Transcript Slide 1

Workshop on
“The Technology Development &
Mechanisation of Mines
for enhancing
Coal Production & Productivity ”
20th January, 2015
Presentation by
Western Coalfields Limited
Western Coalfields Limited
WCL operates 80 Mines (41 UG, 39 OC) in 10
Areas (7 in Maharashtra & 3 in Madhya Pradesh)
WCL contributes more than 7% of the total
National Coal Production from its 3.26% of the
total National Geological Coal Reserves
2
Western Coalfields Limited
Coal Reserves
(in Billion Tonnes)
Coalfield
Resources
Reserves
Total
Maharashtra
Wardha Valley
Umrer Nand Bander
Kamptee
2.90
0.36
0.87
0.82
0.21
0.21
3.72
0.57
1.08
Madhya Pradesh
Pench Kanhan
Pathakhera
Total
1.07
0.22
5.42
0.20
0.07
1.51
1.27
0.29
6.93
(As on 01.04.2013)
3
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Unique Feature of WCL
Adverse geo - mining condition
Deep seated Reserve
High stripping ratio
Presence of Black Cotton Soil & Silt
Lower grade Coal
Smaller Capacity Opencast Projects
Very old and extensive UG Mines
Heavy Water seepage (Kamptee Series)
Performance at a Glance : Coal Production
50
Growth: 10.7%
43.65
43.11
42.29
39.73
34.09
32.00
36.10
20
34.72
30
34.95
Million Tonnes
40
44.00
8.7
8.39
8.2
7.73
7.9
2010-11
2011-12
2012-13
2013-14
2014-15
BE
10
0
Underground
Opencast
Figures in Million Tonnes
5
Performance at a Glance : OB Removal
Growth: 8.3%
130.00
62.00
120.08
59.30
61.15
80
113.69
2011-12
2012-13
68.00
2010-11
60.78
20
52.54
40
58.93
60
53.42
Million Cum
100
115.82
62.40
120
122.49
63.56
140
2013-14
2014-15
BE
0
Hired
Departmental
Figures in Million CuM
6
Performance at a Glance : Composite Production
180
Growth: 8.7%
160
145.7
60
141.0
80
150.3
100
2010-11
2011-12
2012-13
2013-14
158.4
120
144.0
Million Cum
140
40
20
0
FY 2013-14
Composite Production (Mcum)
CCL
92.57
BCCL
ECL
107.16 109.78
WCL
145.7
2014-15
BE
MCL
169.65
7
Performance at a Glance : Coal Offtake
Growth 12.65%
45
42.56
40
4.48
41.97
39.95
41.55
5.13
4.73
3.98
13.80
15.69
25
18.80
30
20.54
35
45.00
4.30
18.70
50
20
22.00
2011-12
22.17
2010-11
21.13
5
18.04
10
17.54
15
2012-13
2013-14
2014-15
BE
0
Rail
Road
Other Means
Figures in Million Tonnes
8
Trend Of Coal Production, Offtake & Operating Profit/ Loss
Crore Rs.
Million Tonnes
Impact of NCWA-IX
Strategy adopted for Enhancement of Production
Coal Production (MT)
15-16 16-17 17-18
18-19
19-20
41.85 39.45
33.36
32.75
32.28
Internal efforts : Five projects
1.60
4.60
6.50
9.30
12.50
BG Relaxation : Six projects
0.50
0.80
1.40
1.80
2.37
Revision of CMPDIL norms : Nine projects
1.05
3.15
8.74
11.15
12.85
Total Production 45.00 48.00
50.00
55.00
60.00
BAU
10
Year wise Opening of Projects
Year
1
2
3
4
5
6
7
8
2015-16
9
(15.58 MT)
10
11
12
13
14
2014-15
(7.00 MT)
Name of Project
Makardhokra-I OC
Bhanegaon OC
Penganga OC
Gokul OC
Sharda UG
Dinesh OC
Dhau North UG
New Majri UG to OC
Amalgamated Yekona-I & II OC
Singhori OC
Amalgamated Pauni-II & III OC
Tawa -III UG
Chincholi OC
Kamptee Deep OC
Area
Umrer
Nagpur
Wani
Umrer
Kanhan
Umrer
Kanhan
Majri
Majri
Nagpur
Ballarpur
Pathakera
Ballarpur
Nagpur
State Capacity (Mty) Opening Date
MAH
2.00
28-Nov-14
MAH
1.00
25-Jan-15
MAH
4.00
25-Mar-15
MAH
1.50
25-May-15
MP
0.32
25-Jun-15
MAH
4.00
25-Jul-15
MP
0.36
25-Aug-15
MAH
0.80
25-Sep-15
MAH
2.50
25-Oct-15
MAH
0.80
25-Nov-15
MAH
2.50
25-Jan-16
MP
1.00
25- Feb-16
MAH
0.30
25-Mar-16
MAH
1.50
25-Mar-16
Replacement Project
11
Year wise Opening of Projects
Year
Area
