Transcript Slide 1

Prof. K. Pathak,
Department of Mining Engineering
IIT Kharagpur-721302
[email protected]
Mineral Production is bound to increase in the coming years!
 construction aggregates is expected to rise 2.9% annually, reaching almost 28.7 billion
tones by the year 2013.
 The power generation demand is going to increase the demands for coal, steel and
copper.
 India aims to add about 100 gigawatts (GW) of power generation capacity by
early 2017. April 1, 2010, India's total installed generation capacity stood at 159.40
GW. Only 6 percent of India's total power mix now comes from renewables.
 India is Asia's third-largest power producer
 coal imports have grown rapidly
 India's coal demand was 597.5 million metric tons in the fiscal year to March, 2010.
 India’s refineries processed 186.562 barrels per day of oil and local gas output was
47.57 billion cubic meters.
 With about 57 Mte of steel production (4.64 % of wolrd production in 2009) India and
with expected growth rate the domestic iron ore consumption will be 190 Mte as per
National Steel Policy. (India’s iron ore reserve is about 252 Bte in 5 Zones)
 The mineral sector has shown a positive growth of 9.75% during the current financial
year i.e. April- March 2009-10 as compared to that of the previous year. The mineral
production in March 2010 was higher by 10.96% as compared to that of the
corresponding month of previous year
 India's mineral production from mining and quarrying sector in March 2010 registered a
growth of 14.41% compared to that of the preceding month.
Mineral Business Growth should be compatible with facilities for Mineral Movements
This higher level productions are distributed in various geographical ‘Mineral belts’
and their users are located at different places requiring multiple handling and
transporation of bulk materials.
Mineral Belt
Location
Minerals found
Coal, iron ore, manganese, mica, bauxite, copper, kyanite,
chromite, beryl, apatite etc. This region posses India's 100
percent Kyanite, 93 percent iron ore, 84 percent coal, 70
percent chromite, 70 percent mica, 50 percent fire clay, 45
percent asbestos, 45 percent china clay, 20 percent
limestone and 10 percent manganese.
North Eastern
Peninsular Belt
Chota Nagpur plateau and
the Orissa plateau covering
the states of Jharkhand,
West Bengal and Orissa.
Central Belt
Manganese, bauxite, limestione, marble, coal, gems, mica,
Chattisgarh, Andhra Pradesh,
graphite etc. exist in large quantities and the net extent of
Madhya Pradesh and
the minerals of the region is yet to be assessed. This is the
Maharastra.
second largest belt of minerals in the country.
Southern Belt
Karnataka plateau and Tamil
Ferrous minerals and bauxite. Low diversity.
Nadu.
South Western Belt
Karnataka and Goa.
North Western Belt
Rajasthan and Gujarat along Non-ferrous minerals, uranium, mica, beryllium,
the Aravali Range.
aquamarine, petroleum, gypsum and emerald.
Iron ore, garnet and clay.
INDIA’S ECONOMIC GROWTH IS LINKED WITH EFFECTIVE HANDLING OF MINERAL RESOURCES
Khullar, D.R. (2006), "Mineral Resources", India: A Comprehensive Geography, pp. 630-659, Kalyani Publishers, ISBN 812722636X.
Distribution of locations of
Bulk material handling
loads in India
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Ports and Road/ Railway Connectivity for Rapid
Movement of Exported or Imported bulk materials is
of paramount importance for India’s economic growth
INDIA: Transport Sector Key Statistics
Transport Sector Bottleneck
Units
As of 2009
Length of Roads
Km.
3,516,452
Main Roads
Km.
666,452
Paved Roads
%
47.3
Access to All-Season-Roads
%
61
km/1,000 sq.
km.
Km.
1115
Road Density
Rail Track Length
No. of Ports
Turnaround time









63,327
199
Days
3
Airports
125
International
11
Roads are congested and of poor quality
Rural areas have poor access and mines are in rural and forest areas
The railways are facing severe capacity constraints, delays are common. Besides they are easy target of
extremists.
Urban centers are severely congested, unplanned urbanization leaving no/little scopes for facility
expansion
Ports are also congested lack rapid bulk handling facilities
Road and rail monitoring and maintenance are not using advanced technology
No attempts visible for maintaining roads and standardizing trucks capacity to optimize energy
efficiency
At present in most cases only two trains run between two stations with the present signaling system,
with advanced technology it may be possible to run 6/8 trains between two stations while ensuring
100% safety.
Scopes of using higher capacity wagons (including lower tare load/ higher-volume wagons depending
on commodity carried), track renewals enable higher axle loading on select corridors to be explored
A major question of near future
How to handle movement of large quantity of bulk
materials economically and environmentally friendly?
