STANDARDISED INFORMATION FOR EMPOWERED SUB-COMMITTEE (ESC) OF CIL BOARD FOR CHURI-BENTI UG PROJECT, CCL (0.81MTY)

CHAPTER - I

INTRODUCTION

1.1

BACKGROUND OF THE PROJECT REPORT

Churi UG is an existing project under the administrative control of North

Karanpura Area of Central Coalfields Limited. The mine has been taken over at the

time of nationalization. Prior to nationalization, it belonged to M/s United Karanpura

Collieries Ltd. Before nationalization, Lower Bachra seam has been worked in distant

past through Incline No. 2, 3, 4 & 5 in patches, which are presently abandoned. The

existence of water, fire etc cannot be ruled out in these abandoned workings. At the

time of nationalization, Churi old mine was under operation. The first Feasibility

Report for the project was undertaken in 1979 to work Upper and Lower Bachra

seams. After approval of the report, the mine development continued in Upper

Bachra & Lower Bachra seams.

Major area under Churi UG project has been developed and is standing on

pillars. Further investment is required in the mine for sustaining the existing

production as well as for production augmentation.

Mass Production Technology with Continuous Miner has been introduced in

few mines of the Coal India Limited. In view of encouraging results in SECL and

WCL, CCL management has also proposed for introduction of similar technology in

UG mines of CCL. Churi UG has been identified as a potential mine for introduction

of Continuous Miner Technology.

Churi-Benti UG project (developed mining area in Churi block & part of virgin

area in Benti block annexed to Churi UG mine) has been identified for introduction of

mass production technology. It is proposed to augment the coal production as well

as liquidate standing pillars at Churi UG. This report has been prepared to assess

the technological and financial implications of the introduction of Continuous Miner

Technology (based on equipment specifications as implemented in other CIL mines)

and to form a guideline for the process of the technological transfer. Recently,

agreement for supply of Continuous Miner package has been signed between ECL

and M/s JOY MINING for Jhanjra Project. The cost and specification of Continuous

Miner package considered for this report is same as that of Jhanjra Project.

1.2

PREVIOUS REVIEW OF THE PROJECT

The Project Report for Churi UG Project (Re-organization) was approved in

Feb’1982 by Government of India for a rated capacity of 0.84MTY with a capital

investment of 16.77 crores. The Churi project could not be completed and the

production remained far below the targeted production of 0.84 MTY. Recently, the

Derating-cum completion (foreclosure) report was prepared and has been approved

by the CCL Board in the 333^rd meeting on 9.9.2006 for a capacity of 0.16MTY. It has

been forwarded to GOI for competent sanction of foreclosure. The RCE of Churi

project has also been approved by CCL Board in Dec’06 and forwarded to GOI for its

consideration.

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Mean while, for improvement in production from the existing project, various

reviews of the project have been taken up (prior to de-rating cum completion report)

and the reports have been submitted. A chronology of various reports is as under:

RPR (0.60MTY)

Jan’91 (Approved by CCL

Board in July’93 but not

approved by CIL Board due to

low IRR

RPR (0.33MTY)

Dec’98

Augmentation Report (0.45 MTY) :

Dec’2005

RPR (0.84 MTY)

March’2006

De-rating Cum Completion Report: July ‘2006

(Approved By CCL Board

In 333^rd meeting in sept’06

And sent to govt of India

For its approval

And RCE of Churi UG project:

Approved by CCL Board in

Dec’2006 and sent to GOI for

approval

1.2

EXPLORATION STATUS

The area within the proposed mine boundary is about 7.69 sq. km. The

present mining area of the project falls under Churi & Benti (part) blocks, about 5.89

sq. km in Churi block & 1.8sq. km in Benti block. Detailed exploration has been

carried out in both the blocks. Total number of boreholes within the proposed

boundary is about 79BHs. The boreholes density works out to 10.26BHs/sq. km.

However, additional boreholes have been proposed for purpose of detailed analysis

of seams/bands and confirmation of seam/band thickness, wherever gap in

geological input exists.

CHURI BLOCK

A total of 56 boreholes have been drilled within mine boundary, including 3

non-coring boreholes. The borehole density works out to 9.50boreholes per square

km. The detailed exploration of Churi blocks revealed two major workable seams, i.e.

Upper Bachra seam (UBS) & Lower Bachra seam (LBS). Upper Bachra seam (UBS)

is not well developed in the north-western part of the block along Damodar river. In

the block, Lower Bachra seam has been interpreted as single geological

seam/horizon. However, the seam structure indicates multiple dirt bands, especially

in LBS. The average grade as per geological report is grade’ C’ but the grade

realization for the project is grade ‘B’ (LF).

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BENTI BLOCK

The total area within mine boundary in Benti block is about 1.80 sq. km. A

total of 23 boreholes exist within the area. The borehole density works out to

12.7boreholes per square km. In Benti Block only Lower Bachra seam is workable.

The lower Bachra seam has splitted in two parts namely BLB (Bottom Lower Bachra)

and Top Lower Bachra. The parting between BLB & TLB varies from 0.30-5.10m in

the block area within mine boundary. Top lower Bachra is again splitted into two

parts namely Upper Section of Top Lower Bachra and Lower section of Top lower

Bachra. Out of these three section, only two section BLB (Bottom Lower Bachra) &

Upper Section of Top Lower Bachra (UTLB) is workable.

TLB has been interpreted as combined Top Lower Bachra (CTLB) in part of

the mining area while in some part has been interpreted as split seam-section, i.e

Upper section of Top Lower Bachra (UTLB) and Lower section of Top Lower Bachra

(LTLB). The parting between UTLB & LTLB varies from 0.30- 2.07m. However, major

part of the mining area is having parting of around 1.0m or less. CTLB occurs as

thick seam with grade of coal D-E. In split seam-section, UTLB has workable seam

thickness, with thinning of seam to unworkable thickness on eastern and northern

side and grade of coal D-F. The LTLB shows workability in patches with grade of

coal B-D. In major part of the mining area, the parting between BLB and UTLB/CTLB

is generally around 1.0m or less. The BLB generally has workable thickness with

grade of coal varying from A-E.

In Benti block, UBS has been developed partly along Damodar river (common

boundary between Churi & Benti blocks). However, the seam is generally

unworkable.

1.3

CHRONOLOGY OF MINING ACTIVITIES

The first Feasibility Report for the project was undertaken in 1979 to work

Upper and Lower Bachra seams in Churi Re-organization (CRO). Subsequently,

Inclines 6 & 7 were driven up to Lower Bachra seam. Since then, B&P development

continued in UBS & LBS. Later, LHDs were introduced in the Churi UG project for

B&P development. After exhaustion of development reserves in LBS, additional area

in adjoining Benti block (sector-A) was annexed to the Churi UG project to continue

with B&P development. Presently, one B&P district with LHDs (5Nos.) is in operation

in Bottom Lower Bachra (BLB) seam/section in mining area under Benti block and

one manual B&P district in Upper Bachra seam in CRO. In Benti block, only initial

trunk roadway development has been done. The coal production during 2005-06

from Churi UG project has been 0.16Mt. Out of this, 0.10 Mt from LHDs panel and

0.06 Mt from manual B&P panel.

1.4

NECESSITY OF RECASTING PROJECT REPORT

Most of the property in Churi Block is developed and standing on pillars.

DGMS is also imposing restrictions on giving permission for further development.

Depillaring of these developed pillars is essential. Recent experiences in SECL and

WCL have shown that depillaring with Continuous Miner (CM) is suitable to achieve

higher production.

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CCL management has desired for introduction of Mass Production

Technology (MPT) to achieve higher rate of production from a mine / project. Churi

UG mine has been identified for deployment of Continuous Miner. The area, which is

free from overlying developed seams or unworkable overlying seams in Churi block,

i.e western section of CRO (Churi Re-organization), few panels of eastern section of

CRO (E12 & E13) and virgin area in Benti block, having thickness >3.0m has been

considered for deployment of Continuous Miner (similar to introduced in Chirimiri &

Tandsi UG mines of SECL & WCL respectively). There is change in technology

proposed for the mine and significant investment is required for production

augmentation as well as sustaining the production. Hence, it is required to recast the

report.

Scope of the report: The purpose of the report is to augment the existing

production by deploying Continuous Miner which may enhance the production,

economics and profitability of the project. The scope of this report is limited mainly to

depillaring of western section of CRO, few panels of eastern section of CRO (E12 &

E13) and development & depillaring in Benti block by Continuous Miner.

1.5

JUSTIFICATION OF PRESENT REPORT

The present status of the mine suggests the following:

 The entire property in Churi block is almost developed and standing on pillars

while mining area in Benti block is almost virgin.

 The development reserve for CM in mining area under Benti block has limited

mine life.

 The development and depillaring reserves for CM in the proposed area is for

about 9 years.

 The liquidation of standing pillars is essential. Depillaring cannot be

undertaken, as surface land is not acquired.

 Additional investment on acquisition of land is required for sustaining

production.

 In the present scenario, the mine is incurring losses @ of about Rs. 266/T,

which is likely to increase further with increase in various cost elements.

 Further investment is required for enhancement of production and/or

introduction of new technology.

 It is desired for production augmentation by adopting new technology on risk-

gain sharing basis.

 Investment is required for man-riding system due to long and arduous

traveling distance.

 Improved ventilation is required for ventilating distant panels.

 Additional capital is required for mine development and P & M.

 Better productivity and performance of Continuous Miner suggests feasibility

of enhanced production by way of introduction of mechanization at working

places.

 Integrated planning for coal & material transport, ventilation and pumping.

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1.6

RISK / DIFFICULTIES & CONSTRAINTS IN MINING

The difficulties / constraints and risk associated are :

 The seams lie at relatively low depth of cover thereby likely poses difficulty in

caving and strata control.

 Presence of Damodar and Saphi rivers on surface - a potential source of

danger

 Surface subsidence likely to significantly damage surface land.

 Coal to be left in UG to protect state highway on surface.

 Relatively low parting between seams

 Developed galleries are roof bolted.

 Crossing of Damodar River.

 Shifting of surface features like road, power trestles, Villages, company/

private quarters etc.

 Other constraints as mentioned in the Chapter-IX

1.7

PROJECT OBJECTIVES & TARGET BENEFICIARIES

The objective of the present report is to augment the coal production from the

mine keeping in view overall demand of better quality coal and better / improved

performance of the mine and higher capacity utilization of the existing resources.

The coal produced from the mine would be included in the basket linkages.

1.8

SALIENT FEATURE OF PRESENT REPORT

The objective of the present report/project is two-fold:

 Production augmentation

 Introduction of modern technology in CCL mines on risk-gain sharing basis.

The present report envisages introduction of Continuous Miner in CCL mines. Churi -

Benti UG project has been identified for introduction of Mass Production Technology.

The basic criteria / requirement as identified are as follows:

(a)

Technology:

Transfer of technical know-how for mechanization of face workings with

introduction of Continuous Miner in underground mining systems to ensure an

average daily production of 1700 -2000TPD from one district / panel.

(b) Production Guarantee on risk-gain sharing basis

Production will be guaranteed for a period of 5 years. The guaranteed

production level will be decided mutually. The mutually agreed production will

be on risk-gain sharing basis, i.e. linked to the production level and cost of

equipment. The contract agreement should include transportation of face coal

up to surface bunker or as agreed mutually.

(c)

Supply of Equipment & Maintenance

As a step for introduction of the technology, the supplier would provide

comprehensive maintenance of the equipment and operational guarantee for

five years at mutually agreed rate of production.

(d) Transfer of Technical know-how

After completion of term of five years the supplier would hand over the

detailed drawings of the equipment and ensure easy availability of the spares.

Maintain office in India to ensure supply of spares.

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(e)

Site Investigation & Scientific Studies

For deployment of continuous miner

Method of development

Method of extraction

Feasibility of mining with CM in contiguous part and other area in Churi UG

(f)

Mine / District Layout

Development & Extraction layout for the mine over a period of 9-10 years and

the proposed panel to match new technology.

(g)

Equipment / Machinery

Detailed requirement of equipment for introduction of the technology.

(h) Infrastructure Requirement

Modifications needed in the existing infrastructure like, transport, ventilation,

electrical layout, workshop, stores, coal handling, etc.

(i)

Manpower

Daily requirement of manpower in the district with their job description.

(j)

Implementation Schedule

Implementation schedule with schedule of transfer of technological know-how,

training of personnel, etc.

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CHAPTER -II

MARKETABILITY & LINKAGE

2.1

Demand & Availability

The demand and availability of Central Coalfields Limited during X^th & XI^th

plan period are as under:

Demand (MT)

End User

No.

