendix-A.8.3.2.
Job No. 340721 Chapter-XIII -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER-XIV
LAND
14.0 The land required for the project Govindpur Ph-II OCP (1.2 MTY) is 207.14 Ha. The forest & non-forest land are 60.47 Ha and 146.67 Ha respectively. The forest in safety zone i.e. 1.95 Ha is included in the above Forest Land. Primary land data of core zone based on remote sensing are as follows:
Present Land use
Sl. Type of Land Area (Ha.) No. 1 Forest 60.47 2 Village NIL 3 GMK Land 45.00 4 Tenancy 10.67 5 Forest in Safety zone (not to be acquired) (-) 1.95 Total 207.14
The break-up of Land Use (in Ha) is given in the below table.
Break-up of Land -use (in Ha)
Sl. Description Forest Non-Forest Total Land No Land (Ha) Land (Ha) (Ha) 1. Quarry 49.82 26.60 76.42 2. OB Dump 0.00 87.00 87.00 3. Infrastructure/ Workshop/ CHP 2.00 1.12 3.12 4. Haul Road 6.70 12.60 19.30 5. Safety Zone 1.95 19.35 21.30 Total 60.47 146.67 207.14 Less forest in Safety Zone (-) 1.95 0.00 (-) 1.95 Total 58.52 146.67 205.19
Job No. 340721 Chapter-XIV -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER-XV
15.0 ENERGY CONSERVATION
15.1 Introduction
Conservation of energy in any form is assuming grater importance in mechanised mines with rapid industrialisation and increase in per capita consumption of energy resulting in insatiable demand of energy. The time is not far off when with the existing quantum of energy; the coal mining industry would be facing a bleak future. Hence it is of paramount importance that the existing quantum of energy is put to optimal and economical use with a high degree of conservation. Special emphasis is laid at the project formulation stage to take all steps for conservation of electrical energy including power consumption and power demand or fuel consumption. All efforts have been made to incorporate energy conservation system and equipment to achieve this in the planning and installation stage itself. At the stage of planning of the equipment of the opencast mine, a careful study has been made with regard to location of power sub-station for the mine, selection of equipment, conductor size, operating power factor with special reference to the conservation of energy.
15.2 Managerial Control
To reduce occurrence of maximum power demand of certain group of equipment at a time and improve the effective load factor, demand meters have been proposed in each circuit breaker controlling the feeders.
This would reduce power demand of the project at the same level of power consumption and also relieve the system of transmitting useless power.
15.3 Energy Audit
It is suggested that energy audit in the mine would be done regularly to even out maximum demand, as far as possible. Such an energy audit would not only pin point the defined areas but also would highlight the areas so that improvement can be implemented immediately.
Job No. 340721 Chapter-XV -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
15.4 Maintenance
A special emphasis would be laid on the preventive maintenance of all electrical, mechanical and HEMM equipment. Energy conservation is very much related to preventive maintenance. Therefore the preventive maintenance would never be over looked.
As part of management system, a feedback is necessary for better performance of equipment and statistical information of breakdowns would help in upgrading maintenance practices, after meaningful and purposeful analysis resulting in saving of diesel and power.
15.5 Distribution Network In the power distribution network, care has been taken to select suitable size of conductors and cables to minimise losses and voltage drop. It is suggested that the conductor sizes recommended in the P.R are drawn at the construction stage of the project itself to avoid duplication of work later on. The size should not be changed either with higher or lower size of the conductor.
Utilisation of voltage for the HEMM within the mine has been recommended as 6.6/3.3 KV. The transformer has been selected to operate at maximum efficiency.
Each transformer has been selected to cater to the total load. However, all the transformers under normal conditions would share the load of the mine.
15.6 Lighting
For the purpose of illumination in mine and dump areas, sodium vapour lamps have been recommended to reduce the energy consumption and to achieve the desired lux level.
15.7 Haul Road
Dumpers used for transportation of O.B and coal, consume lot of energy inform of consumption of diesel. For effective fuel conservation, it is suggested that haul roads, which play an important role in the use of dumpers and fuel consumption
Job No. 340721 Chapter-XV -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
are made better to reduce group resistance. To save energy, therefore, it is absolutely necessary to maintain good haul roads specially at ramps and turnings.
15.8 The important areas in the opencast mine working where there is scope of energy saving, have been indicated above. This emphasizes the following: -
(1) The necessity for going in new system technology and equipment. (2) Even during planning, the aspect of energy conservation with respect to equipment size is considered. (3) During operation, it is imperative to conduct an energy audit just lime preventive maintenance. (4) Complete monitoring by proper communication and instrumentation would identify the areas where there is energy wastage so that corrective measures are taken. (5) If it deviates from the standards, causes should be identified and corrective action may be taken. (6) Maximisation of utilisation within the load allocated by supply agencies by flattening the peak demand. (7) Provision of adequate size of pumps in the mine especially during monsoon. (8) Staggering mining activities during usual peak hours.
Job No. 340721 Chapter-XV -3
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Chapter – XVI
ECONOMICS
16.0 PR of Govindpur phase-II OCP has been planned at an annual rated target production of 1.2 MT of coal. The estimated economics has been worked out considering departmental workings for Coal winning and OB removal. The summary of the workings is as given below:
OPTION-I Coal Production Departmental OB removal Departmental Average Grade E CHP Coal size (-) 100mm Evacuation of coal Pipradih Railway Siding
The estimated economics has been discussed in the subsequent paragraphs.