State
Capacity
(Mty)
Opening
Date
Wani
Chandrapur
Ballarpur
Chandrapur
Wani
Kanhan
MAH
MAH
MAH
MAH
MAH
MP
4.00
1.00
1.70
2.50
3.00
0.14
25-Apr-16
25-May-16
25-Jul-16
25-Jan-17
25-Apr-17
25-May-17
(Mah -33.1
MP -1.82)
Name of Project
15
2016-17 16
(9.20 MT) 17
18
2017-18 19
(3.14 MT) 20
Mungoli Nirguda Deep OC
Hindustan Lalpeth Expn. OC
Dhuptala Extn. (Sasti UG to OC) *
Padmapur Deep OC
Niljai Expansion (Deep) OC
Harrradol UG
Grand Total
Contribution from above 20 Projects by 2019-20
BAU Production by 2019-20 due to depletion of reserves
Total Production by 2019-20
34.92
27.72
32.28
60.00
Replacement Project
12
MILLION TONNES
Coal Demand Vis-à-vis Production
75
70
65
60
55
50
45
40
35
30
68.98
69.08
69.28
70.08
13-14
70.58
60.00
57.78
39.73
70.58
55.00
42.00
14-15
45.00
15-16
48.00
16-17
51.00
17-18
YEAR
18-19
19-20
Production (Now Projected)
Demand
13
Million Tonnes
Group-wise Future Production Scenario
65
60
55
50
45
40
35
30
25
20
15
10
5
0
60.00
Total Production
44.00
45.00
48.00
55.00
50.00
39.73
Ongoing Projects
24.91
14.82
24.03
19.97
Future Projects
22.67
22.27
21.03
15.63
10.10
25.67
21.10
16.26
12.64
1.30
18.93
10.40
28.05
21.60
10.35
Existing & Completed Projects
13-14
14-15
15-16
16-17
17-18
18-19
19-20
14
Share of UG and OC production
70
Million Tonnes
60
50
39.73
44.00 45.00
40
30
60.00
Total Production
32.00
36.10 37.00
55.00
48.00 50.00
39.78 41.69
46.23
50.83
OC
20
10
7.73
7.90
8.00
8.22
8.31
8.77
9.17
18-19
19-20
UG
0
13-14
14-15
15-16
16-17
Year
17-18
15
OC Composite Production : Departmental & Outsourcing
350
300
253.56
290.69
311.72
335.23
250
200
150
100
50
178.87
247.9
169.2
206.3
225.4
81.8
84.4
84.4
86.4
87.4
2015-16
2016-17
2017-18
2018-19
2019-20
97.1
0
Composite Deptt
Composite OS
Figures in Million CuM
16
Opencast : Existing
&
Required Equipment
17
Existing HEMM Population
Equipment
Model
Capacity Population
Dragline
Shovels, Electric
Rope
3
5 Cu.mt
Equipment
Model
Capacity
Population
Dozer Crawler
410 HP
6
Dozer Crawler
320 hp
139
39
Shovels,
Hydraulic
More than
2.5 Cu.mt
67
Shovels,
Hydraulic
Less than
2.5 Cu.mt
29
Dumpers
Dumpers
Dumpers
35 Ton
50 Ton
60 Ton
55
225
174
Wheel Dozer
460 HP
RBH Drill
250 mm
RBH Drill
160 mm
Graders
280 HP
Cranes
30 -40 Ton
TOTAL
12
21
82
24
11
887
18
Status of existing major Equipment & their Performance
S
N Equipment
1
Dragline
Capacity
Supplier
(No)
24Cum /96 m
Bucyrus (1)
20 Cum /90 m
Uralmash(1) • Age – 22 Yrs
9Cu Yds /70 Yds
2 Electrical
Rope
Shovel
5 Cum
Marion (1)
HEC (39)
Performance
• Age – 23 Yrs
• Age - 45 Yrs
• Delayed supply of spare parts
• Inferior quality of spares
19
Status of existing major Equipment & their Performance
S
N Equipment
3
Hyd.
Excavator
4 Dumper
Capacity
Supplier (No)
Performance
4.5/5.5 Cum
BEML (28)
• Swing pump life –failing at an average
life of 7000 Working Hour , against
desired life of 20,000 WH
• Power-Take Off–failing at an average
life of 8000 WH, against desired life of
20,000 WH
60/50 T
TATA Hitachi(15)
• High cost of sub assemblies.
BEML(248 )
• Poor Supply of spare parts
• Less Transmission Life
Caterpillar (151 )
• High cost of spares
20
HEMM to be procured against replacement
Equipment Model
Capacity
Shovel Hydraulic
4.3 / 5.5 Cu.mt
Shovel Hydraulic
Less than 2.5 Cu.mt
Dumper
Dozer, Crawler
Dozer, Crawler
Wheel Dozer
RBH Drill
RBH Drill
Grader
Crane
60 Ton
410 HP
320 HP
460 HP
250 mm
160 mm
280 HP
30 - 40 Ton
21
HEMM required for new projects (Dept.)