2005-06

2006-07

2007-08

2008-09

2009-10

2010-11

2011-12

Existing TPS

31.43

X Plan TPs

2.19

7.11

13.07

14.53

XI Plan TPS

0.00

1.45

4.47

12.81

19.48

22.49

Total Power Utility

33.62

38.54

45.95

50.43

58.77

65.44

66.45

Captive Power

2.77

1.35

Steel

5.50

6.00

6.1

6.20

6.30

6.40

6.50

Cement

0.18

Sponge Iron

0.92

Other sectors

6.84

6.78

6.73

6.68

5.63

6.58

6.53

Total Demand

49.83

55.19

62.65

55.76

74.15

80.87

83.93

Production

40.40

42.00

47.50

52.50

57.80

61.70

367.00

Gap

-9.43

-13.19

-15.15

-13.26

-16.35

-19.17

-16.93

Source: Consolidated coal availability report of CCL, March 2006

The above table reflects that even after achievement of projected additional

production from Churi UG project, there would be enormous gap in coal

availability in CCL. The Augmentation report will help to reduce this gap with

consistent supply of superior grade of coal.

2.2

Linkage

At present coal from Churi U/G project is mainly being sent to various sponge

iron plants. The additional production will be included in basket linkages.

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CHAPTER - III

PROJECT SITE INFORMATION

3.1

LOCATION

Churi-Benti U/G project is located in the South-central part of North Karanpura

coalfield between the latitudes 23^o41'05" and 23^o42'04" and the longitudes

85^o03' and 85^o04'20" covering an area of about 7.68 sq.kms. in Chatra district

of Jharkhand state. It is covered by topo sheet Nos. 73E/2 and 73A/14 (Scale

1"=1 mile) of Survey of India. Saphi River forms the south-eastern boundary

and arbitrary line beyond Fault F11A and along the fault plane of F11A of

Benti Block forms the western boundary of the project. Ray Bachra colliery

and Ashok OCP of Piparwar area is situated to the North / North-east and

Manki colliery (now exhausted) to the south/south- west of Churi project as

shown in the Location Plan (Plate-I). It has two units.

3.2

COMMUNICATION

Churi-Benti UG project is situated at a distance of 8 km on fair weather road

connecting Khalari and Ray railway stations on the Gomoh-Dehri-on-Sone

loop line of the East Central Railway. An all weathered 25 km long road links

Khalari with Bijupara village on the state highway connecting Ranchi and

Daltonganj.The P.W.D. road connecting Khalari and Barkagaon in Hazaribagh

district also passes through the Churi block. CCL Hq. at Ranchi is situated at

a distance of about 73km from Churi UG project.

3.3

TOPOGRAPHY, DRAINAGE AND HYDROLOGY

The topography of the area except in the western part is gently undulating and

sloping towards Saphi and Damodar rivers. The area as per borehole records

and colliery records lies between RL 404.50m and RL 476.80m above Mean

Sea Level. In the western part of the block, adjoining Manki mine, the terrain

is hilly, as few spurs of the Belangi Hill (RL 529.74m) traverse the block.

The average annual rainfall of the area is around 1500mm, most of the

precipitation of which is during the monsoon season with some winter rains.

Damodar and Saphi rivers control the drainage of the area. Water has been

found in some drilled boreholes but there has been no evidence of any water

under positive piezometric head in any of the boreholes drilled in the block.

However, seepage of water has been recorded in the workings of the Lower

Bachra seam through the floor of the seam in Incline No. 2A. A highly porous

and permeable coarse-grained sandstone and conglomerate layer forming the

floor of the Lower Bachra seam appears to be under water pressure and is

being recharged in the outcrop region by the Saphi River.

The High Flood Level of Saphi River as recorded close to the incline mouth by

the colliery authorities in 1976 and supplied to the Exploration Division is

420.95m above the M.S.L. Part of developed working of Churi UG in W7 ,

W8,and W9 panels falls below HFL. One seasonal nala is also passing over

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CHAPTER - IV

GEOLOGY AND DEPOSIT APPRAISAL

4.1

Background

The summarized geological assessment has been prepared from the

following geological reports:

Geological Report on Churi Block, 1977

Supplementary Note on Geology of North-Western part of Churi

Colliery, May 1985.

Geological Report for Benti Block, March 1992.

The approved Feasibility Report of 0.84 MTY was prepared on the basis

of Geological Report on Churi Block, 1977.

4.2

Exploration Status

Churi Block: The exploration in Churi Block was initiated in 1975

and concluded in Jan, 1976. A total of 15 Boreholes (NNKC

1,2,3,6,11,15,

24-32) were drilled along with 5 boreholes (CBH

1,3,4,5 and CHPR) by colliery authorities. In 1983-85, additional 13

boreholes (NNKC 33-36, 40-48) were undertaken in virgin North-

Western part. The data of these 13 boreholes were utilized for

updating the stratum contours of Lower Bachra seam for the virgin

north-western patch of Churi Block. 3 more non-coring boreholes

(NNKC 37,38,39) were also drilled for dewatering and sinking

electrical cables.

In June 1990, 6 (six) boreholes were drilled for proving of structure

and determining the physico-mechanical properties. Subsequently,

CCL drilled 4 (four) boreholes in the eastern part to confirm

continuity of Lower Bachra seam. In 2001-02, 10 (ten) no of bore

holes were drilled by CMPDI for updating of seam plans.

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Table 4.1: Details of Boreholes

Agency

Period/

Series

No.

Meterage

Year

Boreholes

(m)

Before

CBH/CHPR

Nationalisation

CMPDI

75-76

NNKC

1332

CMPDI

8385

NNKC

1236.60

CMPDI

83-85

NNKC

3(Non-

280.75

coring)

CMPDI

1990

NNKC

579.20

CCL

CCPS

365.15

CMPDI

2001-02

CMCPS

918.00

4711.70

The total area of the block is about 5.89 Km² and the borehole

density is 9.5 boreholes/km².

Benti Block: A total of 101 boreholes were drilled over on area of

8.55 km² in Benti Block. Out of the total boreholes, 93 boreholes

were coring and remaining 8 boreholes were partly coring/non-

coring. The borehole density works out to 11.81 bore hole per

square kilometer. The borehole density for the area proposed to be

mined in Benti block (Sector-A) through Churi is

12.7

boreholes/km².

4.3

Geology and Structure of Project Area

4.3.1 The general geological sequence of the North Karanpura Coalfield is as

follows:

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Table 4.2: Sequence of Geological Formation

Upper Gondwana

Mahadeva Formation

Triassic

Panchet Formation

Lower Gondwana

Raniganj

Formation

Permian

Barren

Measure

Formation

Damuda Sub-group

Barakar formation

Karharbari formation

Permo

Talcher formation

Carboniferous

----------------------------------- Unconformity----------------------------------

Gneisses and schists

Pre-cambrian

Of the above, only Karharbari and Barakar formations contain economical

coal seams.

4.3.2 Geological Succession of Churi Block

On the basis of available surface and sub-surface data, following

succession has been established for Churi Block.

Table 4.3: Geological succession in Churi Block

Formation

Broad Lithology

Thickness (m)

Recent

Soil and sub-soil

0.23 (CBH-3) to

12.20 (NNKC-3)

Barakar

Conglomerate,

30.03 (NNKC-27)

sandstone,

alternate

to 84.61 (NNKC-31)

bands of sand stone &

shale, grey shale, fire

clay etc.

Karharbari

Sandstone, fire clay,

20.22 (NNKC-15)

grey

shale,

to 47.42 (NNKC-27)

conglomerate

Upper Bachra seam

0.13 (NNKC-35)

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to 4.84 CCPS-10)

Parting

0.49 (CCPS-10)

conglomerate,

to 20.27 (CCPS-4)

sandstone, alternating

bands of sandstone &

shale, sandy shale,

grey

shale

carbonaceous shale

Lower Bachra seam

1.71 (NNKC-32)

to 11.24 (NNKC-48)

Sandstone & shale

Not drilled

Talcher

Khakhi

green

sandstone, shale &

boulder bed

The Karharbari formation contains two major coal horizons i.e. Upper

Bachra seam and Lower Bachra seam.

4.3.3 Geological Structure

Churi Block: The area presently under consideration in Churi Block lies

between faults F17 & F10. Fault F17 exists in the north-eastern part of the

block where as fault F10 exists in the southern and south-western part of

the block . The throw of fault F17 is about 50m towards north-west in the

northern part which gradually decreases to around 5m near borehole No.

CHPR-57 located on the left bank of Saphi river. The throw of fault F10

varies from 15-25m and the throw is towards north-east. The area

between these two faults is characterized by simple geological structure.

There are three more faults (F11A, F12, F13) in addition to above two

faults which trend almost NW-SE with north-easterly throw of 5 to 13m.

There are four minor slips also F11B, F11, F15 and F18) whose throw

varies from 2 to 5m (Ref. Stratum contour plans).

Of the above faults, F11, F11A, F11B, F12 and F15 have been

encountered in the mine workings while F18 was responsible for omission

of Upper Bachra Seam in NNKC-24. Fault F15 encountered in the mine

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workings was also responsible for omission of Upper Bachra seam in

NNKC-19.

Table 4.4: Details of Faults in Churi Block

Sl.

Fault

Trend

Direction

Amount of throw

Remarks/Evidence

No.

of throw

(m)

F₁₀

NW-SE

7-15m throw

Omission of Lower Bachra seam in

diminishing in SE

CBM-6; also encountered in workings of

direction

south central part.

F₁₁

NW-SE

0-10m dies out in

Encountered in the workings of Lower &

the west

Upper Bachra seam in the south Central

part and seen in the Saphi river.

F11a

NW-SE

N-E

Based on stratum contours.

F11b

E-W

South

Based on stratum contours

F₁₂

NW-SE

Encountered in UG workings.

F_12A

NE-SW

0 to 3m, dies out in

Omission of Upper Bachra seam in

the north

CCPS-3.

F₁₃

NW-SE

8 to 10m

Based on aerial photographs & stratum

contours.

F₁₅

East-

South

Upper Bachra seam omitted in borehole

West

NNKC-19. Minor slips in the workings of

Churi Colliery.

F₁₇

NW-SE

5-50m Reduces

Based on aerial photographs and floor

eastward

contours

F₁₈

E-W

0-4m

Omission of Upper Bachra Seam in

NNKC-28.

The strike within the block is roughly NE-SW in the major part of the area

which gradually swings to almost north-south in the eastern part. The

strike between fault F₁₃and F₁₇ in the north-eastern part has further taken

swing to almost NNW-SSE. The local swings in strike is mainly due to

rolls. The dip of the strata generally varies between 2⁰ & 3⁰ (1 in 20 to 1 in

40) in the major part of the property. However, in the southern part of the

area, gradient gradually increases locally as could be seen from the

stratum contour plans.

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The seam belong to Karharbari formation, which is known to contain

seams with erratic behaviors, therefore, the confidence level of geological

interpretation is comparatively low.

Benti Block: In the Benti Block, only Karharbari formation is coal bearing

having Bachra seam normally in 2 to 4 splits. The Benti block is a part of

the northern limb of Karkatta- Piparwar plunging anticline. The strike in the

northern and south central part is roughly N-S with westerly dip, which

swings to NW-SE in the northeastern corner of the block. The N-S strike of

the northern part swings to almost NE-SW strike before becoming E-W in

the north-western part of the block. The strike again swings to more or

less NE-SW strike in the western part. In sector-‘A’, the strike varies from

N-S to NW-SE and dip ranges from 1 degree to 3 degree (1 in 60 to 1 in

20) due SW to west. In Benti Block, 18 faults have been established.

Table 4.5: Sequence of coal seams & partings in Benti Block

Formation

Seam/Parting

Sector ‘A’ of Benti Block

Thickness range (m)

Minimum

Maximum

Karharbari

Strata between

47.50

62.35

Barakar & Upper

Bachra/Top

Lower Bachra

Upper

Bachra

0.53

0.96

seam

Parting

0.50

1.61

Lower section of

0.40

2.0

Top

Lower

Bachra

Combined Top

3.0

5.10

Lower Bachra

Parting

0.3

3.0

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Bottom

Lower

2.12

4.25

Bachra

4.4

Coal Seams

In the Churi Block, two seams namely Upper Bachra and Lower Bachra

have been encountered.

4.4.1

Upper Bachra Seam

It varies in thickness from 0.13 m (NNKC-35) to 4.84 m (CCPS-10) and is

mostly devoid of any dirt bands. Generally, it is 2 to 3 m in thickness in

major part of area. The seam thickness decreases to less than 1.2m in the

south-western part (NNKC- 26,28, 33, 35, 40, 48) and in the northern part

of the property (NNKC-

43,

44,

49). The immediate roof of UBS is

generally grey shale, sandy shale, conglomerate, medium to coarse

grained sands ton, carbonaceous shale etc. The immediate flor is

predominantly carbonaceous shale and grey shale.

4.4.2

Lower Bachra Seam

It is the bottom most seam having thickness from 1.71m to 11.24m

(NNKC-48) and occurs 0.68m to 20.27m (CCPS-4) below Upper Bachra

seam. The Iso-parting indicates that the parting gradually increases from

3m in the middle of the property to about 18m in the south-eastern region.