16.1 Total Capital Investment
Initial capital investment has been provided in the proposal till the year of achieving rated coal production, which is the 4 th year. The capital investment, both Initial as well as beyond target year, has been proposed from the internal resources of the Company. The capital requirement in Rs. Crores is given below:
Sl No Particulars Option-I 1 Total Capital up to Target Yr 142.11 2 Existing Capital Expenditure up to 31.3.09 * 45.95 3 Additional Capital Requirement 96.16 4 Specific Investment Rs./te 1184.26 5 Capital beyond target year 2.39 * The Existing capital expenditure of Govindpur and New Swang upto 31.3.2009 has been considered in this report.
Job No. 340721 Chapter-XVI -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI
The head-wise net effective actual capital expenditure considered in this PR has been shown in the Table below
New Govindpur Particulars Sawang Total Rs. lakhs Rs. lakhs Rs. lakhs Service Building 30.69 95.98 126.67 Land 1284.56 1284.56 Res. Building 22.88 290.20 313.08 Road &Culverts 31.15 111.75 142.9 Water Supply 34.85 4.50 39.35 Electrical 28.94 21.00 49.94 Pump & Pipe 0 0 Weigh Bridge / CHP 0.64 0.64 Work Shop 0 4.36 4.36 Hyd Shovel 64.41 0 64.41 Elec. Shovel 400 K.W. 745.63 745.63 Dumper 35 T 821.72 821.72 Float Engine for Dumper 0.00 0 0 Tipping Truck 2.78 2.78 Water Sprinkler 0.00 0 Elec. Drill 100.87 99.53 200.40 Deisel Drill 0 Dozer 259.64 259.64 FE Loader 31.42 31.42 Surface Crane 0.00 0 0 Veh. General Truck 5.92 7.68 13.60 Exploisive Van 0 Vehicle General Others 5.89 5.89 Vehicle General Jeeps 5.81 5.81 Vehicle General Car 0 Ambulance 0 Prospecting & Boring 0 221.44 221.44 Development CMPDIL Expenses 0 160.78 160.78 Development others (Forest Land) 0 Development Others 0 Other P&M 0 5.64 5.64 Air compressor 0 Mining equip. Mov aux fan 0 Stone Drill 0 Furniture & Fittings 0 Development Sinking wells 0 R&D 0 Drift Others 0 94.36 94.36 Total 2180.90 2414.12 4595.02
Job No. 340721 Chapter-XVI -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
The head-wise actual capital expenditure not considered in this PR has been shown in the Table below:
Rs.in Lakhs New Swang Govindpur TOTAL Pumps 4.61 4.61 Work Shop 6.63 6.63 Spare Engines 16.58 275.57* 292.15 Tipping Trucks 29.67 29.67 Old Shovel 27.9 27.90 Tata Hitachi EX-350 51.74 Excavator 51.74 Old Dozers 91-92 3.11 3.11 Old FE Loader 1.21 1.21 Prospecting Boring 423.16 423.16 CMPDIL Expenses 81.79 81.79 Other P&M 0.67 0.67 Drifts 4.76 4.76 Total 651.83 275.57 927.41 *- For shovel
16.2 Capital Investments for P&M Capital investment on P&M is given in Appendix-A.3. The specific capital investment on P&M worked out for the options is given below: Sl No Particulars Option-I Existing 1 Investment on P&M 77.49 21.84 2 Investment on HEMM 53.77 21.23 Specific investment in Rs./te of coal 3 P&M 645.75 HEMM alone 448.08
Method of Estimation of Capital Cost The method of estimation of capital investment for P&M, Civil estimates, Development Capital, Revenue expenditure capitalised etc. is as follows.
Prices of Plant & Machinery For the plant and machinery, as far as possible, the prices have been taken from the Standard Price List of Mining Equipment published by CMPDI and whenever information regarding price was not available, a broad estimate was made.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
16.3 Capital Investment on Vehicles The total estimated existing capital expenditure on vehicles is Rs. 0.82 crs. Most of the existing vehicles are very old and thus additional provision has been made for some essential new vehicles.
16.4 Opening of Revenue Account Though the two mines exist, the Revenue expenditure for OB removal in the first year of operations has been capitalized. The proposed project will generate revenue surplus from the second year of its operations in which it will produce 0.4 Mty of coal.
16.5 Estimates of Operating Cost Appendix-C of the respective Option gives the details of average cost and profitability for the target production of 1.20 MTY. The method adopted in estimating the costs are briefly explained as follows:
(a) Wages The requirement of manpower for the targeted production of 1.20 MTY of coal is estimated category-wise/ scale-wise and details of manpower are given in the respective Appendix - B1. Prevalent pay scales for executives and non- executives are adopted. End points of the relevant pay scales of executives & non-executives have been considered in estimating the salary and wages cost.
(b) Stores Stores cost consists (1) diesel and lubricants, (2) explosives and detonator, (3) spares for routine repairs etc. Prevalent norms have been followed in estimating stores cost.
(c) Power The Power cost is worked out on the basis of KWH for the machines and other electrical requirements.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
(d) Miscellaneous Expenditure This covers the expenditure on printing & stationery, postages, telephone, repairs and maintenance of assets other than P&M, workshop debits for annual servicing and overhauling of HEMM, insurance and taxes for vehicles, normative contractual cost of major maintenance of HEMM.
