PERFORMANCE ASSESSMENT OF SURFACE MINER IN INDIAN COAL MINES A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE DEGREE OF MASTER OF TECHNOLOGY (DUAL DEGREE) IN MINING ENGINEERING BY SEETHIRAJU ESWAR NANDAN 710MN1171 Dept. of Mining Engg. National Institute Of Technology Rourkela- 769008 2015
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PERFORMANCE ASSESSMENT OF SURFACE MINER
IN INDIAN COAL MINES
A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR
THE DEGREE OF
MASTER OF TECHNOLOGY (DUAL DEGREE)
IN
MINING ENGINEERING
BY
SEETHIRAJU ESWAR NANDAN
710MN1171
Dept. of Mining Engg.
National Institute Of Technology
Rourkela- 769008
2015
PERFORMANCE ASSESSMENT OF SURFACE MINER
IN INDIAN COAL MINES
A THESIS SUBMITTED IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR
THE DEGREE OF
MASTER OF TECHNOLOGY (DUAL DEGREE)
IN
MINING ENGINEERING
BY
SEETHIRAJU ESWAR NANDAN
710MN1171
UNDER THE GUIDANCE OF
PROF. H.K.NAIK
Dept. of Mining Engg.
National Institute Of Technology
Rourkela- 769008
2015
i
NATIONAL INSTITUTE OF TECHNOLOGY
2015
CERTIFICATE
This is to certify that, the thesis entitled “PERFORMANCE ASSESSMENT OF SURFACE
MINER IN INDIAN COAL MINES” submitted by Sri Seethiraju Eswar Nandan in partial
fulfilment of the requirements for the award of Master of Technology (Dual degree) in
Mining Engineering at National Institute of Technology is an authentic work carried out by
him under my supervision and guidance.
To the best of my knowledge, the matter embodied in the report has not been submitted to
any University/Institute for the award of any Degree or Diploma.
Date: 10/05/2012 Prof. H.K.Naik
Dept. of Mining Engg.
National Institute of Technology
Rourkela- 769008
ii
ACKNOWLEDGEMENT
It is my privilege to acknowledge all those persons who helped me in completion of the
project.
The most pleasant point of presenting a thesis is the opportunity to thank those who have
contributed to it. Unfortunately, the list of expressions of thank no matter how extensive is
always incomplete and inadequate. Indeed this page of acknowledgment shall never be able
to touch the horizon of generosity of those who tendered their help to me.
First and foremost, I would like to express my gratitude and indebtedness to Prof. H.K.Naik,
for his kindness in allowing me for introducing the present topic and for his inspiring
guidance, constructive criticism and valuable suggestion throughout this project work. I am
sincerely thankful to him for his able guidance and pain taking effort in improving my
understanding of this project.
An assemblage of this nature could never have been attempted without reference to and
inspiration from the works of others whose details are mentioned in reference section. I
acknowledge my indebtedness to all of them.
And my sincere thanks to the Officers of Lakhanpur Opencast mines and Samaleswari
Opencast mines and to all my colleagues and also my family who have patiently extended all
sorts of help for accomplishing this undertaking.