In the north-western part, parting varies from 1 to 3m. The thickness

normally varies from 3-5m, which gradually increases to 9m in the western

part near Damodar river.

It has been observed from the seam structure plans that there is generally

a persistent dirt band of carbonaceous shale/grey shale occurring about 2

to 2.5m below the roof. The bottom section of the seam is generally clean

and better in quality than the upper section which is commonly inter

banded and often contains thick shaly coal horizons.

The immediate roof of LBS is carbonaceous shale, grey shale, fine to

medium grained sandstone. Floor is generally grey shale, intercalation of

shale and sandstone, carbonaceous shale, sandy shale and at times by

Job No: 3507127

IV/7

medium to coarse grained sandstone. The summarized range of Analytical

parameters for LBS & UBS is given in Table: 4.6.

Table 4.6: Analytical Parameters for LBS & UBS

Seam

Particula

On 60% RH & 40⁰C

UHV

Grade

Ash%

VM%

(Kcal/kg)

Analysis

Upper

Ex-band

6.4-8.5

17.8-27.6

25.6-27.7

4210-

C-D

Bachra

5420

In-band

5.4-8.0

17.8-30.3

23.2-27.7

3685-

C-E

5420

Lower

Ex-band

7.6-9.4

10.9-25.5

24.1-26.5

4330-

A-D

Bachra

6225

In-band

6.3-9.0

15.9-31.0

21.5-27.3

3640-

B-E

5865

Clean

7.6-9.2

9.0-14.2

23.9-25.3

5755-

A-B

bottom

coal

6610

section

4.4.3 In the Benti Block: Upper and Lower Bachra seams occur.

Upper Bachra Seam:

It occurs in a small patch in sector-A along the eastern block boundary.

This has completely pinched out near the boundary of Benti and Churi

mine. This seam has not been considered in this Report due to low

thickness (<1m). The grade of coal varies from ‘D’ to ‘F’.

Lower Bachra Seam:

The Lower Bachra seam in Benti Block splits into two parts.

Top Lower Bachra seam(TLB), and

Bottom Lower Bachra seam(BLB)

The Top Lower Bachra seam (2 to 5m thick) has again splitted into two

distinct sections designated as:

Upper Section of Top Lower Bachra (UTLB)

ii)

Lower section of Top Lower Bachra ( LTLB)

Job No: 3507127

IV/8

However, both the above upper and lower sections have merged together

in small isolated patches in Sector ‘A’ and designated as combined Top

Lower Bachra( CTLB).

The Bottom Lower Bachra seam has thickness range of 0.24 to 4.18m and

is persistent throughout the property.

4.4.4

Upper section of Top Lower Bachra seam

It is persistent throughout the property as well as in sector-A, except near

the western block boundary where it has pinched out completely.

Thickness : It varies generally from 1.5 - 3.5m.

Dirt Bands: It is normally less than

0.30m in thickness and are

carbonaceous shale in nature.

Roof & floor:The immediate roof is represented by medium to coarse

grained sandstone, carbonaceous shale, grey shale and

conglomerates. The floor is marked by carbonaceous shale,

sandy shale, grey shale, medium shale to coarse grained

sandstone and alternate bands of shale and sandstone.

Quality:

The UHV and grade (In Band) varies from 3105 K.cal/kg (‘F’)

in NNKA-394 to 4955 K.cal/kg (‘C’) in NNKA-65. The overall

grade of coal is ‘D’.

4.4.5

Lower Section of Top Lower Bachra seam

This section is overlain by Upper section of Top Lower Bachra seam after

a parting of 0.50m to 11.33m and pinches out completely in the western

part of the block.

Thickness: It is genrally 1.2 to 2m in the proposed area.

Dirt Bands: The seam is mostly free from dirt bands. It has been found in

only 3 bore holes and is generally less than 0.38m in

thickness.

Roof & Floor:

The immediate roof is represented by carbonaceous

shale, sandy shale, medium to coarse grained sandstone

and alternate bands of shale and sandstone. The floor is

Job No: 3507127

IV/9

normally sandy shale, alternate bands of shale and

sandstone, medium grained sandstone and gray wackes.

Quality:

The UHV and grade (In band) ranges from 4070 K.cal/kg

(‘E’) in NNKA-394 and 5725 K.cal/kg (‘B’) in NNKA-65. The

overall grade is ‘D’.

4.4.6

Combined Top Lower Bachra Seam

The Upper and Lower sections of Top Lower Bachra seam have merged

together in three narrow isolated patches in the sector.

Thickness: The thickness of the combined Top Lower Bachra seam

varies from 1.10m (NNKA-372) to 5.10m (KP-1). The combined seam is

geerally around 4.0m in thickness in the north-eastern patch in Sector-A.

Dirt Bands: The thickness of the dirt bands is less than 0.19m. The dirt

bands have been found in 4 boreholes out of the 15 boreholes.

Roof & Floor:

Immediate roof is generally represented by

carbonaceous shale and coarse to very coarse-grained sandstone. The

floor is marked by the sandy shale, carbonaceous shale and greywacke.

Quality:

The UHV/grade varies from 3285 K.cal/kg (‘F’) in NNKA-375

to 4275 K.cal/kg (‘D’) in NNKA-66. The overall grade is ‘D’ in the Sector’A’.

4.4.7

Bottom Lower Bachra seam

It is the Lower most split of the main Bachra seam.

Thickness: The thickness of Bottom Lower Bachra seam varies from 2

to 4m.

Dirt Bands: The dirt bands are generally carbonaceous shale and grey in

nature. Its thickness is less than 0.30m except in one boreholes.

Roof & Floor:

The immediate roof is coarse to very coarse grianed

sandstone, carbonaceous shale, grey shale and sandy shale. Floor is

represented mostly by sandy shale, alternate bands of shale and

sandstone and carbonaceous shale followed by shale, grey wackes and

coarse to very coarse grained sandstone.

Quality:

The overall grade is ‘B’.

4.5

Geological Reserve

Job No: 3507127

IV/10

Churi Block:The estimated net-in-situ geological reserves in Upper &

Lower Bachra seams is about 36.29 MT.

Benti Block (Sector-‘A’):

The estimated net-in-situ geological reserves in Upper section of

Top Lower Bachra seam and Bottom Lower Bachra seam are 4.171 MT

and 8.697 MT respectively.

The detailed break-up of extractable reserve in Churi-Benti blocks is as

under:

Seam / Section

Churi block

Benti block

Total

Dev.

Dep.

Dev.

Dep.

A. Continuous Miner

Lower Bachra seam (LBS)

0.224

2.979

---

3.203

Bottom Lower seam (BLB)

---

0.464

0.547

1.011

Sub-Total

0.224

2.979

0.464

0.547

4.214

B. Heightening District

Lower Bachra seam (LBS)

0.915

---

0.915

Sub-Total

0.915

---

0.915

C. Bord & Pillar

Upper Bachra seam (UBS)

0.755

2.928

---

3.683

Lower Bachra seam (LBS)

0.242

5.037

---

5.279

Bottom Lower Bachra (BLB)

---

0.521

0.748

1.269

Upper section of Top Lower

---

0.418

0.430

0.848

Bachra (UTLB)

Sub-Total

0.997

7.965

0.939

1.178

11.079

Job No: 3507127

IV/11

CHAPTER - V

PRESENT STATUS OF MINE

5.1

GENERAL

Churi U/G Project is a nationalized project in the North Karanpura Area of

Central Coalfields Limited. At the time of nationalization, Churi old mine was

under operation. Manual development was in progress in LBS & UBS. After

nationalization, a feasibility report for Churi Underground (Re-organization)

was prepared and approved in Feb’82 for a rated capacity of 0.84 MTY with

capital investment of 16.77 Crores. The feasibility report was a combination of

the two mines (Existing and Proposed) with certain common arrangement for

transport, Ventilation and Pumping.

5.2

PRESENT DEVELOPMENT OF THE PROPERTY

The entire property of Churi Block has been developed in stages:

(a)

Churi old (Manual section):

This development is prior to

nationalization of the mine. Both Upper Bachra Seam (UBS) and Lower

Bachra Seam (LBS) have been approached through Incline Nos. 3A, 4A and

1A, 2A respectively and fully developed by Bord & Pillar method of mining

with manual loading. Almost entire property in Churi old mine is standing on

pillars and is available for depillaring. Presently return airway of CRO is

through this Churi old section.

(b)

Churi Underground (Re-organization): The remaining area of Churi

Block is approached through Incline No 6 & Incline no-7as envisaged in the

approved feasibility report (0.84 MTY). The proposed method of mining for

Upper Bachra seam were re-treating Long wall caving with solid blasting &

Manual loading onto AFC and friction prop as support for Thickness 1.2 - 2.0

m and Manual Bord and Pillar for Thickness 2.0m to 4.0m. Whereas for Lower

Bachra seam, the proposed methods were Blasting gallery method with

Jumbo drill and remote controlled LHD for Thickness 4.5m-6.0m & Manual

Bord & Pillar for Thickness 3m-4.5m.

Presently, almost entire area of Lower Bachra is developed by conventional

Bord and Pillar method with LHD and Upper Bachra seam is developed

manually. The development reserve of CRO is near to exhaustion. Almost

Job No.:3507127

V/1

entire property is developed and standing on pillar and is available for

depillaring.

Benti Section: Part of the Benti Block (Sector-A) is annexed to the Churi

Block. This annexed part has been approached by driving 3 nos. of drivages

headings from W-6 panel in the western section of CRO. Presently, Bottom

section of Lower Bachra seam is being developed by Bord & Pillar method

with LHDs (5 nos.). The annexed part to Churi project is beyond the scope of

the approved feasibility report.

Before nationalization, few patches of the Churi Block are also worked

in lower Bachra seam through incline no. 2,3,4 & 5, which is presently

abandoned. The existence of water, fire etc cannot be ruled out in these

abandoned workings.

5.1

PRESENT INFRASTRUCTURE

Churi underground project is an ongoing project. Most of the infrastructure

likes approach road, service buildings and residential buildings for the mine is

already exists. The Churi-Benti Project shall utilize the existing infrastructure.

Various mine development activities like incline drivages (6 & 7 Nos.); Airshaft

and surface coal handling arrangement (5 x 125 Te) have already been

completed.

5.1.1

Existing Underground Coal Transport

The existing UG coal evacuation system in Churi UG project is through a

series of 1000 / 800 mm belt conveyors, which includes trunk conveyors (TB1

to TB4) covering entire length of trunk roadways in Incl. No.7and gate belt

conveyors. Coal from the working face is loaded either manually or by LHDs

on to chain conveyors and Chain conveyors fed it to gate belt conveyors. The

gate belt conveyors feed coal on to trunk belt conveyors, which in turn carries

coal up to surface bunkers. This existing transport system is also for workings

in Benti section.

5.1.2

Existing Men & Material Transport

A direct haulage of 65 KW rating is installed on surface for transport of

material from surface along the Incline no.6 to underground. Thereafter,

endless rope haulages are used to haul the material trollies to the out bye of

the existing panels. Within the panel, endless haulage is also used to supply

material to in bye faces of the panels .

Job No.:3507127

V/2

5.1.3

Surface Coal Transport

Coal evacuated from UG is stored on surface in 5 overhead steel hoppers of

125 Te capacities, which directly loads either on to consumer’s truck or side

dumps on to surface, in case emergency arises.

5.2

PRESENT STATUS & METHOD OF MINING

LBS: Bord and Pillar with LHD (Development almost completed)

UBS: Manual Bord and Pillar (Development is in Progress)

BLB: Bord and Pillar with LHD (Development is in Progress)

Major part of the area is standing on pillars and manual development is being

carried out in upper Bachra seam in the eastern side of the Churi Re-

organization (CRO) and development with LHD is in progress in Bottom

Lower Bachra seam/ Section in Benti Block. .

5.3

EXISTING VENTILATION ARRANGEMENT

At present, exhaust system of ventilation is being followed for ventilating the

workings of mine. Presently, Churi UG mine is an operating mine with two

incline entries (Inc. 6 & 7) on the rise side working as main intake airways and

an air shaft serves as main return airway with a main mechanical ventilator

(PV200 make) installed in the air shaft. The present air discharge through the

main fan is about 50.0m³/s at an operating fan pressure of about 58mm of

WG.

Two standby fans exist, one a Model AF-80 fan in the fan drift parallel to the

existing fan drift and other a Model PV-160 fan in 1A incline. Only the main

fan PV200 make is in operation.

5.4

EXISTING POWER SUPPLY ARRANGEMENT

The existing Churi Reorganization sub-station (2x1MVA, 11/3.3KV) receives

power at 11 KV from old KDH 33/11 KV substation via Dakra sub-station. Out

of these two 1 MVA transformers, one transformer caters the loads of surface

and some underground loads. The other transformer feeds power to different

underground equipment through 3.3 KV overhead lines. which is being tapped

by cables passing through boreholes to underground substation & different

load points.