(e) Incidence of Corporate Social Responsibility : To create a fund for corporate social responsibility, an element of cost has been kept in the average cost of production. The estimated fund has been computed as 2% of the total capital over the life of the project. Based on total reserve, the incidence of this fund on cost of production, works out to Rs. 1.48/t. This has been absorbed as year-wise cost in the cost of production on the basis of year-wise production.
(f) Final Mine closure Cost A fund equal to Rs. 6 lakhs/hectare of leasehold land is proposed to be created towards a fund for final mine closure. The incidence of this fund on cost of production at 100% capacity, based on total reserve, works out to Rs. 6.36/t. This has been absorbed in the cost of production on the basis of year-wise coal production considering an annual escalation of 5% p.a.
(g) Administrative Charges This includes area overhead, apex overhead etc. and the cost has been taken as per the actual administration cost of CCL.
(h) Interest on Working Capital Rate of the interest on working capital is taken as 14.50% per annum.
(i) Interest on Loan Capital: As the investment for the project is proposed to be met from the internal resources of the Company, there is no impact due to interest on loan capital.
(j) Depreciation Depreciation on assets is computed as per the prevalent norms. The straight-line method of charging depreciation has been adopted. Job No. 340721 Chapter-XVI -5
Project Report for Govindpur Ph-II OCP, CCL CMPDI
(k) Cost & Profitability
The details of the average cost and profitability estimates at 100% capacity and at 85% capacity are given in Appendix-C. These have been summarized in the table below for the three options proposed:-
COAL & OB BOTH DEPARTMENTAL 100% 85% Year AVR. COST Rs./TONNE Salaries & Wages 164.88 193.98 Stores cost 183.73 203.18 Power cost 21.03 23.81 Miscellaneous cost 25.16 26.93 Cost Incidence of CSR 1.48 1.48 Adminstrative Expenses 100.00 117.65 Final Mine Closure Cost 11.02 12.97 Interest on working capital 24.52 28.03 Depreciation 98.76 116.19 Total Cost 630.58 724.22 Sales Value/Te (In Rs.) 851.00 851.00 Profit/Loss Per Tonne (In Rs.) 220.42 126.78
The declared Selling Price per tonne of coal has been adopted as follows:
Coal Production Departmental Average Grade ‘E’ Coal size (-) 100mm Pipradih Railway Evacuation of coal Siding Declared Price Rs./te 790.00 Additional charge for sizing Rs./te 61.00 Desired Selling Price to yield 12% IRR at 849.73 85% Capacity Rs./te
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
16.6 FINANCIAL ANALYSIS
The year-wise cash flows at 100% and 85% capacity utilisation have been estimated and are detailed in Appendix-D. & D.1 respectively. The cash- flows exclude depreciation and interest on loan capital. The financial IRR on total capital of the project at 100% and 85% level of the rated output have been worked out based on the estimates of the aforesaid cash flows and these work out to be 21.37% and 12.10% respectively.
16.7 ECONOMIC ANALYSIS
The year wise cash flow for the economic analysis at 100% and 85% capacity utilization have been estimated and are detailed in Appendix- D2 and D.3, respectively. In estimating the economic prices, all taxes, duties and levies have been excluded from cost of inputs and the shadow rate for wages and salaries have been taken as 1.00. The economic price of coal has been assumed to be same as its ruling price. Based on the above methodology, the economic IRR of the project, at 100% and 85% level of the rated output work out to 28.30% and 19.11% respectively.
16.8 SENSITIVITY ANALYSIS
The following parameters have been identified for assessing their impact on the profitability of the project. a) Capital investment b) Operating cost c) Capacity utilisation d) Selling price of coal The above parameters have been increased / decreased in Steps of 5% to a maximum of 25% over the base case and the IRR have been computed. The following table summarises the results of sensitivity analysis:
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
IRR AT DIFFERENT STAGES OF Sl No Variable Parameter 0% 5% 10% 15% 20% 25% 1 Increase in Capital 21.37 20.58 19.80 19.07 18.36 17.67 Increase in Cost of 21.37 19.30 17.17 14.96 12.65 10.20 2 Production 3 Decrease in Capacity 21.37 18.47 15.39 12.10 8.49 4.41 4 Decrease in Selling Price 21.37 18.07 14.53 10.69 6.39 1.32
16.9 Completion cost of the project
Completion cost of the project is up to targeted year is given at Annexure- A’. Financial and Economic IRR of the project, based on the estimated completion capital is given in Appendix- D.4, D.5, D.6 & D.7, respectively for both 100% and 85% capacity utilization.
Sl. No. Particulars OPTION 1 Completion Capital Rs. Crs 165.22 Fin. Internal Rate of return 2 a) at 100% Capacity 18.79 b) at 85% Capacity 9.97 Economic Internal Rate of
return 3 a) at 100% Capacity 25.66 b) at 85% Capacity 15.66
Job No. 340721 Chapter-XVI -8
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER-XVII
SAFETY & CONSERVATION
Outside agency deploying HEMM or any equipment in the mine for excavation of coal shall plan their activities in conformation with the prevailing statutory provisions as per Mines Act 1952 and CMR 1957 applicable for safety in opencast mines. However, all statutory rules, regulations, applicable laws etc. and statutory requirement related to Govt. licenses, workers compensation, Insurance, etc., including minimum wage act for workers employed by the outside agency shall have to be adhered to. Rules if any imposed by local/State/Central authorities should also be complied by leaser of HEMM/equipment and then shall have to supply various protective equipments viz. helmet, shoes etc. to the workmen at their cost. All the regulations & schedules of coal mines Regulations 1957 relating to opencast mining have to be adhered to and implemented in order to maintain day to day safety precautions as per stature.
