Workshop on The Technology Development Mechanisation of

Workshop on “The Technology Development & Mechanisation of Mines for enhancing Coal Production & Productivity ” 20 th January, 2015 Presentation by Western Coalfields Limited

Western Coalfields Limited v WCL operates 80 Mines (41 UG, 39 OC) in 10 Areas (7 in Maharashtra & 3 in Madhya Pradesh) v 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 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

• • 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 43. 11 42. 29 39. 73 44. 00 Million Tonnes 43. 65 Growth: 10. 7% Figures in Million Tonnes 5

Performance at a Glance : OB Removal Growth: 8. 3% 113. 69 120. 08 130. 00 Million Cum 115. 82 122. 49 Figures in Million Cu. M 6

Performance at a Glance : Composite Production Million Cum Growth: 8. 7% FY 2013 -14 Composite Production (Mcum) CCL 92. 57 BCCL ECL 107. 16 109. 78 WCL 145. 7 MCL 169. 65 7

Performance at a Glance : Coal Offtake Growth 12. 65% 42. 56 41. 97 41. 55 39. 95 45. 00 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 Area State Capacity (Mty) Opening Date Makardhokra-I OC Umrer MAH 2. 00 28 -Nov-14 Bhanegaon OC Nagpur MAH 1. 00 25 -Jan-15 Penganga OC Wani MAH 4. 00 25 -Mar-15 Gokul OC Umrer MAH 1. 50 25 -May-15 Sharda UG Kanhan MP 0. 32 25 -Jun-15 Dinesh OC Umrer MAH 4. 00 25 -Jul-15 Dhau North UG Kanhan MP 0. 36 25 -Aug-15 New Majri UG to OC Majri MAH 0. 80 25 -Sep-15 Amalgamated Yekona-I & II OC Majri MAH 2. 50 25 -Oct-15 Singhori OC Nagpur MAH 0. 80 25 -Nov-15 Amalgamated Pauni-II & III OC Ballarpur MAH 2. 50 25 -Jan-16 Tawa -III UG Pathakera MP 1. 00 25 - Feb-16 Chincholi OC Ballarpur MAH 0. 30 25 -Mar-16 Kamptee Deep OC Nagpur 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 MP 4. 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 YEAR 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 39. 73 44. 00 45. 00 48. 00 55. 00 50. 00 Ongoing Projects 24. 91 14. 82 24. 03 19. 97 Future Projects 13 -14 14 -15 22. 67 21. 03 22. 27 15. 63 10. 10 12. 64 1. 30 15 -16 21. 10 16. 26 25. 67 18. 93 10. 40 28. 05 21. 60 10. 35 Existing & Completed Projects 16 -17 17 -18 18 -19 19 -20 14

Share of UG and OC production Million Tonnes Total Production OC UG Year 15

OC Composite Production : Departmental & Outsourcing 350 300 253. 56 290. 69 311. 72 250 169. 2 206. 3 225. 4 247. 9 81. 8 84. 4 86. 4 87. 4 2015 -16 2016 -17 2017 -18 2018 -19 2019 -20 200 178. 87 150 97. 1 100 50 0 335. 23 Composite Deptt Composite OS Figures in Million Cu. M 16

Opencast : Existing & Required Equipment 17

Existing HEMM Population Equipment Model Dragline Capacity Population Equipment Model Shovels, Electric 5 Cu. mt Rope More than 2. 5 Cu. mt 67 Shovels, Hydraulic Less than 2. 5 Cu. mt 29 Dumpers 35 Ton 50 Ton 60 Ton 55 225 174 Dozer Crawler 410 HP 6 320 hp 139 39 Shovels, Hydraulic Population Dozer Crawler 3 Capacity 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 Dragline Supplier (No) 24 Cum /96 m Bucyrus (1) 20 Cum /90 m 1 Capacity Uralmash(1) • Age – 22 Yrs 9 Cu 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 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 TATA Hitachi(15) 4 Dumper 60/50 T • 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 Wheel Dozer 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 100 T 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 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 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 Despatch 3. 60 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 Production 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 (-200 mm) 42 2 Crusher(-100 mm) 4 35

CHPs : Plan for 2015 -16 Machine Secondary Crushers Feeder Breaker/ Crusher Capacity -100 mm 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