Job No.:3507127

V/3

5.5

SERVICE & RESIDENTIAL BUILDINGS

The major service buildings like Pit office, cap lamp room, sub-station,

workshop, store, service magazine, Haulage room etc. already exist at Churi

UG Project. However, the existing sub-station, workshop, store need further

strengthening and additional construction of water reservoir, shed etc. on

surface.

The break-up of existing residential buildings at Churi is as under:

Type of Quarters

Existing no of Quarters

MQ(LCH)

910

Barrack

Total

1110

5.6

WATER SUPPLY

The present water supply is from Damodar River, which is fed directly for

consumption. Saphi River is another source of water for water supply to the

colony after treatment. Present system of water supply and sewerage is

sufficient to fulfill the potable and industrial water demand.

5.7

EXISTING MANPOWER

The existing manpower deployed at Churi UG is 905 ( as on 1.1.07). The

details of the existing manpower are as under:

Sl.

Particulars

Existing Manpower

No.

Piece Rated Workers

177

Daily Rated Workers

576

Monthly Paid Staff

130

Executives

TOTAL

905

5.8

LAND ACQUISITION STATUS

Job No.:3507127

V/4

Non-forest land (24 Ha) has been acquired for colony construction. Major part

of the mining area is under forestland, which is yet to be acquired. Total land

for mining is yet to be acquired.

5.9

PAST PERFORMANCE

(a) Production

Year

86-

87-

88-

89-

90-

91-

92-

93-

94-

95-

Prod (MT)

0.156

0.150

0.205

0.228

0.214

0.230

0.240

0.246

0.204

0.226

Year

96-

97-

98-

99-

00-

01-

02-

03-

04-

05-

Prod (MT)

0.236

0.229

0.244

0.233

0.210

0.172

0.175

0.185

0.168

0.161

(b)

Other Existing Parameters of the project

 Selling price/Te

Rs. 1441.00

 Cost price/Te

Rs. 1707.00

 Profit/loss

(-) Rs.266.00

 Manpower (as on 31.3.06) :

945

 O.M.S

0.66

 Production

0.162 MT

Job No.:3507127

V/5

CHAPTER - VI

SALIENT FEATURES OF APPROVED PR

6.1

GENERAL

The Feasibility Report of Churi UG for a rated capacity of 0.84 MTY was

approved by Govt. of India in Feb 1982 for a capital investment of Rs. 16.77

Crs.

The method of work proposed and production envisaged is as follows:

(a)

Upper Bachra seam

 Retreating Long wall caving with solid blasting & Manual loading

onto AFC and friction prop as support for Thickness 1.2 - 2.0 m

 Manual Bord and Pillar (Thickness 2.0m to 4.0m)

(b)

Lower Bachra Seam

 Blasting gallery method with Jumbo drill and LHD (Thickness 4.5m-

6.0m)

 Manual Bord & Pillar (Thickness 3m-4.5m)

( c ) Production Envisaged

* Upper Bachra

0.135 MTY (Long wall Panel )

0.150 MTY (B & P Panel)

Sub-total

0.285 MTY

* Lower Bachra

0.42 MTY (2- Blasting gallery panels)

0.15 MTY ( B & P panel )

Sub-total

0.57 MTY

Total

0.855 MTY ( Approved for 0.84 MTY)

6.2

SUMMARISED DATA

Sl.No.

Technical/Financial

As per Approved Feasibility

Parameters

Report (0.84 MTY)

Name of the Report

Feasibility Report for Churi

Underground

Project

(Re-

organization)

Target Capacity (MTY)

0.84

Seams considered

Upper Bachra seam (UBS)

Job No.:3507127

V/6

Lower Bachra Seam (LBS)

Thickness of Seam

UBS:

0.13 - 4.42 m

LBS:

1.71 - 11.24 m

Seam gradient

1 in 20 ( 2 Deg. to 3 Deg.)

Av. grade

‘C’

Extractable Reserve (MT)

Manpower

1858

O.M.S. (Te)

1.651

Life (Yrs.)

Target Years

1983-84

SPT (Rs./Te)

Rs. 63.26

CPT (Rs./Te)

At 100% target production

Rs.59.92

At 85% target production

Rs. 68.81

Profit/Loss (Rs./Te)

At 100% target production

Rs. 3.34

At 85% target production

(-) Rs. 5.55

Internal Rate of Return (%)

At 100% of target production

7.2 %

At 85% of target production

1.4 %

6.3

SALIENT FEATURES OF DE-RATING-CUM-COMPLETION REPORT

The Derating- cum- completion Report of Churi UG was approved in the 333^rd

Board meeting of CCL on 9.9.2006 at a production level of 0.16 MT. The

Board also directed that a Revised Cost Estimate (RCE) reflecting the

notional approved capital cost vis-à-vis actual expenditure incurred against

the approved items be informed to the Board and the Govt. The RCE for Churi

UG was prepared in Jov.’06 and approved by CCL Board in Dec.’06 and sent

to Govt. of India for its approval. The existing capital expenditure approved by

CCL Board as on 31.3.06 for Churi UG project is Rs. 21.39 Crs.

Job No.:3507127

V/7

Head-wise Capital Investment Approved by CCL Board for De-rating

Sl.

Particulars

As per

Capital

Variance

No.

Feasibility

Investment

Report

(As on

(Feb.’82)

31.3.06)

Land

42.00

79.09

(-) 37.09

Buildings

144.59

248.16

(-) 103.57

Plant & Machinery

1019.94

1508.63

(-) 488.69

Furniture& Fittings

4.44

14.41

(-) 9.97

Railway siding

233.66

24.09

209.57

Vehicles

11.67

19.91

(-) 8.24

Prospecting&

4.10

60.60

(-) 56.50

Boring

Mine Development

Capital outlay in

Mines

Road & Culverts

Water Supply

SR & FR cost

Revenue

expenditure

capitalized

Sub-Total

216.28

184.41

31.87

Total

1676.68

2139.30

(-) 462.62

Approval of RCE for Churi Under ground project from Govt of India is still

waiting.

Job No.:3507127

V/8

CHAPTER-VII

MINE BOUNDARY, RESERVES & MINE LIFE

7.1

SELECTION OF MINING AREA

Existing mine boundaries : The existing mine boundaries of Churi UG mine

covers area lying in Churi mine block and part of Benti block The present boundary

of the Churi UG is as under :

North/North-East :

Adjusted boundary between Ashok OCP (Piparwar

Area) & Churi UG in Benti block and Common

boundary with Ray Bachra UG along fault F17-F17

West

Arbitrary line beyond Fault F11A along the fault F11A

plane and Damodar river

South -East

Saphi river

South/South-West

Common Boundary Between Churi and Manki Colliery

Subsequently, alteration / addition has been done in the approved boundary

(on the northern side) within Churi block as boundary fault (F-13) was not

encountered. However, Ray Bachra UG had encountered a fault (F-17). Hence,

natural extension of the mine boundary of Churi UG was made by adjustment of

common boundary between Churi & Ray Bachra UG mines. Later, after exhaustion

of development reserves in Lower Bachra seam & non-availability of surface land for

depillaring, part of the virgin property lying in Benti block across Damodar river up to

fault F-11A (Sector-A) was also annexed into Churi UG.

While evaluating and finalizing the boundaries of proposed Churi-Benti UG

project, the mining area of existing Churi UG lying within Churi & Benti geological

blocks have been considered

The total area within mine boundary of Churi-Benti UG project is 7.68 Sq.kms

Out of the above Churi block has 5.89 sq. km. of area. Only 2.03 sq km has been

considered for this reporting in Churi Block.. Out of the 1.79 Sq.Kms of the area in

Benti Block ,0.41 sq.kms is considered for CM deployment in Benti block.. The total

area for the Churi -Benti Block for CM deployment is 2.44 sq.kms.

Criteria for selection of mining area for CM: It is now proposed for deployment of

Continuous Miner in the mine on similar specifications, as done in some other UG

mines of CIL. Accordingly, mining area having seam thickness more than 3.0m has

been identified for application of Continuous Miner. Similarly, extractable reserve has

been estimated for workable seam/section thickness up to 4.6m.

The present report has been prepared for augmentation of production by

deploying Continuous Miner (CM) in the Churi - Benti UG project. The area selected

for deployment of CM is the western section of CRO, where Upper Bachra Seam

(UBS) is not workable , few panels in Eastern section of CRO (E12 & E13) and part

of sector-A of the Benti Block having thickness greater than 3.0m. So the extent of

Job No: 3507127

VII-1

working for this report limits only to panels (W1 to W15) in western section of CRO

and few panels in Eastern section of CRO (E12 & E13) of Churi Block and part of

Benti Block only for CM.

The area having thickness less than 3.0 m in Benti Block have been proposed

to work with Low Height LHD in Churi-Benti project. Area having thickness greater

than 3.0m have been proposed to work with Continuous Miner.

Feasibility of extension of project boundary:

The possibility of extension of existing boundary was examined for adding more

reserves for deployment of Continuous Miner. It is not possible to extend the existing

boundary. The possibility of extension of existing boundary in Benti Block up to Fault

F-13 was also examined. Due to presence of link road for Ashok project and existing

Benti nala, the extension of the boundary up to fault F13 is not possible. The colliery

authority has also communicated this.

The existing mine boundary in Benti Block has been taken as project

boundary for the Churi-Benti project.

7.2

MINE BOUNDARIES

The proposed boundary for Churi-Benti UG project is same as existing

boundaries of Churi UG mine.

7.3

EXTRACTABLE RESERVES

The area under the Churi-Benti project falls under the Churi & Benti (partly)

blocks. While calculating the reserves for continuous miner, the following

considerations have been made:

 The area having thickness greater than 3.0m has been considered for CM

deployment. The remaining areas has been considered for conventional Bord

& Pillar development/ Depillaring.

 The virgin patches falling within the proposed CM panels shall be developed

and depillared by continuous miner itself. Its reserves are shown in the table

below.

 The thickness of extraction in development and depillaring for CM has been

considered as 4.6m

 The percentage of extraction has been taken as 65% of coal in standing

pillars

 The development height for B &P working has been considered as 2.4m or

less (actual thickness of the seam after leaving 0.3m-0.5m of coal in roof).

 The extractable thickness for the conventional B & P depillaring has been

taken as 4.0m or less (actual seam thickness).

 Roof coal beyond 2.40m in the developed galleries shall be taken while

depillaring.

Job No: 3507127

VII-2

 Out of total

11.079 M.Te of extractable reserves only 0.939 M.Te of

extractable reserves in Benti Block is considered for B &P development.

Table 7.1: Summary of Estimated Extractable Reserves

Seam / Section

Churi block

Benti block

Total

Dev.

Dep.

Dev.

Dep.

A. Continuous Miner

Lower Bachra seam (LBS)

0.224

2.979

---

3.203

Bottom Lower seam (BLB)

---

0.464

0.547

1.011

Sub-Total

0.224

2.979

0.464

0.547

4.214

B. Heightening District

Lower Bachra seam (LBS)

0.915

---

0.915

Sub-Total

0.915

---

0.915

C. Bord & Pillar

Upper Bachra seam (UBS)

0.755

2.928

---

3.683

Lower Bachra seam (LBS)

0.242

5.037

---

5.279

Bottom Lower Bachra (BLB)

---

0.521

0.748

1.269

Upper section of Top Lower

---

0.418

0.430

0.848

Bachra (UTLB)

Sub-Total

0.997

7.965

0.939

1.178

11.079

7.4

PRODUCTION TARGET & LIFE OF THE MINE

Considering an average productivity of the loading equipment over the life of

the mine, proposed production target from the mine is as under:

Existing production

0.16 MTY

Additional Production

Heightening District

0.15 MTY

(2 Remote Controlled LHDs - 2.7Cu.m.)

Continuous Miner Panel

0.50 MTY

TOTAL

0.81 MTY

Considering the extractable reserves in western section of Churi block, few

panels in Eastern section of CRO (E12 & E13) & part of Benti block and the

production schedule, the life of the mine is expected to be about 11years (including

production built-up & tapering periods).

Job No: 3507127

VII-3

CHAPTER-VIII

MINE ENTRIES

8.1

SELECTION OF MINE ENTRIES

Churi underground(Re-organization) is an on going project. It has been

approached through a pair of inclines (Inc.No-6 & Inc. No-7). Presently the mine is

operating in Bottom Lower Bachra seam in Benti block and Upper Bachra seam in

Churi block with above-mentioned entries. It is proposed to continue with same set of

mine entries for Churi-Benti project. The brief detail of the existing entries along with

their proposed utility is shown in Table 8.1.

For deployment of continuous miner in Benti block (including one of the

existing panel) to enhance production, it is proposed for additional drivages in coal

below Damodar River. It is necessary to make additional drivages at appropriate

location for optimal ventilation system, traveling/ man-riding route, provide approach

for transport of CM package equipment requiring tramming height of around 2.7m,

provide alternative escape route and to make optimal use of existing resources.