SAFETY ASPECTS FOR OUTSOURCING/HIRING OF HEMM/EQUIPMENT
Special precaution should be taken while deploying workers in the mine. Before employing any labour to the mine proper vocation training should be imparted and recommendations of VIII Safety Conference should be strictly followed. Terms and conditions shall be fixed by management for deployment of labourers by outside agency. Some of the major aspects are as follows:-
A) For persons : i) No persons shall be deployed unless he is trained at VTC ii) Records in Form-B Form-D shall be maintained. iii) Records of Vocational training Certificate and driving license of operators shall be kept by HEMM outsourcing agency and shall be made readily available for inspection by management.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
iv) No person shall be employed unless person holds VTC certificate and Management is informed. A record of it shall be maintained. v) Adequate supervision shall be maintained by qualified competent persons. vi) Outside agency shall follow safety guidelines and safety instructions from Project Authorities.
B) For Machineries as recommended by DGMS Cir. (Tech.) 1 of 1999:
i) All the machineries to be deployed in mines should be checked before deployment by competent authority. ii) Regular checking of m/c deployed by outside agency shall be done. No unfit machine shall be deployed before the defect is rectified. iii) A proper record of repair and maintenance along with inspection done by management and defect pointed out shall be maintained and signed by authorized person. iv) The trucks deployed by outside agency shall be provided with Audio-visual alarms, proper light for use at night and period when natural light is not sufficient. Also audio-visual alarms for reversing on trucks shall be provided.
Other Precautions for machines
i) RTO certificate photo copies of all vehicles shall be submitted to management ii) Daily welding, monitoring, inspection shall be done by the agency’s mechanic as directed by management. iii) Machine manufacturers should be asked to give risk analysis details in respect machines deployed by outside agencies.. iv) Suitable type of the fire extinguishers shall be provided in every machine.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
C) General :
i) No person/vehicle shall be deployed at any place other than authorized place. ii) All workers should obey lawful instruction of mine management. iii) Risk Management Plan of tipper/pay loader shall be made and implemented. iv) All drivers shall obey systematic traffics rules prepared by management v) Before deploying workers they must be trained and briefed about safety aspects in opencast mine. However during course of execution of the work, if any accident occurs whether major or minor, the matter shall have to be immediately informed to mine management i.e. Colliery Manager/Agent/GM of Area so that Notices of accidents in a accordance of (Reg.9 of CMR 1957) and Section 23 of Mines Act 1952 may be given and other necessary steps may be taken in accordance with the Mines Act 1952. vi) Outside Agency shall operate transport system in such a way so as to minimize pollution in the mine.
Stability of Benches, Quarry High walls and Spoil Dumps:
During quarry operations, it is necessary to adopt required mining parameters for the stability of benches, high walls and spoil dumps. It is also mandatory to examine systematically the fencing of mine workings, land slides and cracks between benches. It is required to maintain well graded and wide roads on benches keeping the width of working areas sufficient for spreading of blasted rock and movement of the mining and transport equipment. During actual mining operation, systematic observations of the condition of benches, high wall slopes and spoil dumps should be carried out and the dimensions be modified if necessary to suit the local conditions.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
Precautions against Danger of Inundation from Surface Water:
1) A careful assessment is to be made against the danger from surface water before the onset of rainy season. The necessary precautions should be clearly laid down and implemented. Garland drains need to be provided to drain away the surface rain water from coming into the mine. 2) Inspections for any accumulation of rain water, obstruction in normal drainage and weakening in embankment. 3) Standing order; for withdrawal of working persons in case of apprehended danger. 4) During heavy rain inspection of vulnerable points is essential. In case of any danger persons are to be withdrawn to safer places. 5) Nallah or water inlets may be diverted or isolated by embankments if so required.
Prevention of Flooding of Equipment Deployed at Bottom Horizons:
During the heavy monsoon period, the mining operation in the lower-most bench may have to be stopped. Therefore, it is proposed to drown the lower- most bench, which would work as a sump. The water will be pumped out and discharged into the nearby Nalla. For ensuring safety of the equipment while working out bottom horizons with no access to surface profile, the following measures should be taken: 1) Drivage of initial trenches and coal cutting on bottom benches should be done during the dry period of the year. 2) Ramps should be made for quick shifting of equipment from bottom horizons, liable to be flooded during monsoon period, to the top horizons.
Prevention of Electric Shocks :
During mining operations, all the statutory provisions of the Indian Electricity Rules 1956, and Indian Standards for installation and maintenance of electrical equipment etc. should be observed.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
1) For protection from electric shocks to persons, from electrical equipment with voltage up to 1000V Earth Leakage Relay should be provided which will automatically disconnect electrical circuits. 2) Closed mobile substations and switchgears should be mechanically interlocked which exclude the possibility of opening the door when oil switch and air circuit breakers are in operation. 3) All metal parts of electrical equipment should be properly earthed to avoid failure of insulation. 4) All H.T lines and cables located within the blasting zones should be disconnected during blasting operations.