DATE:
SEETHIRAJU ESWAR NANDAN
PLACE: Dept. of Mining engineering
National Institute of Technology
Rourkela – 769008
iii
TABLE OF CONTENTS
CERTIFICATE ...................................................................................................................... i
ACKNOWLEDGEMENT ...................................................................................................... ii
ABSTRACT .......................................................................................................................... v
List of Figures....................................................................................................................... vi
List of Tables ........................................................................................................................ xi
Figure 2.1: Interspersed dirt band in coal seam ................................................................................................ 3
Figure 2.2: Cutting, Crushing and Loading in one go ....................................................................................... 5
Figure 2.3: Machine with middle drum configuration ...................................................................................... 5
Figure 2.4: Machine with front boom cutting drum .......................................................................................... 6
Figure 2.5: Machine with front cutting drum .................................................................................................... 6
Figure 2.11: Conveyor loading system .............................................................................................................. 12
Figure 2.12: Windrowing system ....................................................................................................................... 13
Figure 2.13: Side casting system ........................................................................................................................ 13
Figure 3.1 (a) Availability of SM-468(RUNGTA)…………………………………………………………….25
Figure 3.1 (b) Availability of SM-625(RUNGTA) ……………………………………………………………25
Figure 3.1 (c) Availability of SM-634(RUNGTA) …………………………………………………………….26
Figure 3.1 (d) Availability of SM-336(RUNGTA) ……………………………………………………………26
Figure 3.1 (e) Availability of SM-L&T-303(015) ……………………………………………………………..26
Figure 3.1 (f) Availability of SM-L&T-303(021) ……………………………………………………………. 27
Figure 3.1 (g) Availability of SM-644(Nagarjuna) ………………………………………………………….. 27
Figure 3.2 (a) Utilisation of SM-468(RUNGTA) ……………………………………………………………..27
Figure 3.2 (b) Utilisation of SM-625(RUNGTA) ……………………………………………………………..28
Figure 3.2 (c) Utilisation of SM-634(RUNGTA) …………………………………………………………….. 28
Figure 3.2 (d) Utilisation of SM-336(RUNGTA) ……………………………………………………………..28
Figure 3.2 (e) Utilisation of SM- SM-L&T-303(015) ……………………………………………………….. 29
Figure 3.2 (f)) Utilisation of SM- SM-L&T-303(021) …………………………………………………… 29
Figure 3.2 (g) Utilisation of SM-644(Nagarjuna) …………………………………………………………….29
Figure 3.3 (a) Performance rate of SM-468(RUNGTA…………………………………………………… 30
Figure 3.3 (b) Performance rate of SM-625(RUNGTA) ……………………………………………………30
Figure 3.3 (c) Performance rate of SM-634(RUNGTA) …………………………………………………… 30
Figure 3.3 (d) Performance rate of SM-336(RUNGTA) ………………………………………………… 31
Figure 3.3 (e) Performance rate of SM-L&T-303(015) …………………………………………………… 31
Figure 3.3 (f) Performance rate of SM-L&T-303(021) …………………………………………………… 31