It is proposed for drivages in coal to connect panel W-11 (in Lower Bachra

seam, Churi block) along true dip and trunk roadway in Bottom Lower Bachra

seam/section (Benti block) at right angle up to fault F-11A. This will facilitate

formation of self-draining panels on either of the trunk roadway and optimal transport

& ventilation layout of the panels.

Justification for additional Drivages :

The proposed drivages will be second drivages below Damodar River. While

granting permission for the first drivages below Damodar River through W-6 panel,

DGMS has made observation for alternate means of access & egress on other side

of Damodar River. The approach to surface site in Benti block is long and difficult. It

will be difficult to maintain such isolated mine entry. Such isolated place is likely to

give way to illegal activities. Moreover, problem of extremists already exists in this

area. In view of the difficulty of maintaining isolated mine entry, it is better to provide

alternate means of access & egress from underground itself.

Besides, the drivages from the surface would take 3-4 years. Considering

limited reserves and life of mine in Benti block, the drivages may not be economic.

8.2

DIMENSION & PURPOSE OF MINE ENTRIES

The detail of the mine entries & other drivages area are shown in Table 8.1

along with dimension and purpose.

8.3

DETAILS OF STRATA BUNKERS

The brief description of mine entries, underground drivages and other

drivages/strata bunkers is given in Table 8.1.

Job No: 3507127

VIII-1

Table - 8.1: Brief Description of Mine Entries & Drivages

The details of existing entries and other mine drivages to be used for the

project are as follows:

Sl.

Mine entry

X-Section

Length/

Gradient

Approach

Purpose & mode of transport

No.

(Incline/shaft -

(Dia/WxH)

Depth

(From / To)

fitted, if any

No./Name)

(m/m x m)

(m)

Existing Entries & Underground Drivages

CHURI OLD MINE AREA (MANUAL SECTION)

Incline No.1

4.8mx2.8m

200

Surface

Sealed off

toUBS

Incline No.1A

4.8mx2.8m

205

Surface to

Return of LBS

UBS/LBS

Incline No.2A

4.2mx1.8m

Surface

Haulage

toUBS/LBS

(Presently sealed off)

Incline No.3A

4.8mx2.8m

172

Surface

Traveling and intake

toUBS

(Presently sealed off)

Incline No.4A

4.8mx2.8m

167

Surface

Haulage (Coal/material)

toUBS

(Presently sealed off)

Air Shaft

1 (Near

4.26m dia

51.82

Vertical

Surface

Return airway (main fan) for UBS.

Incline No.4A

toLBS

CHURI RE-ORGN. AREA (MECHANISED SECTION)

Incline No.6

4,8m x 2.8m

400

1 in 4

Surface to

Haulage (Material supply) & Intake.

LBS

Incline No.7

4.8m x 2.8m

450

1 in 4.5

Surface to

Coal transport (Belt conveyor),

LBS

Travelling & Intake.

Drivages below river

3.0m x 2.0m

Churi to Benti

Haulage and belt roadway,

Damodar, 3-headings

Block

intake/return airways

(Existing)

CHURI OLD MINE AREA (DEVELOPED & SEALED OFF)

Incline No.2, 3, 4 & 5

Proposed Additional Other Drivages

Drivages below river

4.8m x 3.0m

Churi to Benti

Additional escape route &

Damodar, 3-headings

Block

Ventilation

Strata

Bunker

600t

Vertical

Strata Bunker

(SB1)/Staple Pit

Strata

Bunker

400t

Vertical

Strata Bunker

(SB2)/Staple Pit

Job No: 3507127

VIII-2

CHAPTER - IX

MINING STRATEGY

9.1

CONSTRAINTS IN MINING

The present constraints within the project boundary are summarized as under:

Surface Constraints

(i)

Acquisition of land (Forest/ Jungle Jhari/Tenancy)

(ii)

Power trestles passing over the proposed mining area of Churi block.

(iii)

Rehabilitation of villages/ families.

(iv)

Roads, Damodar & Saphi rivers, nala and HFL over the mining area,

(v)

Existing mine boundary, diverted Benti nala & approach road to Ashok

OC project in Benti block

(vi)

Piparwar rehabilitation site over Benti block

(vii)

Other surface features, like Piparwar GM office, BOC quarters, DVC

sub-station, water filter plant, etc. over Churi block

Underground Constraints

The proposed mining area of the project consists of area under Churi block

and part of area under Benti block (up to existing boundary in sector A). The details

of the underground constraints for the blocks are stated as under :

Churi block

(i)

The development reserve in Lower Bachra seam (LBS) and Upper

Bachra seam (UBS) has almost exhausted.

(ii)

The thickness of Lower Bachra seam to the west has gradually

increased. The average thickness being

5.5 m. In one isolated

borehole NNKC-48 (in the south-west), the thickness has increased to

as much as 11.24m.

(iii)

LBS & UBS are contiguous in major part of the property except in a

small part to the east in Churi old, where the parting is more than 9m.

The parting reduces to as low as 0.47m.

(iv)

Analysis of seam structure of LBS shows presence of bands mostly in

the upper section. Extraction of full seam thickness of LBS may affect

the overall grade.

(viii)

Existing galleries of the developed panels of UBS & LBS has low

development height up to 2.4m.

(ix)

The system of support in the existing developed galleries of the panels

in UBS & LBS is roof bolting.

(x)

Low parting thickness between the seams in major part of mining area

(xi)

Narrow x-section (3.0m x 2.0m) of the approach to Benti block through

3-headings in W-6 panel of Lower Bachra seam (LBS) in Churi block to

Bottom Lower Bachra (BLB) in Benti block below Damodar river.

Benti block

(i)

The upper Bachra seam has not developed over the entire proposed

mining area, except a small part near to Damodar River.

Job No: 3507127

IX/1

(ii)

Lower Bachra seam splits in two parts. Top (TLB) & Bottom (BLB)

sections. Top section further splits in two parts, i.e Upper (UTLB) &

Lower (LTLB) sections. The splits of Top section combines (CTLB) in

some part of the property.

Splitting / merging of the seam/section over the proposed mining area

is observed in Benti block. The property shows presence of irregular

banding of seam/sections. Therefore, it is essential to ensure exact

working over the entire property in the proposed mining area

(iii)

The parting between the seam/section mainly comprises of shale/ carb.

Shale/ sandy shale, which may not be self-supporting and may require

leaving of 0.3-0.5m of coal in roof.

(iv)

Grade of the coal for bottom split (BLB) varies from B - E and top

section (UTLB) varies from D-F.

(v)

The parting between BLB & LTLB/CTLB varies from 0.30-5.0m. In

major part of the area, it is generally less than 1.0m. The parting

between LTLB and UTLB in major part of the area is also less than

1.0m. Hence, entire middle section may be lost either in maintaining

statutory parting of 3.0m between two workable sections or due to its

unworkable thickness.

9.2

GEO-MINING CHARACTERISTICS

The geo-mining parameters of the workable seams/sections in Churi & Benti

block have been summarized in the tables below :

Table 9.1 : Geo-mining Characteristics of mining area under Churi block

Sl.

Parameters

Upper Bachra Seam (UBS)

Lower Bachra seam (LBS)

No.

Area within mine boundary

5.89 sq. km

Mining area considered for CM

2.03 sq. km

deployment

No. of borehole intersections

within mine boundary

Boreholes density (BHs/sq.km)

9.5

General Thickness range (m)

0.13-4.84

1.71-11.24

Depth range (m)

26.21 - 91.00

21.59 - 93.65

Parting (m)

0.47-20.27

Grade of Coal (inband)

C - E

B - E

Present declared grade

Grade ‘B’ Long Flame

Immediate roof

Grey shale, sandy shale,

Carb. Shale / grey shale /

conglomerate, medium to

fine to medium grained

coarse grained sand stone

sandstone

Immediate floor

Carbonaceous shale, grey

Grey shale, intercalations of

shale

shale & sandstone,

carbonaceous shale, sandy

shale

Present Status of mining

Manual B&P development being

Development almost

carried out

completed. Standing on

pillars

Job No: 3507127

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Table 9.2: Geo-mining Characteristics of mining area under Benti block

Sl.

Parameters

Upper section of Top Lower

Bottom Lower Bachra

No.

Bachra (UTLB) / Combined

(BLB)

Top Lower Bachra (CTLB)

Area within proposed mine boundary

2.1sq. km

Existing area

1.79sq. km

Additional area beyond existing

0.31sq. km

boundary ( not considered for this

report)

Mining area considered for CM

0.41 sq. km

deployment

No. of borehole intersections within

proposed mine boundary

Boreholes density (BHs /sq. km)

12.7

General Thickness range (m)

0.45 - 4.15 (UTLB)

0.24 - 4.25

1.10 - 5.10 (CTLB)

Depth range (m)

73.10 - 109.19 (UTLB)

76.27 - 121.68

74.06 - 106.75 (CTLB)

Parting (m)

0.30 - 5.17

(parting between BLB & CTLB/LTLB)

Grade of Coal (inband)

C - F (UTLB)

A - E

D - F (CTLB)

Present declared grade

Grade ‘B’ Long Flame (BLB)

Immediate roof

Medium to coarse grained

Coarse to very coarse

sandstone, carbonaceous

grained sandstone

shale grey shale &

carbonaceous shale, grey

conglomerate

shale & sandy shale

Immediate floor

Carbonaceous shale, sandy

Sandy shale, alternate

shale, grey shale, grey wacks,

bands of shale &

medium to coarse grained

sandstone, carbonaceous

sandstone & alternate band of

shale, grey wacks, coarse

shale & sandstone

to very coarse grained

sanstone

Present Status of mining

Virgin

Initial B&P development

by LHD being done

9.3

SELECTION OF MINING METHOD

Existing Mining Method

The entire property in Churi UG project is almost developed along the floor in

both Upper Bachra & Lower Bachra seams except few virgin patches in UBS.

The parting thickness over the entire property of Churi UG mine varies from

0.47m to 20.27m.

The property lying between the parting ranges of 0.47m to 9.0m falls under

the contiguous condition. Therefore, the entire property of the mine has been

classified into two categories i.e. contiguous property & Non-contiguous

property.

In the discussions held at CMPDI HQ, it was decided to deploy Continuous

Miner in the areas free from workable thickness of UBS and having parting

(between UBS and LBS) greater than 9 m. This area lies west to the main dip

in the CRO and few panels of eastern section of CRO.

Job No: 3507127

IX/3

Subsequently, in the review meeting, chaired by CMD, CCL on 16.09.2006 at

N.K area office, it was decided to deploy CM in the western section of CRO

only. The remaining area i.e. eastern section of CRO & Churi old section shall

be worked later on by any other suitable method. It was also advised that CM

should first be utilized for development in any virgin patch of the mine to gain

experience. Accordingly, the working strategy has been formulated.

PRESENT PROPOSAL

The property lying in the western section of CRO, panel E12 & E13 and part

of Benti Block has been considered for deployment of CM. The extractable

reserve for CM in the above mentioned area has been estimated 4.214 MT.

FUTURE POTENTIAL FOR CM DEPLOYMENT:

Eastern section of Churi Re-organization and Churi Old section.

Both the seams are almost developed and standing on pillars in the eastern

section of CRO and Churi old mine. The extractable reserves of about 8.9 MT

may be available for depillaring. The details of the reserve are given in

Chapter-IV. But this requires scientific investigation for parting stability to work

both the seams independently. The major portion of the above-mentioned part

is contiguous in nature.

9.4

SELECTION OF MINING METHOD

9.4.1

Introduction of Mass Production Technology

The various methods of Mass Production Technology are as follows:

(i)

Blasting Gallery Method

It is suitable for depillaring of thick coal seams. The optimum thickness

of seam for this method is at least 8.0m. The area having seam thickness

more than 8.0m in Churi UG is in a very small patch. Rest part of the area is

having thickness less than 8m and also has overlying Upper Bachra seam

having workable thickness with low parting. To work Upper Bachra seam, a

minimum parting of at least 3.0m has to be maintained. To maintain a parting

of 3.0m or more, the effective thickness of extraction in Lower Bachra seam

will further get reduced. If full thickness is extracted in Lower Bachra Seam,

the Upper Bachra Seam will not be extractable. Contiguity of seams exists in

a considerable part of the property. The average seam thickness of LBS is

around 5.5 m. Even if it is considered for extraction of reduced seam

thickness in LBS (<8m), it will not be suitable for the exploitation of both the

seams. Analysis of seam structure shows that seam/ section comprises of

multiple bands and generally band exists beyond 4.0 m. Therefore, if the

extraction will be done by Blasting gallery methods, the grade of the seam will

fall down at least by one grade due to presence of multiple bands in upper

section of the seam. The project may not be economically viable on reduction

Job No: 3507127

IX/4

of grade from the declared grade’B’. Hence, this method has not been

considered.

(ii)

Longwall Method

As both the seams are almost developed on Bord & Pillar method and

balance virgin reserve is not sufficient for longwall mining. So, this method

has not been considered.

(iii)

Working in Double Sections

Churi -Benti project is planned for the area where upper seam is not workable.