Dust Suppression & Dilution of Exhaust Fumes:
The following measures should be adopted for dust suppression at all quarry working places, dumps, haul roads, CHP and near other auxiliary mining operations. 1) Spraying with water on all working faces & haul roads, by special spraying machines or water-sprinkler. 2) While drilling holes, it is necessary to use dust extraction devices. 3) Installation of local dust suppression and air conditioning devices in cabins of excavators and drilling rigs may be considered. 4) Levelling of spoil dump surface. 5) Separate dust suppression arrangement should be provided for CHP.
To prevent collection of harmful mixtures in the atmosphere, from the different sections of quarry workings, it is recommended: - 1) To spread out the sources of dust formation and omission of harmful gases throughout the working area of the quarry. 2) Drilling & blasting operations should be timed for periods of maximum wind activity during the day. 3) Dumpers may be provided with purifiers for exhaust gases.
Job No. 340721 Chapter-XVII -5
Project Report for Govindpur Ph-II OCP, CCL CMPDI
Measures to be taken for Fire Fighting and Fire Prevention:
In addition to statutory provisions, the measures for fire fighting and prevention of fires are as follows:
1) Organisation of special cell for systematic observations to examine and prevent fire 2) Removal of spillage of coal on benches and cleaning of coal horizons to prevent cases of coal heating. 3) Storage of lubricants and cotton waste in enclosed fireproof containers in working places. 4) Provision of fire extinguishers
Measures to be taken while Drilling Blasting:
Following measures should be taken while drilling and blasting operations in the quarry: 1) Drilling and Blasting in quarry should be done in accordance with the provisions of Mines Safety Act, rules and regulations. 2) Adequate safety measures have to be taken during blasting operation in the quarry so that men/machine is not affected.
Conservation:
The project considers exploitation of Upper Karo group of seams from Seam VI to Seam XI as per the calendar plan.
Job No. 340721 Chapter-XVII -6
Project Report for Govindpur Ph-II OCP, CCL CMPDI
CHAPTER- XVIII
MINE CLOSURE
Mine closure operations is proposed to be undertaken after examination and detailed study that there is no further expansion possibility of the mine and the void is to be suitably filled up so that the land is utilized gainfully by the society. Intermediate stoppages of operations due to any reasons for a period of time do not come under the proposed scheme of mine closure. This chapter proposes following aspects: - A. Technical Aspects B. Environmental Aspects C. Social Aspects D. Financial Aspects
18.1 TECHNICAL ASPECTS V Safety aspects. V Pit slopes and waste dumps. V Hydrology and hydrogeology. V Details of decommissioning of the infrastructures. V Closure of entries like pits and entry to the mine.
18.1.1 Safety After attaining the final stage dump (including internal Dump) the remaining portion between dump toe and final stage Quarry floor should be fenced properly so that no human being or stray animals should be trapped within. Internal dumps are proposed to be suitably re-graded to avoid deep trenches.
18.1.2 Pit Slopes and waste dumps The final pit slopes are designed to avoid any slope failure. Technical study is proposed to be conducted before deciding upon the final slope. Both the external and internal Dumps are designed in such a way that there are minimal chances Job No. 340721 Chapter-XVIII -1
Project Report for Govindpur Ph-II OCP, CCL CMPDI of slope failure. The external Dump is sloped ultimately in the overall range of 25 degree to 28 degrees. The internal dump slopes are designed at milder gradient so that even with the percolation of water in the dip side of the quarry, the dumps remain stable. It is proposed that the internal and external dump must be provided with toe walls/ silt arrestors and garland drains. Vegetation cover on surface of these dumps is proposed to be ensured as a final closing operation.
18.1.3 Hydrology and Hydrogeology In the mine closure plan, the surface flow pattern of precipitation and mine water drainage is envisaged to be examined and the water channel suitably laid down so that this is acceptable to the local community and it do not disturb the general hydrology of the area. Efforts are proposed to be made to regenerate the ground water resources.
18.1.4 Decommissioning of the infrastructure- The coal project develops lot of infrastructure for sustaining their operations. These include Workshop, Coal Handling Plant, Railway Siding, Office Complex, Residential Complex, Roads, Pipe Lines and Transmission Line. Decommissioning of the infrastructure should be planned in such a way that the Land occupied by these infrastructures is released. However, these infrastructure is proposed to be reused for the neighboring projects /mine.
18.1.5 Closure of entry to the mine- All entries to the mine must be effectively sealed. This will prevent illegal mining, entry of fire and water etc.
18.2 ENVIRONMENTAL ASPECTS V Air, water, dust. V Reclamation of forest/vegetation. V Management of recharge areas. V Acceptable surface and ground water flows. V Alternative use of land Job No. 340721 Chapter-XVIII -2
Project Report for Govindpur Ph-II OCP, CCL CMPDI
18.2.1 Air, water, dust It is proposed that air quality; water quality and dust level is to be monitored. Necessary actions to check the pollution from the closed mine, if any, in respect of air, water and dust is to be taken after examining the local site conditions then prevailing.