Major modes of ore transport practiced in India are
Will Need Modernization
like advanced Wagons,
Control system, safety
monitoring to cater large
scale transport of iron ore,
coal, alumina, Cu
concentrate etc.
• RAILWAY
• ROAD
• WATER WAYS
• COASTAL SHIPPING
• PIPE LINE
Inadequate and poor
quality roads will have to
be transformed rapidly.
Caters 65 % of all freight
and 80 % of passenger
Not used effectively
Bulk ports are mainly for export import
Minimal use, almost nil other than crude
oil transport. Not many slurry pipe lines.
RAIL TRANSPORTATION ISSUES & CHALLENGES
 Inadequate rail capacity for handling both domestic requirements and to handle
bulk materials for export and import.
 Lower Haulage capacity leading to higher lead time
 Matching demands of passenger and freight train
 Frequent Changes in rail freight affects the planning of mineral producers and
consumers
 Threat of exorbitant Punitive charges for overloading leads to under loading of
rakes and thus loss due to dead freight payment.
 Lack of rail connectivity to ports and long time lines for rail projects.
Critical situation during natural but anthropogenically induced
calamity: Mumbai Flood
How to protect transportation systems from such
situations is a technical challenge
India has scope to improve inland water ways and ports.
INLAND WATER WAYS
• Almost not used for Bulk material
transport
• East and North East India can
explore its economics
Waterways…………….
India has a large number of perennial rivers and a very long coastline of 6100 km.
Types :-
(a.) Inland water transport
(b) Ocean water transport
National Waterways :1.The Ganga river
- Allahabad to Haldia - 1620 km.
2. The Brahmaputra river - Sadiya TO Dhubri
- 891 km.
3. The West Coast Canal - Kollam to Kottapuram - 14 km.
4. The Champakara Canal – Kerala
-13 km.
5. Udagmandalam Canal - Kerala
-22 km.
Major Sea Ports :- At the time of Independence - 5 sea ports
Sea ports at West Coast
Seaports at East Coast
1. Kandla
1. Tuticorin
2. Mumbai
3. Nhova Sheva (Jawahar Lal Nehru)
4.Mormugao
5. Mangalore
6. Kochi
2. Chennai
3. Ennore
4. Vishakhapatnam
5. Paradip
6. Haldia
PORT INFRASTRUCTURE: POSSIBLE SOLUTIONS TO CHALLENGES
• Port capacities to be augmented to gear up for higher exports
of all commodities
• Modernization of all machinery and mechanization
• Develop higher drafts to take advantage of handling vessels of
higher capacity with lower unit freight costs.
• Compress time lines in port projects implementation
• Matching port capacities with rail-road infrastructure to remove
bottlenecks
• Develop facilities for railway rakes to go inside the ports for
unloading / loading and dispensing with interchange/exchange
yards to reduce cycle time.
• Seamless movement in/out of port for both road and rail to cut
down waiting time and increase throughput.
Are the Indian roads ready to handle the projected growth?
Traffic handled by Road (MT)
177
MT
200
100
0
34
27
61
100 77
2004-05
2019-20
Raw
Materials*
Finished Steel
Total
* Excludes traffic due to export of iron ore
 Traffic for roads, due to steel industry by 2020, would increase
by 300%(approx.).
 The road network needs would be expanded
 The steel plants and mines to be integrated with the national
highway development.
Are the Railways ready to handle the projected growth?
Traffic handled by Railways (MT)
300
263
230
MT
200
100
91
80
11
33
2004-05
2019-20
Raw Materials*
Finished Steel
Total
0
* Excludes traffic due to export of iron ore
 Traffic for railways, for steel industry by 2020, would increase by
300%(approx.).The railway facilities would be expanded substantially.
 Participation by the steel industry in creation of railway Infrastructure
would be necessary
Are the Ports ready to handle the projected growth?
Port Traffic
Bulks to be handled at ports (MT)
2004-05
Import
Raw
Materi
als*
Export
CAGR
2019-20
Total
Import
Export
Total
19.3
78
97.3
85
100
185
4.4%
Steel
2
4
6
6
26
32
11.8%
Total
21.3
82
103.3
91
126
217
5.1%
* Including iron ore
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
Enormous dependency on port infrastructure is foreseen in the near
future.
Steel producers intervention in development of ports and berth
facilities is needed for improving productivity, turn around time,
capacity to handle larger vessels and other operational
parameters of
efficiency.