Only lower seam (LBS) is workable having average thickness of 5.5m. Double

section workings may be considered for the eastern section of CRO. Double

section workings may be considered later on.

(iv)

Depillaring with Continuous Miner

This method has been successfully used in Indian mining conditions.

Experience in zero seam of Anjan Hill Mine of SECL and Tandsi Underground

mine of WCL is encouraging. The geological conditions of both the mines are

almost similar to that of Churi UG. The only difference is that Churi

Underground project is developed along the floor of the seam having

development height of 2.4m.and bolted galleries. The proposed area for CM

deployment consists of Western section of CRO and part of the Benti block.

The proposed area for CM deployment shows overlying seam/ section

unworkable and is suitable for deployment of CM. The area proposed in Benti

is virgin. Development and depillaring of property in Benti will further help in

gaining confidence for CM operation. Hence, this method may be adopted for

depillaring of developed pillars of western section of Churi Reorganization and

for development and depillaring in Benti block.

9.4.2

Reasons for Selecting Continuous Miner

Continuous Miner has been selected for development of virgin property

in Benti block and depillaring of developed pillars in Churi UG project.

The reasons for selection of this method are as follows:

Churi UG has been developed on Bord & Pillar method. It has a flat

gradient (2-3 degree) and the av. thickness of seam is 5.5m.

Benti block is almost virgin. Seam thickness, gradient and declared

grade are favorable for CM deployment.

Benti Block has been already approached through W-6 panel.

The working panel can be isolated quickly from goaf area as the rate of

extraction is faster.

The proposed method is flexible and does not require large

geologically undisturbed patches as in the case of longwall mining. In

Churi UG, the developed workings are almost free from any geological

disturbances.

Job No: 3507127

IX/5

This method requires relatively low capital cost for high production and

productivity in comparison to longwall method.

The rate of extraction of this method is high and the method has been

proved successful in Anjan Hill/ NCPH mines and Tandsi mines of

SECL and WCL respectively.

9.5

MINE DEVELOPMENT/DEPILLARING STRATEGY

9.5.2 PROPOSED MINE DEVELOPMENT STRATEGY

The broad mining strategy proposed for implementation is briefly described as

under :

Delineation of Mining Area (for CM)

(i)

The mining area having seam thickness >3.0m and unworkable overlying

seam/sections and/or free from workable seam/sections shall be worked with

Continuous Miner.

Accordingly, virgin area in Bottom Lower Bachra seam/section of Benti block,

developed panels of western section of CRO (panels W1 -W15) and E12 &

E13 panels of eastern section of CRO have been considered for deployment

of Continuous Miner.

(ii)

Virgin patches falling within the developed panels in LBS in Churi-Benti

underground project are proposed to be developed and depillared by

Continuous Miner.

(iii)

No working has been proposed in the areas having thickness less than 2.0m.

If any doubt arises regarding the thickness of the seam in the proposed area

by different suggested method, the same may be verified by putting some

extra exploration boreholes. Provision for exploratory boreholes have been

made in this report.

IV.

The assessment of reserves for continuous miner panels has been done on

the basis of CM deployed in some of the mines CIL with operating height

limited to 4.6m, thereby leaving some coal in roof in western section of CRO.

Efforts should be made while finalizing the technology for implementation to

maximize the recovery/extraction.

Heightening and Widening of Galleries

Existing galleries of developed panels in western section of CRO except W-16

panel is proposed for heightening. No heightening is proposed in Benti

section.

The existing Churi underground mine is developed along the floor in both the

seams having height of working 2.4m and width of gallery is 4.2m. The

Job No: 3507127

IX/6

approved and available Continuous Miner, presently operating in CIL mines,

is available for 4.6m heights. So the existing developed workings, wherever

feasible, are to be heightened up to 4.6m and it shall be re-supported with

roof bolting. The blasted coal will be loaded by Remote controlled LHDs.

Provision for the same has been made in this report.

The workings of heightening shall be kept sufficiently ahead of

Continuous Miner panels so that working of CM is not affected.

Adjustment of mine boundary.

As colliery authorities communicated us that further extension of boundary up

to fault F-13 is not possible and existing boundary in Benti should be

considered as the final boundary. So, property beyond the existing boundary

in Sector-A of Benti block has not been considered for this report

Additional Approach to Benti block by crossing below Damodar River:

It is proposed to first deploy the CM in Benti block for development and

depillaring of BLB seam/section. This requires crossing of Damodar River by

driving 3 headings from panel W-11, to facilitate the transport of CM package

equipment and effective ventilation system of the project. The existing

headings for approach to Benti block through W-6 panel has effective x-

section of 3.0x2.0m, which may not be adequate for CM transportation

The heightening of existing headings below Damodar River from panel W-6

may not be practically feasible. Hence, it is proposed to re-cross Damodar

river from panel W-11 with limited number of headings of adequate x-cross

section after taking permission from DGMS.

Strategy for remaining area

(i)

It is proposed to develop and depillar simultaneously the remaining area of

Benti block in two sections having thickness less than 3.0m by Bord &

Pillar method with low-height LHDs.

(ii)

It is also proposed to develop and depillar simultaneously the remaining

property in eastern section of CRO and Churi old in two sections by B & P

with LHD or any other suitable method.

Sequence of operation for B & P working

 The existing LHD panel will continue in Benti Section for Bord and

Pillar development of trunk heading (T-2) up to dip most point.

 After development of trunk heading (T-2) , the development of BLB and

UTLB shall be done in those panels where CM cannot be deployed.

 The existing manual development in UBS will continue for development

of the remaining virgin reserves in UBS in CRO.

 The manual workings shall be phased out before arrival of CM

package.

Job No: 3507127

IX/7

 After exhaustion of development and depillaring reserves in Benti block

and heightening reserves in western section of CRO, the equipment

deployed there may be utilized for depillaring of the developed pillars in

remaining panels of eastern section of CRO and Churi old.

Sequence of operation for Continuous Miner

 It is proposed to first deploy the CM in Benti block for development and

depillaring of BLB seam/section.

 After development and depillaring of proposed area by CM in Benti

block, the CM is proposed to be deployed in western section of CRO

for depillaring of standing pillars in W1-W15, except W6. Depillaring of

W6 panel is not proposed till complete exhaustion of reserves in Benti

block.

 Deployment of Continuous Miner may be done in the dip most panels

in western section of CRO (leaving W-6 & W-16 panels) and panel E-

12 & E-13 in eastern section of CRO. The sequence of deployment of

CM may be changed as per the operational requirement at that time of

the project to facilitate the safe operation.

 After exhaustion of reserves in Benti block and western & eastern

(panels E-12 & E-13) sections of CRO, the remaining property under

Churi block may be depillared simultaneously with LHD in both the

seams.

Depillaring of panel W6 is possible only after complete exhaustion of reserves

in Benti block.

Phasing out of manual system of mining

The B&P development reserves for UBS are nearing exhaustion. Hence, it is

proposed to phase out the manual Bord & Pillar district for CM panel.

Strategy for coal evacuation

 The existing belt lay out will be strengthened by replacing the existing

drive heads etc.

 For coal evacuation from Benti, the proposed evacuation route will be

through W-6 Panel. The trunk belt layout will be in Inc. no.7, W-6 panel,

T1, T2, T3 panel of Benti block. Gate belt layout shall be in panels

where CM and LHDs are proposed to be deployed.

 After exhaustion of reserves for the continuous miner in Benti block,

the trunk belt of T1, T2 & T3 panel may be re-utilized for laying beyond

W-6 panel to cater need of continuous miner in Churi CRO.

 The existing belt will cater the need of heightening districts in western

section of CRO till the life of CM in Benti block.

Job No: 3507127

IX/8

Re-organization of Ventilation System

It is for re-organization of ventilation system considering the high resistance of

the existing mine. It is for opening of trunk roadways of old Churi section for

establishing return airway path. Further, the existing approach to Benti block through

W-6 panel is proposed to be used as intake airway while the additional approach

proposed through W-11 panel is to be used as return airway.

Land acquisition for the project

The land acquisition for the project is proposed for one complete life cycle of

continuous miner as decided during presentation of Production Augmentation

report before the FDs of CCL on 5.12.06.The provision for the same has been

made in the report.

9.5.2

Utilization of Existing Resources

(i)

Presently, there are 5 nos. of LHDs. For heightening & widening of developed

galleries in the western section of CRO, 2 remote controlled LHDs has been

proposed. The existing LHDs may be gainfully utilized for development in

Benti Block. Low Height LHD will replace the existing LHDs.

(ii)

Existing transport layout and mine infrastructure shall be utilized after

modification as per Supplier’s requirement to suit Continuous Miner

technology.

(iii)

W-6 panel of LBS in western section of CRO shall be left intact and

maintained to facilitate the approach to Benti UG, which is presently being

developed after crossing the Damodar River from this panel.

(iv)

In addition to above, other existing resources may also be utilized as and

when required.

9.5.3

Prior Permission from DGMS

Prior permissions from DGMS is required for the following:

(i)

Heightening and widening of existing developed galleries in LBS for

deployment of Continuous Miner in CRO.

(ii)

Permission for development and depillaring of B&P panel with Continuous

Miner.

(iii)

Working below any surface features such as nalla, road, water reservoir, fire

etc. These surface features include all the features, which may endanger the

safety of mine.

(iv)

Permission for Continuous Miner deployment shall be sought in consultation

with the Supplier.

In addition to above, routine mining operations, which require prior permission

from DGMS and other permission for safe working has also to be obtained.

9.5.4 Scientific Study

The technology suggested for depillaring of Lower Bachra seams by

continuous miner in CRO is a new concept in CCL. It has been successfully

Job No: 3507127

IX/9

deployed and worked in SECL and WCL. It requires some scientific study in

consultation with the bidder for safe working of the mine.

This scientific study may be conducted to:

(i)

Ascertain the hydro-geological regime, since the property proposed for

working is bounded between two rivers namely, Saphi and Damodar.

(ii)

Ascertain the connectivity of Churi UG working with any potential source of

danger, which may endanger the safety of the mine.

(iii)

Ascertain the connectivity of fault etc. to rivers or any other water bodies.

(iv)

Ascertain the support requirement for depillaring with CM.

In addition to above, any activity, which requires verification and may

endanger the safety of the mine, shall further be confirmed by the scientific study as

and when it is required.

9.6

MINE DEVELOPMENT ACTIVITIES

9.6.1 Proposed Mine Development Activities:

The following other developmental activities have to be completed:

 Acquisition of surface land (forest/tenancy).

 Rehabilitation of villages & shifting of power line.

 Heightening of existing haulage roadway (Incline no:6) for underground

transportation of Continuous Miner package.

 Heightening/widening of existing developed galleries of the working

panels in western section of CRO.

 Strengthening of existing coal evacuation system by belt conveyors.

 Drifting required for construction of Underground Strata Bunkers of

adequate capacity.

 Arrangement for storage & supply of clean water for Continuous Miner

operation.

 Construction of main sump of adequate capacity with arrangement for

cleaning.

 Strengthening of existing electrical supply system at surface &

underground power supply arrangement for CM package.

 The existing 37 KW endless haulage for material transport is to be

replaced by 90 KW.

Job No: 3507127

IX/10

CHAPTER - X

METHOD OF WORK

10.1 METHOD OF DEVELOPMENT

The whole property of Churi Underground mine has been developed in stages

and their present status are as follows:

CHURI BLOCK:

Churi Old (Manual Section) : Developed fully by Conventional B&P

with drilling, blasting and manual loading into tubs with rope haulage transport

in both the seams. Presently workings are isolated except few headings for

return airway.

Churi Old (Sealed Off): In this part of the property only Lower Bachra

seam is worked which is developed and depillared in distant past by

Conventional Bord & Pillar method and presently sealed off. It falls beyond the

proposed mining area for Churi-Benti UG Project (greater than 150m from

proposed boundary). The presence of water / fire cannot be ruled out.



Churi Re-Organization(CRO) Section : Mechanized development of

Lower Bachra seam by LHD with LDCC/MDCC and Gate Belt Conveyor

transport system whereas Upper Bachra seam is developed manually.

Development of LBS in CRO section is almost complete except in patches,

which requires conformity of thickness by putting extra exploration boreholes.

Upper Bachra Seam is partly developed and partly virgin which has to be

developed by the Conventional Bord & Pillar method of mining. Depillaring of

seams in CRO and Churi Old has not been done in any of the seams due to

non-availability of land.

BENTI BLOCK:

Benti Section: Presently development with LHD is in progress in the Bottom

lower Bachra seam/section after crossing the Damodar River through W-6

panel in CRO.

10.1.1 PRESENT MINING METHOD & MINE DEVELOPMENT

The status of the seams being worked is as under:

(i)

Upper Bachra (UBS)

-B & P Development in progress.

(ii)

Lower Bachra (LBS)

-Almost fully developed by B&P.