18.2.2 Reclamation of Forests/ vegetation: It is proposed that major portion of the project area is covered with vegetation. This will involve both forestland as well as non-forest land. Certain areas, mostly industrial areas, where service building are proposed to be located and to be used are not proposed for plantation.
18.2.3 Management of recharge areas: It is proposed that the recharge areas are fully utilized and sufficient availability of water, if feasible, is ensured to enhance ground water availability.
18.2.4 Surface and ground water flows In the final stage, wherever the mine water is likely to flow out to surface and meet the natural drainage system, the quality of water is proposed to be assessed and flow pattern for mine water be properly modified/ redesigned. Alternately, the water treatment arrangements may be considered depending upon the local site conditions.
18.2.5 Alternative use of land During the mining operation, the land usage changes from its pre-mining scenario. The final stage land use plan shows the use of land in a post-mining scenario when coal-mining operations have completed. Alternative use of land, specially released from infrastructure areas and vacant areas, as proposed to be planned and properly designated for post-mining land uses depending on the existing conditions prevailing at that point of time. While for OB dumps and acquired forest areas, vegetation and afforestation has been proposed as a final land use. While agriculture may be the best land use, if feasible, and if it is supported by some irrigation facilities.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
18.3 SOCIAL ASPECTS V Re-deployment of work force. V Management of community facilities V Canalization of available water
18.3.1 Re-deployment of work force The peak work force required for mine operations is in the first few years of the mine when construction activities as well as operational activities achieved their peak. This work force slowly goes down with completion of development and when only the operational work remains. Again near the end of the mine life, say 4-5 years before closure, the activity of the mine starts getting reduced and therefore management gets opportunity to taper the operational manpower. After closure, skeleton service people are proposed to be left for continuing with the actual closure operations. The reduction of manpower could be done as per the following options: • Natural retirement. • Implementation of VRS schemes for age group of +50. • Retraining and redeployment of younger groups – 40. • Transfer of experienced middle-aged groups between 40-50 years to other projects. Retrenchment of people with suitable compensation after exhausting all the above options.
18.3.2 Management of Community Facilities The community facilities are proposed to be developed by coal projects for betterment of the neighboring community. The project management provides or assists in developing educational facilities, health facilities, community halls and also some communication facilities. After the mine closure, these facilities are to be continued for the neighboring communities to the possible extent. The closure plan will envisage interaction of mining company with the state or local bodies who will take over these facilities and run the same for the community. A onetime Job No. 340721 Chapter-XVIII -4
Project Report for Govindpur Ph-II OCP, CCL CMPDI payment may be made by the coal companies towards running these facilities, which is proposed to be taken care of by the local/state bodies.
18.3.3 Canalization of available water If it is found that the mine is having sufficient water and on closure, the mine water flows into the surface watercourses, canalizing this water for surrounding community for their irrigational/domestic uses may be taken up.
18.4 FINANCIAL ASPECTS:
V Creation of a corpus fund for the final mine closure V Cost of closure activities. V Cost towards organization for executing the closure activities. V Cost of the post project monitoring V Bond/insurance for the closure cost V
18.4.1 Creation of a corpus fund for the final mine closure It is proposed that a corpus fund for final mine closure to be created from the retained earnings of the project. The fund creation is proposed to be started after the project earns revenue, which is in surplus, after deducting all the negative cash flows. Preferably the corpus fund should be created after the mine comes under revenue. However, in case of shortage of funds, corpus fund creation may be deferred till the mine attains target production. This fund should be judiciously created so that the objective of the final mine closure can be smoothly met. This will depend on the local site conditions, requirement of mine closure, mine closure plan. Site specific mine closure plan is proposed to be prepared and approval of the company board may be obtained. A provision towards Corpus fund equal to Rs. 6 lakhs/hectare of leasehold land is proposed to be created towards a fund for final mine closure. The incidence of this fund on cost of production at 100% capacity, based on total reserve, works out to Rs. 6.36/t. This has been absorbed in the cost of production on the basis of year-wise coal
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Project Report for Govindpur Ph-II OCP, CCL CMPDI production considering an annual escalation of 5% p.a. This fund will not only cater for re-grading but will also cover other ancillary expenditure.
18.4.2 Cost of Closure Activities As proposed above, many activities are proposed to be undertaken after the closure of the mines, which naturally will involve expenditure. Some of the closure activities will, in fact, form part of normal mining operations. However, some activities are proposed to be addressed only after completion of the coal mining operations. The cost for all those activities, which are to be executed after coal winning, is proposed from the retained earning of the project for meeting the expenses.
18.4.3 Cost of Organization for executing the closure activities After the completion of the coal mining, an organization consisting of persons of different disciplines is proposed to be maintained to undertake and implement the closure activities. The organization may be provided with a vehicle for discharging day-to-day duties. Maintenance cost of this organization is proposed from the retain earnings of the project. A small team consisting of 2-3 technical people may be required to oversee the efficacy of the closure activities. This monitoring may be conducted for 4-5 years after the mine closure activities.
18.4.4 Cost of the post project monitoring After the closure activities have been implemented the project is proposed to be monitored regularly for 4 to 5 years. During this period of 4-5 years, cost towards project monitoring is proposed from the retain earnings of the project.