Figure 3.3(g) Performance rate of SM-644(NAGARJUNA) ………………………………………………32
Figure 3.4 (a) Theoretical OEE and Estimated OEE of SM-468(RUNGTA) …………………………… 32
Figure 3.4 (b) Theoretical OEE and Estimated OEE of SM-625(RUNGTA) ……………………………..32
Figure 3.4 (c) Theoretical OEE and Estimated OEE of SM-634(RUNGTA) ……………………………..33
Figure 3.4 (d) Theoretical OEE and Estimated OEE of SM-336(RUNGTA) ………………………… 33
vii
Figure 3.4 (e) Theoretical OEE and Estimated OEE of SM-L&T-303(015) …………………………… 33
Figure 3.4 (f) Theoretical OEE and Estimated OEE of SM-L&T-303(021…………………………………34
Figure 3.4 (g) Theoretical OEE and Estimated OEE of SM-644(NAGARJUNA) …………………………34
Figure 3.5 (a) Achieved Production of SM-468(RUNGTA) …………………………………………… 34
Figure 3.5 (b) Achieved Production of SM-625(RUNGTA) ……………………………………………… 35
Figure 3.5 (c) Achieved Production of SM-634(RUNGTA) …………………………………………………35
Figure 3.5 (d) Achieved Production of SM-336(RUNGTA) …………………………………………………35
Figure 3.5 (e) Achieved Production of SM- L&T-303(015) …………………………………………………36
Figure 3.5 (f) Achieved Production of SM-L&T-303(021) …………………………………………… 36
Figure 3.5 (g) Achieved Production of SM-644(NAGARJUNA) ………………………………………… 36
Figure 3.6 (a) Breakdown hours of SM-468(RUNGTA) ………………………………………………… 37
Figure 3.6 (b) Breakdown hours of SM-625(RUNGTA) ………………………………………………… 37
Figure 3.6 (c) Breakdown hours of SM-634(RUNGTA) ………………………………………………… 37
Figure 3.6 (d) Breakdown hours of SM-336(RUNGTA) ………………………………………………… 38
Figure 3.6 (e) Breakdown hours of SM-L&T-303(015) …………………………………………………….38
Figure 3.6 (f) Breakdown hours of SM-L&T-303(021) ………………………………………………………38
Figure 3.6 (g) Breakdown hours of SM-644(NAGARJUNA) ………………………………………………39
Figure 3.7 (a) Idle hours of SM-468(RUNGTA) …………………………………………………………….39
Figure 3.7 (b) Idle hours of SM-625(RUNGTA) ……………………………………………………………..39
Figure 3.7 (c) Idle hours of SM-634(RUNGTA) ……………………………………………………………..40
Figure 3.7 (d) Idle hours of SM-336(RUNGTA) …………………………………………………………….40
Figure 3.7 (e) Idle hours of SM-L&T-303(015) ……………………………………………………………..40
Figure 3.7 (f) Idle hours of SM-L&T-303(021) ……………………………………………………………..41
Figure 3.7 (g) Idle hours of SM-644(NAGARJUNA) …………………………………………………… 41
Figure 3.8 (a) Availability of L&T KSM 303(24) in January………………………………………………45
Figure 3.8 (b) Availability of L&T KSM 303(24) in February…………………………………………… 45
Figure 3.8 (c) Availability of L&T KSM 303(24) in March…………………………………………………45
Figure 3.9 (a) Utilisation of L&T KSM 303(24) in January……………………………………………… 46
Figure 3.9 (b) Utilisation of L&T KSM 303(24) in February…………………………………………… 46
Figure 3.9 (c) Utilisation of L&T KSM 303(24) in March……………………………………………… 46
Figure 3.10 (a) Performance rate of L&T KSM 303(24) in January…………………………………… 47
Figure 3.10 (b) Performance rate of L&T KSM 303(24) in February…………………………………… 47
Figure 3.10 (c) Performance rate of L&T KSM 303(24) in March…………………………………………47
viii
Figure 3.11(a) Theoretical OEE and Estimated OEE of L&T KSM 303(24) in
January……………………………………………………………………………………………………… 48
Figure 3.11(b) Theoretical OEE and Estimated OEE of L&T KSM 303(24) in February…………… 48
Figure 3.11(c) Theoretical OEE and Estimated OEE of L&T KSM 303(24) in
March………………………………………………………………………………………………………. 48
Figure 3.12 (a) Achieved Production of L&T KSM 303(24) in January………………………………… 49
Figure 3.12 (b) Achieved Production of L&T KSM 303(24) in February……………………………… 49