(iii)

Bottom Lower Bachra (BLB) -B & P Dev. is in progress in Benti block

In Churi Block, both the seams namely lower Bachra & Upper Bachra are

almost fully developed by Bord & Pillar method of mining. Lower Bachra seam

Job No: 3507127

X/1

has been fully developed with LHD in CRO & manually in Churi old Section of

Churi block. Upper Bachra seam is being developed manually in CRO. The

UBS has also been developed manually by B & P method in Churi old mine.

Part of the property of Upper Bachra seam in CRO, is still to be developed,

which is in progress.

The Churi UG project is developed along the floor of the seam in both the

seams. The size of pillar is 25x25m centre-to-centre and size of gallery

4.2x2.4m (in LBS) & 4.2x1.5-2.0m. Depth of working for UBS and LBS varies

from 18-91m & 37-93m respectively. The dip of the coal bearing strata

generally varies from 1 in 20 to 1 in 40 (2⁰-3⁰), generally towards northwest.

In Benti Block, major part of the property is virgin. Development of Bottom

Lower Bachra seam/section is in progress by LHD along the floor of the seam.

The size of pillar is 25x25m centre-to-centre and size of gallery 4.2x2.4m (in

BLB).

10.1.2 Trunk Road Development

At present Churi Old and CRO have separate set of trunk roadways in each

section along the mine entries. The trunk roadways (in each section)

comprises of 4-6 headings. Trunk roadways have been driven up to the

adjusted boundary between CRO and Ray-Bachra underground mine in

Lower Bachra Seam.

Trunk headings development in Churi old mine has been done up to 47^th

level. The present length along the trunk roadway up to extreme point in CRO

is more than 2.5km whereas in Churi Old mine is about one km. The method

of trunk roadway development in CRO is mechanized Bord & Pillar with LHD

whereas in Churi old mine it is manual Bord and Pillar. At present drivage of

trunk roadway is complete in both the seams and sections of workings (CRO

& Churi old). Benti block has been approached through W-6 panel in CRO

with 3 headings. Trunk heading development is in progress with LHD in

Bottom Lower Bachra seam/section.

10.1.3 Panel Development and Extraction

The panel layout in CRO and Churi Old consists of 5-6 headings, except few,

in both the seams/sections. The panels have gallery size of 4.2x2.4m & size

of pillar is 25x25m center-to-center. In few cases, the size of pillar may be of

lesser dimension. The seam thickness of Upper Bachra Seam varies from

1.2m to 4.0m whereas the seam thickness of Lower Bachra seam varies up to

11.24m (visual thickness) as in NNKC-48. The panels in Churi block are

generally developed up to the boundary of the mine but in some cases it has

not been developed up to the boundary due to thickness problem or practical

operational difficulties at that time. The panels are developed generally with

2.0-2.4m height of extraction leaving 0.5-0.6m solid coal in roof against

immediate shaly roof.

Job No: 3507127

X/2

10.1.4 Existing Transport

Presently the mode of transport of coal from face to surface is as follows :

(a)

SDL/LHD feeds coal to face conveyor/medium duty chain conveyor

and then to Gate Belt Conveyor and brought to surface by trunk belt

conveyor and then fed to CHP at Ray Siding.

(b)

Material transport from surface to underground is through incline No.6

by direct rope haulage and endless haulages.

(c)

Coal from manual district is directly loaded manually onto face

conveyors which feeds to the gate belt conveyor and finally to trunk

belt conveyor for transport up to surface.

10.1.5 Existing Ventilation

The mine is categorized as Degree-I in gassiness. The ventilation system

comprises of Incline 6 & 7 as intake and air -shaft and Incline 1A as the return

for the Upper Bachra, Lower Bachra and Bottom Lower Bachra seam/section.

One PV-200 type Fan is presently installed to serve the ventilation

requirement of the mine.

10.1.6 Existing Support System

The existing practices of roof support in the workings of Churi & Benti blocks

are roof bolts with W-strap as per approved SSR from DGMS. It is also

supplemented with conventional support as and when required.

10.1.7 Existing Production:

The present production from Churi UG is from Upper Bachra in CRO and from

Bottom Lower Bachra in Benti Section. The mine is presently producing

around 0.165MTY with mechanized as well as manual districts.

10.2 PROPOSED METHOD OF WORK

The suggested method of extraction for the Churi-Benti project comprises of:

 Bord & Pillar development & depillaring with Continuous Miner

 Bord & Pillar development & depillaring with low height LHD

 Heightening of existing galleries with remote controlled LHD.

10.2.1 BORD & PILLAR DEVELOPMENT & DEPILLARING WITH CONTINUOUS

MINER

The Continuous Miner will be deployed for development and depillaring of virgin

reserves in Benti block (Panel B-5 to B-9 & T-3). Subsequently, it will be shifted in

Churi Block for depillaring of panels W-1 to W-15 in the western section of CRO and

panel E12 & E13 of eastern section of CRO. The virgin patches within the panel are

also proposed to be developed and depillared by Continuous Miner.

Geo-mining Parameters: The geo-mining parameters of the area proposed

for deployment of Continuous Miner is briefly stated below:

Job No: 3507127

X/3

Table 10.1 : Geo-mining Characteristics of mining area under Churi

block

Sl.

Parameters

Upper Bachra Seam (UBS)

Lower Bachra seam (LBS)

No.

Area within mine boundary

5.89 sq. km

Mining area considered for CM

2.03 sq. km

deployment

No. of borehole intersections

within mine boundary

Boreholes density (BHs/sq.km)

9.5

General Thickness range (m)

0.13-4.84

1.71-11.24

Depth range (m)

26.21 - 91.00

21.59 - 93.65

Parting (m)

0.47-20.27

Grade of Coal (inband)

C - E

B - E

Present declared grade

Grade „B‟ Long Flame

Immediate roof

Grey shale, sandy shale,

Carb. Shale / grey shale /

conglomerate, medium to

fine to medium grained

coarse grained sand stone

sandstone

Immediate floor

Carbonaceous shale, grey

Grey shale, intercalations of

shale

shale & sandstone,

carbonaceous shale, sandy

shale

R.M.R

47.3

41.72-61.0

10.2: Geo-mining Characteristics of mining area under Benti block

Sl.

Parameters

Upper section of Top Lower

Bottom Lower Bachra

No.

Bachra (UTLB) / Combined

seam (BLB)

Top Lower Bachra (CTLB)

Area within proposed mine boundary

2.1sq. km

Existing area

1.79sq. km

Additional area

0.31sq. km

Mining area considered for CM

0.41 sq. km

deployment

No. of borehole intersections within

proposed mine boundary

Boreholes density (BHs /sq. km)

12.7

General Thickness range (m)

0.45 - 4.15 (UTLB)

0.24 - 4.25

1.10 - 5.10 (CTLB)

Depth range (m)

73.10 - 109.19 (UTLB)

76.27 - 121.68

74.06 - 106.75 (CTLB)

Parting (m)

0.30 - 5.17

(parting between BLB & CTLB/LTLB)

Grade of Coal (inband)

C - F (UTLB)

A - E

D - F (CTLB)

Present declared grade

Grade „B‟ Long Flame (BLB)

Immediate roof

Medium to coarse grained

Coarse to very coarse

sandstone, carbonaceous

grained sandstone

shale grey shale &

carbonaceous shale, grey

conglomerate

shale & sandy shale

Immediate floor

Carbonaceous shale, sandy

Sandy shale, alternate

shale, grey shale, grey wacks,

bands of shale &

medium to coarse grained

sandstone, carbonaceous

sandstone & alternate band of

shale, grey wacks, coarse

shale & sandstone

to very coarse grained

sanstone

Present Status of mining

Virgin

Initial B&P development

by LHD being done

Job No: 3507127

X/4

Mining Parameters for CM Panel

No. of Headings

4-8

Gallery width

4.2m

Development height

2.4m(Already developed)

4.6m(where heightening proposed)

Pillar Extraction height

2.7m - 4.6m

Av. Pillar size

25 x 25m center to center in UBS & LBS.

(Size varies within the panels)

Panel width

79.2m - 179.2m (In Churi Block)

125m - 150m (In Benti Block)

Panel length

Up to 1000m in both blocks

Cut out distance for CM

15m in split

(assumed)

10m in Slices

Cutting width

3.3m

Panel Development

CHURI BLOCK

Most of the panels in Churi block are almost developed. Panel formation has been

done by considering existing panel barriers, which shows panels of 4 to 8 headings.

The av. pillar size is 25m x 25m centre to centre with a gallery width of 4.2m. The

virgin patches falling within the panels are proposed to be developed and depillared

by CM itself.

BENTI BLOCK

Major part of the Benti block is virgin. Five headings panel has been proposed for

development and depillaring. The proposed pillar size is 25m x 25m centre to centre

with a gallery width of 4.2m or 4.8 m. The proposed development height for Low

Height LHD panels is 2.4 m or actual seam thickness after leaving 0.3m to 0.50m

coal in roof and 4.6m for CM development district. Proposed width of galleries for

CM development panels are 4.8m.

Development height and Horizon - The existing average height of development in

Upper Bachra, Lower Bachra, Bottom Lower Bachra and Upper Section of Top

Lower Bachra seam/section proposed to 2.4m or seam thickness leaving 0.3 to 0.5m

coal in the roof to provide additional support to the immediate shaly roof. The seam

has been proposed to develop along the floor of the seam.

LOW HEIGHT LHD PANEL

Pillar Size

: 25m x 25m ( center to center)

Gallery Size

: 4.2m

Development Ht

: 2.4m or actual seam thickness after leaving

0.3m to 0.5m coal in roof

Depillaring Ht

: Actual seam thickness

Job No: 3507127

X/5

CONTINUOUS MINER PANEL b

Pillar Size

: 25m x 25m ( center to center)

Gallery Size

: 4.8m

Development Ht

: 4.6 m or actual seam thickness after leaving

0.3m to 0.5m coal in roof

Depillaring Ht

: 4.6m or Actual seam thickness

Method of Pillar Extraction

Method of extraction would be depillaring with caving. There are many

methods of pillar extraction by continuous miner like:

 NAVID METHOD

 CHRISMAS TREE METHOD

 POCKET AND FENDER METHOD and

 Other methods

The sketches of the above methods are enclosed in this chapter. However the

method of work will be finalized after scientific study for the project .Out of the

above-mentioned methods POCKET AND FENDER METHOD has been

successfully tried in some other mines of CIL .The brief description of the

above method is as under.

The method of extraction of pillars comprises of the following:



Splitting and Slicing of the pillar.



Line of extraction.



Extraction height and horizon.



Manner of extraction.



Sequence of operation in Pillar extraction.

Splitting and Slicing: The existing developed pillar shall be splitted into two

parts by driving a roadway of 6.6m width parallel to pre developed rises and

perpendicular to the face line at the centre of pillar. The height of the splitted

gallery may be 4.6m.

The existing size of pillar is 25m x 25m in which two slices in each fender may

be possible. The width of one slice may be 6.6m and the width of other slice

may be 3.3m. The height of extraction in slices may be 4.6m.

As the method suggested for depillaring is totally new for CCL, so the width

and height of split and slices may change depending upon the method of

extraction. The above width & height of splits and slices are proposed as per

the method being practiced in SECL.

Line of Extraction: The pillars in a depillaring panel will be extracted while

retreating from boundary, maintaining a straight line of extraction. The

straight-line method with fully mechanized equipment has several advantages

over the diagonal line of extraction as it reduces both the tramming distance

and cable length.

Job No: 3507127

X/6

Extraction Height and Horizon: The extraction height in pillar shall be up to

4.6m and it shall be worked along the floor of the seam.

Manner of Extraction: It is proposed to introduce one fully mechanized Bord

& Pillar district using Continuous Miner and Ancillary equipments in Churi -

Benti Project for development and depillaring of Lower Bachra and Bottom

Lower Bachra seam/section. The Continuous Miner will develop virgin

property in Benti block (Thickness >3m) with pillar size 25mx25m and gallery

size 4.8mx4.6m. The developed pillars of the Churi-Benti Project will be

depillared by the CM up to 4.6m height or actual seam thickness.

The manner of extraction would be splitting and slicing, which is common in

the mines of CIL. The mine management and the work force are familiar with

the method and the subsequent strata behaviour. The pillars in a depillaring

panel will be extracted while retreating from boundary, maintaining a straight

line of extraction. There may be several methods/layout for depillaring in a

panel. A tentative layout for depillaring by C.M. is indicated in sketches 1 to 4.

Keeping in view the extraction system/layout being followed in other mines of

CIL with CM, one of the suggested method may be “Pocket and Fender

Method”. In this method, the sequence of extraction may be as under:

A split roadway of suitable width is to be developed parallel to pre-developed

rises and perpendicular to the face line at the center of the pillar. It will form

two fenders and the fenders so formed shall be extracted by making inclined

pockets into that fender at an angle of 60⁰ to the horizontal. These inclined

pockets are made at a particular distance from the side of the pillar to form a

snook that will provide temporary stability to the workings and later on it will

get crushed and helps in regular caving of the roof. While making fenders, the

roadway shall be supported with bolts in a manner specified in the approved

systematic support plan.