New technology need to be investigated to
meet the transportation needs of India’s
Mineral Sector
RopeCon Conveyor:
The Latest Innovation in Bulk Material and Unit Load Handling- a combination of conveyor
belt and aerial ropeway
RopeCon is a long-distance
continuous conveyor system
suitable for the transportation of
bulk materials and unit loads of
any kind. This product is the
result of well-proven transport
technology combined with
Doppelmayr's decades of
experience in the ropeway
industry.
•
•
•
•
Sinberi Gold : Papua New Guinea
Application areas:
Single conveyor lengths up to
20,000 m
Capacity up to 10,000
tonnes/hour
Easy traversing of streets, railway
tracks, rivers and other obstacles
Tower spacing up to 2,000 m
Jamaica, bauxite
"Mt. Olyphant", Jamaica
"Zöchling“, Austria
Examples of Use of
RopeCon
"Tüfentobel", Switzerland,
St.Gallen
"Lenzing", Austria (for wood chips)
"Strengen", Austria
Scopes of RopeCon in India
Application of this system can be useful for transport of iron ore from Barbil area of
Orissa to the port for exporting. At present the NH 33 is highly congested due to road
transport of the ore. Traffic jam in the area causes extreme problems leading to wastage
of diesel and emission of greenhouse gases. Long time is wasted on the transport.
A techno-economic feasibility can be studied for a centralized export depo at a suitable
receiving station near Joda and a ropecon terminal near port. Even an integrated ship
loading system can be examined.
Feasibility studies may also be carried out for Tata Steel’s new mines at Khanband for
transportation of the processed ore from the proposed processing plant to steel plant at
Tata Nagar.
Modern technology is needed at
Toll Gates and Weigh Bridges
 To meet the projected mineral movements on roads along with the expected
increased traffic density, toll gates and interstate boarder gates will be
nightmare in future if it is left like the present.
 Toll gates must be electronic. Automatic identification of moving
vehicles in the gates and deduction of prepaid toll from the special
deposit system linked with bank would save some vital time.
 Electronic vigilance and surveillance of traffic movements will have to
be used for elimination of traffic jams on the highways.
 The weigh bridges will have to be a matter of the past with introduction
of on board weighing and RF based data transferring system.
 Illegal mining, theft of produced coal through the loop holes of manual
security system will be eliminated by introduction of tracking ssytem.
To solve the challenges of Bulk Material handling associated with growth in mineral sector
RESEARCH AND DEVELOPMENT NEEDED IN MANY AREAS…….
•
RS GIS For Bulk Material Handling
•
Developing power generating road
•
Safety in Bulk Material Handling
•
Pollution control in Bulk Material Handling
•
Assessment of energy demands
•
Energy efficiency enhancement in Bulk Material Transport
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Alternative technology development for bulk material handling
•
Techno-economic modeling for bulk transports
•
Facility planning and site locations for bulk material handling
•
Logistic planning
•
Supply-chain management for bulk material handling
Research needed…..
• Initiation of feasibility study for alternative system: Detailed techno-economics
Truck Ramp
Transfer Point
Unloading/Reloading Bin
Truck Ramp
Transfer Point
Conveyor
Crusher Plant
Combination System
Mobile Slope Conveyor
Some systems that may be in India in near
future
Go Green: Closed Belt of Pipe Belt
Mobile Grasshopper Conveyor : Eliminate Trucks and Diesel
A GREEN BULK MATERIAL HANDLING
CONCLUSION
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Rail ways need to initiate
 Designing / modifying tracks and rolling stock to higher axle load will increase
throughput
 Usage of lighter material like steel in place of iron for rolling stock could increase
tare to pay load ratio to 1: 3.4 thereby increasing quantity hauled/rake
 Expediting facilities for manufacture of higher axle load wagons , new technology
bogies , couplers , draft gears and other equipment to get rolling stock suitable
for 30.0 - 32.5 Tonne axle load .
 Development of rapid loading unloading system
Use state-of-the-art technologies for forecasting rainfall, measuring runoff, traffic operating
systems.
On-line flood forecasting and traffic operation system(s).
Steps to be taken to improve road density and quality
Industry status will have to be accorded to road transport operators
Roadside amenities and Emergencies services will have to be improved urgently
Development of high load carrying roads and vehicles will enable movement of higher
quantity per vehicle
 Rail connectivity to ports like Belikeri, Karwar, Krishnapatnam needed to avoid
more truck movements and diesel consumption and CO2 emissions.
 Participation by the steel industry in creation of railway Infrastructure would be
necessary
Thanks
All are doing good with their best capacity but better options are always there and
we must
 study,
 investigate,
 experiment and
 implement
to manage the changes associated with growth.