Figure 3.12 (c) Achieved Production of L&T KSM 303(24) in March……………………………………49
Figure 3.13 (a) Breakdown hours of L&T KSM 303(24) in January………………………………………50
Figure 3.13 (b) Breakdown hours of L&T KSM 303(24) in February………………………………… 50
Figure 3.13 (c) Breakdown hours of L&T KSM 303(24) in March……………………………………… 50
Figure 3.14(a) Idle hour of L&T KSM 303(24) in January…………………………………………… 51
Figure 3.14(b) Idle hour of L&T KSM 303(24) in February…………………………………………… 51
Figure 3.14(c) Idle hour of L&T KSM 303(24) in March……………………………………………… 51
Figure 3.15 (a) Availability of L&T KSM-303(15) from Dec-2012 to Nov-2013……………………… 54
Figure 3.15 (b) Availability of L&T KSM-303(15) from Dec-2013 to Nov-2014…………………………54
Figure 3.15 (c) Availability of L&T KSM-303(15) from Dec-2014 to Mar-2015……………………… 54
Figure 3.16 (a) Utilisation of L&T KSM-303(15) from Dec-2012 to Nov-2013……………………………55
Figure 3.16 (b) Utilisation of L&T KSM-303(15) from Dec-2013 to Nov-2014……………………………55
Figure 3.16 (c) Utilisation of L&T KSM-303(15) from Dec-2014 to Mar-2015……………………………55
Figure 3.17 (a) Performance rate of L&T KSM-303(15) from Dec-2012 to Nov-2013……………………56
Figure 3.17 (b) Performance56 rate of L&T KSM-303(15) from Dec-2013 to Nov-2014…………………56
Figure 3.17 (c) Performance rate of L&T KSM-303(15) from Dec-2014 to Mar-2015……………………56
Figure 3.18 (a) Theoretical OEE and Estimated OEE of L&T KSM-303(15) from Dec-2012 to Nov-
2013……………………………………………………………………………………………………………..57
Figure 3.18 (b) Theoretical OEE and Estimated OEE of L&T KSM-303(15) from Dec-2013 to Nov-
2014…………………………………………………………………………………………………………….57
Figure 3.18 (c) Theoretical OEE and Estimated OEE of L&T KSM-303(15) from Dec-2014 to Mar-
2015………………………………………………………………………………………………………………57
Figure 3.19 (a) Achieved production of L&T KSM-303(15) from Dec-2012 to Nov-
2013…………………………………………………………………………………………………………. 58
Figure 3.19 (b) Achieved production of L&T KSM-303(15) from Dec-2013 to Nov-
2014………………………………………………………………………………………………………. 58
Figure 3.19 (c) Achieved production of L&T KSM-303(15) from Dec-2014 to Mar-
2015………………………………………………………………………………………………………… 58
Figure 3.20 (a) Breakdown Hours of L&T KSM-303(15) from Dec-2012 to Nov-
2013……………………………………………………………………………………………………….. 59
ix
Figure 3.20 (b) Breakdown Hours of L&T KSM-303(15) from Dec-2013 to Nov-
2014……………………………………………………………………………………………………….. 59
Figure 3.20 (c) Breakdown Hours of L&T KSM-303(15) from Dec-2014 to Mar-
2015……………………………………………………………..………………………………… 59
Figure 3.21 (a) Idle hours of L&T KSM-303(15) from Dec-2012 to Nov-
2013……………………………………………………………..………………………………… 60
Figure 3.21 (b) Idle hours of L&T KSM-303(15) from Dec-2013 to Nov-2014………………………… 60
Figure 3.21 (c) Idle hours of L&T KSM-303(15) from Dec-2014 to Mar-2015……………………………60
Figure 3.22 (a) Availability of L&T KSM-303(21) from Sep-2013 to Nov-2014……………………… 62
Figure 3.22 (a) Availability of L&T KSM-303(21) from Dec-2014 to Mar-2014……………………… 62
Figure 3.23 (a) Utilisation of L&T KSM-303(21) from Sep-2013 to Nov-2014……………………… .62
Figure 3.23 (b) Utilisation of L&T KSM-303(21) from Dec-2014 to Mar-2014……………………… 63
Figure 3.24 (a) Performance rate of L&T KSM-303(21) from Sep-2013 to Nov-2014………………… 63
Figure 3.24 (b) Performance rate of L&T KSM-303(21) from Dec-2014 to Mar-2014……………………63
Figure 3.25 (a) Theoretical OEE and Estimated OEE of L&T KSM-303(21) from Sep-2013 to Nov-
2014………………………………………………………………………………………………………………64