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Project Report for Govindpur Ph-II OCP, CCL CMPDI
ENVIRONMENT
18.5 General Govindpur Phase - II Opencast project is one of the new coal projects of the East Bokaro Coalfields of C.C.L. The proposed OCP is located in the North – West part of existing Govindpur lease hold area between Konar River on the west and Montico Nallah on the east. The block covers an area of about 8 sq. km. Govindpur OCP Phase - II falls in the Govindpur Northern sub-block, which forms the northern most part of the Govindpur Block, with an area of about 3.5 sq. km. are potential seams for opencast mining, both qualitatively and quantitatively. Considering the mining aspect, shovel- dumper mining system has been envisaged.
Due to liberalization and globalisation in the country, there are sudden surge in power demand. In our country, 80% of total power demand is met by thermal power. This trend is expected to continue for at least another 50 Years. As per a study, it has been estimated that there would be shortage of power grade coal for generation of electricity in the country. So, to meet the power demand, it would require more thermal power stations and consequently more coal. There is already shortage of indigenous coal and this shortfall is expected to be around 260Mt in XI year plan. To meet the coal demand, it is very important to increase the coal production by opening the new mines or expanding old project. In order to bridge the gap, between demand and availability, a project report of Govindpur Phase - II OCP (1.20Mty) has been prepared. Opening of Govindpur Phase - II OCP is being sought because it is technically and economically viable. This project will be very much helpful in the development of economical condition of country. More over, this will generate employment opportunity. This will also increase the economical condition of these places with the improvement in basic needs of people such that communication, education and medical facilities. Thus, we can see that opening of this mine is very important in the economical development of country.
Job No. 340721 Chapter-XVIII -7
Project Report for Govindpur Ph-II OCP, CCL CMPDI
18.5.1 Pollution & Mitigation Measures: - Any opencast mining project particularly coal mines pollutes the various attributes of environment. Major affecting parameters are Air, Water, Noise and land. Details of study about the effect due to pollution in this parameter have been discussed and various mitigation measures are suggested in respective chapter. Precautions against the pollution are taken, right from the planning time of the project. Utmost care has been taken during the planning period so that there is least generation of pollution and suitable mitigation measures against these pollutants.
18.5.1.1 Air : -One of the worst affected environmental attributes in mining project is air, which gets polluted due to blasting, excavating, transporting, loading & unloading of coal and OB. These activities of mining create the pollution by increasing the SPM level in the environment. This is low fugitive in nature and settled quickly and more over this is not harmful gas. Emission from the exhaust of vehicle spread SO x and NO X. The SOx and NO X are fugitive in nature and disperse in atmosphere. It is envisaged that there would be good quality haul road with maximum slope 1:16 in general and coal transport is to be done by rail. HEMM to be maintained on time schedule frame and low Sulphur diesel would be used. This will reduce the emission from the exhaust of vehicles, so the SO X and NO X. During the operational time, water sprinkling will be done regularly; Haul road and other roads will be maintained and cleaned properly and regularly. Dust bag is to be used in drilling machine and blasting will be done at the time of maximum mixing height. All loading, unloading and transfer point will be wetted by water. These measures will reduce the generation of SPM to a large extent. For preventing the SPM to spread, green belt along the quarry, haul road workshop, external OB dump, colony, etc would be developed.
Job No. 340721 Chapter-XVIII -8
Project Report for Govindpur Ph-II OCP, CCL CMPDI
18.5.1.2 Water : - Water is another environmental attributes that get polluted from the effluent of mine water, workshop etc. However, these pollutants are only physical in nature in the form of TSS, which are easily filterable and not much harmful to human or aquatic life. Generally, water does not get polluted chemically in Indian mines. Preventing the water pollutions also start right from the planning stage. Planning is done in such a way that there is zero effluent discharge in dry days. Effluent will be recycled. In rainy days, effluent is allowed to discharge only after proper treatments. Storm water drain network in the whole area, have been planned in such a way that the surface run-off flow from the dirty area do not get mixed up with clean area flow. Clean area water flow will be allowed to discharge directly in to natural drain. While the dirty area water flow will be treated properly before discharging in to natural drain. These measures will reduce the surface water pollution to a large extent. Due to opening of mine, there is lowering of water table. As per detailed hydrological report, water table is to be affected up-to a maximum distance of 600 m from the edge of quarry for the mining depth of 100 m. It is not a big area, so there is no hindrance for a large population.
18.5.1.3 Spoil Dump
The total volume of O.B to be removed is estimated as 28.66 M.cum. 24.00 M.cum of O.B is proposed to be placed at the external OB dump and the rest OB of 4.66 M cum is to be placed as internal dump. The area of proposed external dump is 87.00 Ha. Big and high spoil dumps give the very ugly look to the local aesthetic view as well as it increase the air and water pollution. Hence it needs a careful reclamation plan so as it can be utilized by local people and aesthetically matches with the local topography. Keeping in view of the above, all spoil dumps would be reclaimed both physically and biologically. Physical reclamation would be done in such a way that human and animal can reach the top easily and it will encourage animals to make their
Job No. 340721 Chapter-XVIII -9
Project Report for Govindpur Ph-II OCP, CCL CMPDI dwellings. Biological reclamation would be done in such a way that local people get benefited from it. Mixed type plantation will be done which is sustainable in the local climate and environment.