Equipment Model
Capacity
Shovel Hydraulic
5 - 6 Cu.mt
Shovel Hydraulic
4.3 / 5.5 Cu.mt
Dumper
60 Ton
Dozer
410 HP
Dozer
320 HP
RBH Drill
160 mm
22
Proposed HEMM required for new projects (Outsourcing)
Equipment Model
Shovel Hydraulic
Dumper
Surface Miner
Capacity
3.1 Cum
4 Cum
10 Cum
18.7 Cum
19.5 Cum
100T
23
Underground : Existing
&
Required Equipment
24
24
Underground : Existing Major Equipment
SN
Equipment
Population
1
Continuous Miner Package
1
2
SDL ( 1.0 Cum)
72
3
LHD (1.5 Cum)
113
4
UDM
45
5
Man Riding System
09
25
Status of existing major Equipment & their Performance
SN
1
2
3
4
Equipment
Continuous
Miner
SDL
( 1.0 Cum)
LHD
( 1.5 Cum)
UDM
Supplier (No)
Performance
Joy Global (1) • Inadequate performance of Quad Bolter
Eimco(57)
BEML (14)
Simplex (1)
Eimco (101)
Simplex (12)
Eimco (36)
Simplex (9)
• Design flaws in the machine
• Delayed supply of spares
• Inadequate Service support
• Delayed supply of spares
• Inadequate service support
• Delayed supply of spares
• Inadequate service support
26
Replacement Equipment To Maintain Existing Production
Machine
Capacity
SDL
1.0 Cum
LHD
1.5 Cum
UDM
27
Underground: New Projects
• Introduction of Continuous Miner Package
on hiring basis
• Mass Production Technology package @ 1
MTY of coal production on Turnkey basis
(MDO Route)
• Manriding system
28
Continuous Miner Package on Hiring Basis
S.No.
NAME OF MINE
Potential Production
(MTPA)
Estimated Year of
Production
1.
Tawa-II Expn.
0.36
2016-17
2.
Waghoda
0.39
2016-17
3.
Tawa-I
0.70
2016-17
4.
Naheriya
0.34
2017-18
5.
Dhau North
0.36
2017-18
6.
Sharda
0.315
2018-19
29
Turnkey Projects through MDO Route
S.
No.
1.
Name Of Mine
Proposed Technology
Potential
Production
(MTPA)
Tawa-III
Mass Production
technology(LW/CCT)
1.00
Estimated
Year of
Production
2018-19
30
Installation of Manriding Systems in UG Mines
15-16
16-17
17-18
18-19
19-20
Nandgaon
Rajur
Mahakali
Saoner III
AB Incline
Adasa
Naheriya
HLC-1
Mathani
Patansaongi
Saoner II
Vishnupuri II
Ghorawari
Silewara
(Winder)
Ambara
3+1(Winder)
4
2
2
3
31
Coal Evacuation
&
CHP Required
32
32
Coal Evacuation Year-wise, Mode-wise
2015-16
2016-17
2017-18
2018-19
2019-20
Production
45.0
48.0
50.0
55.0
60.0
Rail
23.29
25.29
26.79
32.06
35.61
Road
17.03
17.11
17.60
18.31
19.26
MGR
1.10
1.10
1.10
1.10
1.10
Despatch
3.60
4.50
4.52
3.53
4.03
Offtake
45.0
48.0
50.0
55.0
60.0
Rakes/day
16.3
17.8
18.8
22.6
25.0
Fig. in MT
Coal Evacuation of 60 MT by 2019-20
• Presently WCL is maintaining evacuation
arrangement for 45 MT through 19 no. of Railway
sidings
• Additional 7 MT will be evacuated by utilizing
spare capacity of existing sidings
• Silo arrangement for 2 OC projects (8 MT) & Rail
Connectivity (15 Km) up to silos by 2019-20
CHP : Existing Crushing Equipment
SN
Equipment
Population
Feeder Breaker/Crusher
1
(-200mm)
42
2 Crusher(-100mm)
4
35
CHPs : Plan for 2015-16
Machine
Secondary Crushers
Feeder Breaker/ Crusher
Capacity
-100mm output
-100mm output
36
Major area of concern
• Availability of experienced Contractors
• Availability
of
required
Excavators,
Dumpers/Hauling Trucks and matching support
equipment in a span of four years for existing
and new projects.
• Trained Manpower for both Departmental &
Outsourced equipment
37
Suggestions
• Workshop for Outsourcing Agencies with
participation of all Subsidiaries.
• Year-wise schedule may also be drawn by
Suppliers/Manufacturers
• Skill Development Centers at Subsidiary level to
tap in-house as well as external (PAPs) potential.
38
Thank
You