Figure 3.25 (b) Theoretical OEE and Estimated OEE of L&T KSM-303(21) from Dec-2014 to Mar-
2014………………………………………………………………………………………………………………64
Figure 3.26 (a) Achieved production of L&T KSM-303(21) from Sep-2013 to Nov-2014………………….64
Figure 3.26 (b) Achieved production of L&T KSM-303(21) from Dec-2014 to Mar-
2014…………………………………………………………………………………………………………… 65
Figure 3.27 (a) Breakdown hours of L&T KSM-303(21) from Sep-2013 to Nov-2014………………… 65
Figure 3.27 (b) Breakdown hours of L&T KSM-303(21) from Dec-2014 to Mar-2014……………………65
Figure 3.28 (a) Idle hours of L&T KSM-303(21) from Sep-2013 to Nov-2014……………………………66
Figure 3.28 (b) Idle hours of L&T KSM-303(21) from Dec-2014 to Mar-2014……………………… 66
Figure 3.29 (a) Availability of L&T KSM-303(20) from Aug-2013 to Aug-2014 ……………………… 68
Figure 3.29 (b) Availability of L&T KSM-303(20) from Aug-2014 to Mar-2015………………… 68
Figure 3.30 (a) Utilisation of L&T KSM-303(20) from Aug-2013 to Aug-2014……………………… 68
Figure 3.30 (b) Utilisation of L&T KSM-303(20) from Aug-2014 to Mar-2015……………………… 69
Figure 3.31 (a) Performance rate of L&T KSM-303(20) from Aug-2013 to Aug-2014………………… 69
Figure 3.31 (b) Performance rate of L&T KSM-303(20) from Aug-2014 to Mar-2015………………… 69
Figure 3.32 (a) Theoretical OEE and Estimated OEE of L&T KSM-303(20) from Aug-2013 to Aug-
2014……………………………………………………………………………………………………………70
Figure 3.32 (b) Theoretical OEE and Estimated OEE of L&T KSM-303(20) from Aug-2014 to Mar-
2015………………………………………………………………………………………………………………70
Figure 3.33 (a) Achieved production of L&T KSM-303(20) from Aug-2013 to Aug-
2014…………………………………………………………………………………………………………… 70
x
Figure 3.33 (b) Achieved production of L&T KSM-303(20) from Aug-2014 to Mar-
2015…………………71
Figure 3.34 (a) Breakdown hours of L&T KSM-303(20) from Aug-2013 to Aug-2014………………… 71
Figure 3.34 (b) Breakdown hours of L&T KSM-303(20) from Aug-2014 to Mar-2015………………… 71
Figure 3.35 (a) Idle hour of L&T KSM-303(20) from Aug-2013 to Aug-2014……………………… 72
Figure 3.35 (b) Idle hour of L&T KSM-303(20) from Aug-2014 to Mar-2015……………………… 72
Figure 3.36 (a) Availability of L&T KSM-303(24) from Dec-2013 to Dec-
2014……………………………..74
Figure 3.36 (b) Availability of L&T KSM-303(24) from Dec-2014 to Mar-
2015……………………………74
Figure 3.37 (a) Utilisation of L&T KSM-303(24) from Dec-2013 to Dec-
2014………………………………74
Figure 3.37 (b) Utilisation of L&T KSM-303(24) from Dec-2014 to Mar-
2015………………………………75
Figure 3.38 (a) Performance rate of L&T KSM-303(24) from Dec-2013 to Dec-
2014………………………75
Figure 3.38 (b) Performance rate of L&T KSM-303(24) from Dec-2014 to Mar-
2015………………………75
Figure 3.39 (a) Theoretical OEE and Estimated OEE of L&T KSM-303(24) from Dec-2013 to Dec-
2014………………………………………………………………………………………………………………76
Figure 3.39 (b) Theoretical OEE and Estimated OEE of L&T KSM-303(24) from Dec-2014 to Mar-
2015………………………………………………………………………………………………………………76
Figure 3.40 (a) Achieved production of L&T KSM-303(24) from Dec-2013 to Dec-
2014………………………………………………………………………………………………………………76
Figure 3.40 (b) Achieved production of L&T KSM-303(24) from Dec-2014 to Mar-
2015………………………………………………………………………………………………………………77
Figure 3.41 (a) Breakdown hours of L&T KSM-303(24) from Dec-2013 to Dec-
2014………………………77
Figure 3.41 (b) Breakdown hours of L&T KSM-303(24) from Dec-2014 to Mar-2015……………………77
Figure 3.42 (a) Idle hours of L&T KSM-303(24) from Dec-2013 to Dec-
2014………………………………78
Figure 3.42 (b) Idle hours of L&T KSM-303(24) from Dec-2014 to Mar-2015……………………………..78