18.5.1.4 Land: As we know, open cast mining completely changes the topography of the area i.e. It creates large open deep excavation pit and huge high O.B. dumps. As the dump materials are in loose state and surface does not conform to natural angle of repose. So in this condition, unless they are treated, they are venerable to erosion caused by blowing wind and surface run-off. Continuous erosion of deep slope may lead to slope failure-causing loss of property and life. Such untreated dumps constitute a potential source of air and water pollution and safety hazard for employees. Overburden dumps needs the continuous parallel process of reclamation with mining works till the closer of mine. After closure of mines it needs reclamation of whole area to improve the over all aesthetics view in such a away that area become the source of income for the local inhabitant. Land Reclamation does not mean restoration of the degraded land to the pre- mining land pattern. There are several options available for land use pattern for reclaimed land. Factors discussed below would be considered for selection of appropriate land use pattern for reclaimed land.
(i) Pre-mining land use pattern (ii) Properties of top soil/sub-soil (iii) Socio-economic factors (iv) Availability of technology for reclamation (v) Climatic condition (vi) Existing Flora & Fauna in the area.
Now-a-days mine plan is being prepared in such a way that there is zero effluent discharge in dry days. In rainy days, effluent is allowed to discharge only after proper treatments. There will be increase in the depth of water table due to deep
Job No. 340721 Chapter-XVIII -10
Project Report for Govindpur Ph-II OCP, CCL CMPDI excavation for mining but this effect would be occurred up-to maximum extent of one Km. from the cutting edge of mine.
18.5.1.5 Infrastructure: 18.5.1.5.1 Housing: The existing Residential Buildings of New Sawang OCP will suffice the needs of this Project. Hence, no additional Residential Buildings will be required. Accordingly, no additional capital has to be provided in this head.
18.5.1.5.2 Services: Major service buildings like PO office, site office, store shed, electrical sub- station, workshop shed etc. are already existing in the project.
18.5.1.5.3 Workshop & Store This Project Report has been prepared for 1.2 MTY, a Unit Workshop consisting of Excavation and E&M workshop has been proposed. This unit of workshop is envisaged to cater the need of daily maintenance schedule maintenance, lubrication, routine inspection, minor/medium repair and replacement of parts/sub assemblies of HEMM such as Dumpers, Dozers Shovels etc.
18.5.1.5.4 Power Supply Presently the Govindpur Ph-II O/C Project substation (1x3 MVA, 11/3.3 kV) is receiving power at 11 kV through one no. independent single feeder with ACSR Conductor from Kathara Regional Substation (1x10 MVA, 33/11 kV). This Substation is situated near Kathara o/c Project at a distance of 12.0 Km (approx). It is proposed to install another 2 MVA 11/3.3 kV Transformer for additional electrical equipments and loads. Power shall be distributed from this sub-station to various additional electrical equipment and load points. Power shall be distributed from this sub-station to various additional electrical equipment and load points. Estimated maximum power demand for this project will be 918 kVA. Heavy Earth moving Machines consume significant power in opencast project. Coal Handling Plant including crushing & material handling facilities, mine dewatering, workshop, offices, colony etc. add to the total power Job No. 340721 Chapter-XVIII -11
Project Report for Govindpur Ph-II OCP, CCL CMPDI demand of the project. On achieving the targeted Coal production and commissioning of Shovels, drills, coal Handling plant, Workshop and Main Pumps, the power demand of the OCP is expected to touch the maximum demand.
18.5.1.5.5 Road & Culverts Approach road to mine and colony roads exist there. However provision of 3.5km of haul road and 1km of approach road to project has made.
18.5.1.5.6 Water Supply and Sewerage Additional provision has been made to fulfill the potable and industrial water demand.
18.5.1.5.7 Railway Siding : The coal from this OCP is proposed to be dispatched to Pipradih Siding.
18.5.1.5.8 Coal Handling Plant The Coal Handling Plant for this project is envisaged to handle total production (1.2 MTY) of coal from the mine. The coal handling plant shall have facilities for receiving coal from rear discharge dumpers, crushing of coal to (-) 100 mm size, conveying, storing, reclamation and loading into evacuation network of conveyor. Sufficient storage has been provided in the coal handling system to meet the eventualities of disrupted coal production in the mine or dispatch irregularities. The plant will be operated in synchronization with the production of the mine. The coal handling plant shall also be provided with suitable repair, communication and other auxiliary facilities to meet the day-to-day requirement in the plant operation.
(a) Feed Size in MM :- (-) 1200 (b) Product Size In MM :- (-) 100 (c) Mode of Dispatch :- By Tipping truck to near by siding or to customer Job No. 340721 Chapter-XVIII -12
Project Report for Govindpur Ph-II OCP, CCL CMPDI
(d) System Capacity :- 1.2 MTY
18.5.1.5.9 Pumping & Drainage The planning of dewatering the mine shall be done in such a way that the working faces and haul roads in these quarries shall remain dry as far as possible. The layout of the quarry provides suitable gradient along the quarry floors and the benches to facilitate self-drainage of water to the sump at the lowest level of the quarry. During the heavy monsoon period, the work in lower most benches may have to be stopped, as it will not be possible to pump out the entire make of water on the wettest day. Therefore, it is proposed to drawn a part of the lower-most bench, which would, then act as sump. Water accumulated in the mine sump will be pumped out to the surface and finally discharged into the near by main drain / Nala of the mine.
Job No. 340721 Chapter-XVIII -13