xi
List of Tables
Table 2.1: Specification of different surface miner models ....................................................... 7
Table 2.2: Surface miner details in Indian coal fields ............................................................... 8
Table 2.3: Comparison of different loading methods ............................................................. 14
Table 2.4: Comparison of Surface Miner and Conventional System of Mining ....................... 14
Table 2.5: Six big losses ........................................................................................................ 16
Table 3.1: Performance of Surface miner (Rungta 468) at Lakhanpur OCP …………………...18
Table 3.2: Performance of Surface miner (Rungta 625) at Lakhanpur OCP ……………..........19
Table 3.3: Performance of Surface miner (Rungta 634) at Lakhanpur OCP …………………..20
Table 3.4: Performance of Surface miner (Rungta 336) at Lakhanpur OCP …………………..21
Table 3.5: Performance of Surface miner (L&T-303(15)) at Lakhanpur OCP…………………22
Table 3.6: Performance of Surface miner (L&T-303(21)) at Lakhanpur OCP…………………23
Table 3.7: Performance of Surface miner Nagarjuna (644) at Lakhanpur OCP……………….24
Table 3.8: Performance of Surface miner L&T KSM 303(24) at Samaleswari OCP…………. .42
Table 3.9: Performance of Surface miner L&T KSM 303(24) at Samaleswari OCP…………. .43
Table 3.10: Performance of Surface miner L&T KSM 303(24) at Samaleswari OCP………... .44
Table 3.11: Performance of Surface miner (L&T-303(15)) at Lakhanpur OCP (Year 2013)….52
Table 3.12: Performance of Surface miner (L&T-303(15)) at Lakhanpur OCP (Year-2014)….52
Table 3.13: Performance of Surface miner (L&T-303(15)) at Lakhanpur OCP (Year-2015)….53
Table 3.14: Performance of Surface miner (L&T-303(21)) at Lakhanpur OCP (Year 2013-
15)…………………………………………………………………………………………………….. 61
Table 3.15: Performance of Surface miner (L&T-303(20)) at Samaleswari OCP (Year 2013-15)..
…………………………………………………………………………………………………………67
Table 3.16: Performance of Surface miner (L&T-303(24)) at Samaleswari OCP (Year 2014-
15)…………………………. …………………………………………………………………………73
CHAPTER 1
INTRODUCTION
1
1 INTRODUCTION
Mining is a very capital-intensive industry, and it is well known fact that the equipment availability
and precise estimation of its utilization are very important because mine managers want to utilize their
equipment as effectively as possible to get an early return on their investments as well reducing total
production cost. While a lot of thrust is put on the selection of mining equipments not much
consideration is paid towards the measurement of effectiveness of those equipments. The increase in
automation, compounded by the increase in the size and capacity of equipment over the years has
drastically changed the consequences of equipment ineffectiveness. In the present economic
conditions, severe global competition, challenges of environmental and safety considerations, in order
to achieve high production and productivity of HEMMs in opencast mines, it is pertinent to have high
% availability and % utilization of equipments besides ensure overall equipment effectiveness vis-à-
vis established CMPDI norms/global bench marks. This necessitates performance assessment of
various equipments in highly mechanized OCPs, critically analyse the idle/down time of equipments
and take ameliorative measures to improve machine productivity and performance.
OEE is a tool which evaluate and indicates how effectively a production operation is utilized
.Utilization of equipments can be only be improved and maintained successfully if an appropriate
performance measurement system is used. One should also try to identify unproductive time losses
within the system as these time losses affect availability, performance and quality. The consequence
of proper data collecting system to estimate equipment effectiveness is also emphasized.
In Indian surface mining industry, surface miners made their debut in 1996. Presently, around 105
surface miners are working in Indian coal and limestone mines. The surface miners are being
deployed largely on trial and error basis and the investors are interested in field experimental runs.
The applicability of surface miners is evaluated by the manufacturers based on compressive strength
of rock. In this context, it is logical to found a method to evaluate the performance of surface miners.
The overall equipment effectiveness (OEE) of the surface miners has been determined to evaluate
their performance.
In this project, an attempt has been made to analyse the performance of Surface miners deployed at
two highly mechanized OCPs of Mahanadi Coalfields Limited (MCL).
1.1 OBJECTIVES
To estimate % availability, % utilization and analyze idle hours of Surface Miners at
Lakhanpur OCP and Sameleswari OCP.
To determine Overall Equipment Effectiveness (OEE) of Surface Miner at LOCP and SOCP.
CHAPTER 2
LITERATURE REVIEW
2
2 LITERATURE REVIEW
2.1 PROJECT PROFILE OF THE MINES
2.1.1 Lakhanpur Mines
SL.NO. INFORMATION DATA
01 Mine Capacity 18.75 MT Coal
02. Total Mineable Coal Reserve 416.32MT
03. Coal Extracted till 31.03.2014 162.09 MT
04. Balance Mineable Coal Reserve as on -01.04.14 254.23MT
05. Expected life of the Mine Up to 2030
06. Stripping ratio (Avg.) 2.34 : 1 cum /Te
07. Date of Introduction of 1st Surface Miner of MCL in
Lakhanpur OCP
20.06.1999.
08. Gradient 1 in 12 to 1 in 17
09. Maximum Quarry Depth 165 m
10. Total Manpower 1572 (907 Dept. +665 Contr.)
11. Quality of Coal 87%F & 13% G
12. Floor Area 1207 Ha.
13. Capital outlay in Rs. /Te. of Annual Out Put 355.86 Rs. /Te.
14. Main Customer ITPS (OPGC)
15. Total land Requirement 2485Ha.
16. Forest Land 328.83 Ha.
17. Production 2013-14(Coal) 149.99 Lakh Te.
18. Coal Dispatch `2013-14 149.58 Lakh Te.
19. O.B. Removal 2013-14 193.56 Lakh CuM.
GEOLOGY:
There are five coal seams in the sub block considered for the opencast mining. They are
1) Belpahar Seam
2) Parkhani Seam
3) Lajkura Seam
4) Rampur Seam
3
5) Ib Seam
In descending order.
In the area chosen for opencast mining under the project report for Lakhanpur Opencast Project, only
Lajkura seam is proposed to be worked where the upper seams do not exist. The two seams (Rampur
& IB) beneath Lajkura occur with large parting and these could be worked by Underground method
after exhausting the Lajkura seam. The available dirt bands (1 to 5 in number) are combustible
(carbonaceous shale) and range in thickness from 1.47 Mtrs to 6.91 Mtrs. (cumulative). One such
thick band persists in the lower half of the seam throughout the block. Thickness of bands tends to
increase towards south as well as towards the west of the property.
REASONS FOR DEPLOYMENT OF SURFACE MINER AT LAKHANPUR OCP:
a) Improvement of quality by selective mining of coal:
Coal in this mine is interspersed with shale & sand stone band of varying thickness because of which
the product from the mine was marked as grade Lower ‘F’. Presence of dirt bands (1 to 5 Nos.) is the
major concern for quality deterioration of coal seam.
Figure 2.1: Interspersed dirt band in coal seam
b) Eco-friendly mining of coal:
Drilling & blasting operation on large scale produces a lot of noise, dust, vibration, fly rock formation
etc. This has prompted the mining community to look for a viable alternative of rock breakage for
overcoming these deficiencies & to increase the production & productivity while meeting the
requirement of environmentally safe operation. Surface Miner fulfilled the required search.
c) Proximity of villages:
Ghanamal (a hemlet of Khairkuni village) and other villages are situated almost at the middle of
quarry No. 1 and 2 of the mine. Due to restriction imposed by Directorate of Mines Safety,
Bhubaneswar region, for carrying out blasting operation beyond 150 Mtrs. from the houses/structures,
4
resulted in locking up of huge amount of Coal. Since no drilling and blasting is required for coal
winning with Surface Miner, not only the coal production has been enhanced tremendously but it has
also changed the attitude of villagers and R&R finalization has become easy and smooth.
d) To Improve quality of coal:
No washing of coal is required to improve the quality of coal. Techno economically the coal from
Surface Miner will be cheaper in view of the size of coal produced within the range of (+) 20 mm to (-
) 100 mm which does not require secondary crushing. It eliminated double handling by eliminating
the process of crushing. Direct dispatch from coal faces to various destinations has resulted in
meeting the increased demand of coal in the country.
e) To Meet the High Demand of Coal due to growth of new industries:
Due to the industrialization policy of the State Government the demand of Coal has been highly
increasing. To meet the high demand production through conventional method was inadequate. By
introduction of Surface Miner, we can fulfil the demand of coal in reduced time and resources.
2.1.2 Samaleshwari Mines
SL.NO. INFORMATION DATA
01 Mine Capacity 15 MT Coal
02. Total balance Mineable Coal Reserve 33.18 MT
03. Coal Extracted till 31.03.2014 133.49 MT
04. Stripping ratio (Avg.) 2.52 : 1 cum /Te
05. Gradient 1 in 17 to 1 in 19
06. Maximum Quarry Depth 120 M
07 Area along floor 98.54 Ha
08 Average seam thickness 23.94 M
09. Total Manpower 1511
10. Quality of Coal 87%F & 13% G
11. Quarry perimeter 6581.93 M
12. Main Customer ITPS (OPGC)
13. Production 2013-14(Coal) 110 Lakh Te.
14. O.B. Removal 2013-14 135.31 Lakh CuM.
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2.2 GENERAL DESCRIPTION OF SURFACE MINERS
2.2.1 Definition
A surface miner also called as continuous surface miner, is the technology in which extraction,
crushing and loading of minerals is done in single pass. So, this technology, can be used as a
substitute to conventional method of mining which involves drilling and blasting of minerals and rock
deposits, if applicable. It also eliminates primary and secondary crushing [].
Figure 2.2: Cutting, Crushing and Loading in one go (www.wirtgen.com)
2.2.2 Types of Surface miner
There are basically 3 types of surface miners that are available in market today, they are categorised
based on their design. Different types of Surface miners are:
Machines with middle drum configuration.
Figure 2.3: Machine with middle drum configuration (www.wirtgen.com)
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These are the most commonly available surface miners in the market. Writgen, Bitelli, Huron and
L&T machines belong to this group.
Machines with front boom cutting drum.
Figure 2.4: Machine with front boom cutting drum
Tesmec, Veermer, Voest alpine surface miners belong to this group.
Machines with front cutting wheel.
Figure 2.5: Machine with front cutting drum (http://www.readbag.com/mine- planning-publications-documents-
large-surface-miners)
KSM type machines from Krupp Fordertechnik, TSM type machines from Tenova TAKRAF belong
to this group.
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2.2.3 Specifications of Surface miners
Details specifications of Different types of surface miners are given in Table 1: Wirtgen (Model no.
SM2100, SM 2200, SM 2500, SM 3700, SM 4200), L&T (Model no.KSM304 & KSM 223), Trencor