The coal cut by the Continuous Miner shall be collected by the gathering arm

of the machine and discharged into Shuttle Cars. The shuttle car feeds the

coal by a Chain Conveyor installed in its body, to a self-propelled Feeder

Breaker. Coal is then discharged to the surface through a series of gate &

trunk belt conveyors.

It is proposed to shift the surface features like villages, roads, power trestles,

private/company quarters, sub-station etc.

Before going for development/depillaring of panels with CM in Churi-Benti

Project, prior permission under Reg. 100 of CMR, 1957 have to be obtained.

Similarly, various public works like road, high tension line etc. passes over the

lease hold property of Churi Block. So before going for depillaring, the

permission under regulation 105 of CMR, 1957 would also have to be

obtained and should be complied effectively.

Job No: 3507127

X/7

Sequence of Operation : The sequence of operation of Continuous Miner for

“Pocket and Fender Method” has been shown in Sketch-2. The details of

sequence of operation of the seams shall be as below :

Cut 1 is driven in a split up to a maximum distance of 15m or as

permitted by DGMS.

The Continuous Miner is trammed to Cut-2 in second split of a pillar

and commences cutting while the Roof Bolter Machine supports Cut-1.

Once the CM completes Cut-2 and Roof bolting is completed in Cut-1,

CM commences Cut-3 (in first split) operation.

When Cut-3 in 1^st split shall be in progress, the roof bolter shall support

the Cut-2.

As the Cut-3 is completed and roof bolter supports Cut-2, CM will again

be trammed to 2^nd split for Cut.4.

When Cut-4 in 2^nd split shall be in progress, the roof bolter shall

support the Cut-3.

When Cut-4 is complete and Cut-3 is supported by the roof bolter, then

CM shall be trammed to first split to take the slice-5 in the fender and

Cut-4 shall be supported by the roof bolter.

This process shall be repeated as shown in sketch.

In addition to above, other method of extraction like Navid method, Christmas

tree method are also available. Final method of extraction may be finalized

after detailed scientific study for deployment of CM.

Support System

Support system shall be of roof bolting supplemented by conventional support

as and when required.

Support System during panel development

: At the time of panel

development, the roadways are proposed to be supported with roof bolts. The

roof bolting may be quick setting resin roof bolt or fixed column-grouted bolt

using cement, sand mortar. Development galleries will be supported by 2-3

rows of roof bolts 1.8m in length. The distance between two adjacent rows of

bolt and between two adjacent bolts in a row should be around 1.2m. The

above specification may change depending upon the results of the scientific

study. In addition to above, the provisions of Reg. 108 of CMR, 1957 together

with related circulars are to be complied. The support system for the

development galleries shall be as per the approved Systemic Support Rules.

Support System in Split and Slice : The tentative support system in split

galleries may be with quick setting type resin bolts at an interval of 1.2m

between the rows and between bolts.

Slices may not be required to be supported as it is to be extracted with remote

operated Continuous Miner.

Job No: 3507127

X/8

Support of Goaf Edges :

(i)

All the goaf edges shall be supported by rows of quick setting type

resin bolts at 0.80m interval in between the two bolts and between two

rows and 0.5m from either sides of the pillar. The length of such bolts

shall not be less than 1.8m or 2.4m. Such goaf edge support shall be

provided in the split/original gallery, as the case may be, at the start of

the slice cut by the Continuous Miner.

(ii)

Each such goaf edge support shall have three parallel rows of bolts

across the original/split gallery.

(iii)

At least two wooden props shall be installed near the goaf edge on the

rib side as indicator type.

Support System at other places: The trunk roadways and other working

places shall be adequately supported and secured by roof bolting system or

other suitable means of support.

Support System for Geologically disturbed area : All dykes, visible slips

and breaks in roof shall be supported by cogs at an interval of 2.4m on either

sides of such disturbances and with cross-bars across them at an interval of

not exceeding 1.2m.

Smaller geological disturbances, wherever feasible, shall be kept supported

by roof bolts on both sides of the disturbances along with W-strap as suitable

intervals. The length of such roof bolts shall be appropriate to the extent of the

disturbances but in no case less than 1.8m. The spacing between the bolts

shall be approximately chosen on the extent of the geological disturbance but

in no case shall be more than 1.0m.

Additional supports shall be erected as and when required.

Monitoring of Roof Bolts : All the recommendations of DGMS Technical

Circular No.3 of 1996 and other applicable regulations and circulars regarding

roof bolting/floor bolting shall be effectively complied whenever applicable in

this mine for safe working.

Support Material : The specifications of the support materials are as follows:

Roof Bolts : (Tor steel/MS IS:1786-1985/IS:226-1975/IS:1570)

Type : Steel/Mild steel

Lenth of rod -

1.8m/2.4m

Dia of rod

20-22mm

Length of thread -

125-150mm

Bearing Plate (IS:226-1975)

Material

Thickness

6mm

Job No: 3507127

X/9

Size

150 x 150 mm²

Nut

: (IS: 1363, Part-3, 1984)

Shape

Hexagonal

Height =

20mm

Cement Capsule

Length

Not exceeding 400mm

Dia

30-32mm

Type

Quick setting (the grout should provide a minimum

anchorage of 3 Te after 30 min and 5 Te after two hours of setting.

While doing the bolting operation in any roadways/workings of the mine, the

provisions of CMR 1957 and various DGMS Circular (Viz Cir Tech 3/1996)

shall be effectively complied for safe working of the mine.

Coal Evacuation From CM Panel

The Continuous Miner would cut and simultaneously load the coal by its

inbuilt stage conveyor into the shuttle car directly. The loaded shuttle car

would discharge coal on to Feeder Breaker. Crushed (-100mm size) coal will

be uniformly discharged on to gate belt conveyor, which is installed in the

Central gallery of the panel. This gate belt conveyor will in turn discharge the

coal on the trunk belt conveyor. The gate belt conveyor would be installed in

the gallery so that loading distance and cable length on each side of the

loading point is minimal. The panel width of the CM panel varies from 79.2m

to 179.2m and length of the panel is up to 1000m. 2x200Te strata bunker is

proposed in the Benti block in T-2 panel and 3x200Te strata bunker is

proposed in the Churi block in the trunk heading near to W-6 panel.

Material Transport

The material transport in the panel is proposed to be carried out by endless

and direct haulages.

Ventilation System in Panel

The CM panel in Churi block comprises of 4 to 8 Headings in a panel where

as in Benti block 5 heading panels are proposed. In a 5 heading CM panel,

three galleries on the dip side of the panel would preferably be used as intake

airway while two galleries on the rise side is to be used as return airways. In

case of other panels, the manager of the mine may accordingly decide the no.

of galleries for intake and return airway for adequate ventilation of the panel.

In no condition, the ventilation of the panel should be neglected.

The faces would be ventilated by auxiliary fan using ventilation ducting. Other

measures, which may improve the ventilation of the mine, may also be

adopted as and when required.

Job No: 3507127

X/10

FACE EQUIPMENT OF CONTINUOUS MINER PANEL

It is proposed that CM panel may have the following list of equipments:

Continuous Miner

One

(Suitable to prevailing geo-mining condition)

Shuttle Car

Three*

Roof Bolter

One

Portable Bolter

One

Load Haul Dumper

One

Feeder Breaker

One

Set of Electrical Distribution equipment

One

Communication equipment

One

* The no of shuttle cars has been taken as per suggestions made vide letter

no. SECL:BSP: DT(O):26/82 dated 28.02.07 of DT(O), SECL addressed to

Dir.(T), CIL.

The details of the equipment as proposed is as below :

Continuous Miner : One suitable Continuous Miner suited to prevailing

condition is proposed. The machine is equipped with radio cord remote

control, dust scrubber and methane monitor. It cuts and loads the coal in

single operation.

Operational Parameters of Continuous Miner (As per CM working in

SECL)

Cutting head width

3.3m

Cutting height

2.2m(Min.) to 4.6m (Max.)

Length of the machine

11.02m

Gallery width required

4.8m

Length of Cut in a single pose -

15m

Actual specification of machine may change depending upon the method of

extraction.

Shuttle Car : It transports the extracted coal from the Continuous Miner

loading conveyor to a self propelled stammer Feeder Breaker. From the

feeder breaker, coal is discharged to the gate belt and gate belt fed to the

trunk belt conveyor. The rated load capacity of low to medium capacity shuttle

car varies from 9-15 Te.

Roof Bolter : Since the development height of the panel is 2.4m, so the roof

bolter which can successfully work in a gallery height of 2.2m-4.6m is

proposed. The size and other specification of bolting material shall be of

approved type.

Load Haul Dumper (LHD): LHD may either be diesel or battery operated. It

has the following operations to perform in the Continuous Miner district.

(a)

Cleaning the spillage coal from Shuttle Car.

Job No: 3507127

X/11

(b)

Cleaning and sweeping up the heading of Continuous Miner after it has

completed cutting and thereby reducing time.

(c)

Transport materials and consumable goods.

(d)

Moving switchgear and transformer and also assisting installation of

main HT feeder cables.

Feeder Breaker: It receives the coal from Shuttle Cars and after crushing it to

the desired size of (-) 100mm, feeds it to the conveyor at consistent controlled

rate. It is mounted on tracks. The Feeder Breaker is having hopper sufficient

to hold a complete shuttle car.

Production Proposed

The production proposed from the Continuous Miner panel is 0.50

MTY.

All the mining operations in Continuous Miner panel should be in accordance

with the various regulations of CMR 1957 and various circulars issued by

DGMS for safe working of the mine.

10.2.2 HEIGHTENING OF EXISTING GALLERIES WITH REMOTE CONTROLLED

LHD

The gallery width required for CM is 4.8m and it can cut coal up to a height of

4.6m but the existing workings have the width and height of galleries as 2.4m

and 4.2m, so heightening and widening of gallery may be required. Widening

of gallery will be done as and where required.

Proposal for Heightening of Galleries

There would be separate remote controlled LHD panel for heightening of

existing galleries in the western section of CRO (W-1 to W-15 panels). Other

than these panels, no heightening of panels is proposed in this report. The

heightening of developed galleries is proposed up to 4.6m only leaving at

least 0.3-0.5m in the roof.

II.

Proposal for Widening of Galleries

Proposal for widening in those galleries is envisaged which shall be required

for the movement of Continuous Miner. All the galleries of the C.M. panels

may not be required for widening. The gallery through which Continuous

Miner (i.e. haulage roadway) is to be driven down would be widened up to

4.8m for lowering of the machine (CM) into the panel. Widening of the

galleries shall be applicable as per the requirement of CM package.

Layout of Panels

The mine is almost developed by Bord & Pillar method of mining in both the

seams along the floor of the seam by LHD or manually in a panel form. So,

the existing panel lay out or lay out proposed in the working plan shall be

taken as the lay out of the panel for heightening of galleries.

Job No: 3507127

X/12

Manner of Heightening

Heightening of galleries may be done by conventional roof blasting up to 4.6m

height. Blasted coal will be loaded by remote controlled LHD.

Manner of Widening

Manner of widening of galleries may be by side blasting with permitted

explosives only and loading of blasted coal by LHD onto Chain Conveyor.

Face Equipment

The coal obtained due to heightening/ widening of coal shall be loaded by

remote controlled LHD. Two numbers of remote controlled LHDs shall be

deployed in Heightening panel.

Coal Evacuation from Panel

The coal shall be loaded on to Chain Conveyor by remote controlled LHD.

Chain Conveyor will feed coal to gate belt conveyor for coal evacuation from

panels.

Ventilation of Panels

Heightening panels comprise of 4 to 8 headings, which is already developed.

In five headings panel, three headings in the dip side of the panel shall act as

the intake air and two headings on the rise side shall act as the return airway

of the panels. In other cases, the manager of the mine may arrange the intake

and return accordingly for safe working.

Face Ventilation

The Auxiliary Fan with ducting shall do face Ventilation.

Support System

The RMR of LBS varies between 41.7-61. It indicates that the immediate roof

of LBS is of fair category.

As remote controlled LHD is envisaged for loading of coal in the panels, it is

necessary that supports should be so designed that clear space is available

for movement of the machineries. At present, the panel is developed up to

2.4m and is supported as per the approved SSR. Now it is to be heightened

up to 4.6m. So, fresh SSR should be prepared and approved by the DGMS

and should be effectively complied.

The bolt density for three types of roof classified on the basis of RMR value as

recommended is as below:

Poor roof

1.2 to 1.5 bolts/m²

Fair roof

1.0 bolt/sq.m.

Good roof

0.7 bolt/m²

Job No: 3507127

X/13

As per the RMR value, the roof of UBS and LBS falls in fair category of roof.

So, the density of roof bolts in the Heightening panels should be 1.0 bolt/sq.m.

The bolt angle should generally be normal to the bedding plane in the

roadways/galleries. This also holds good for other panels of the mine.

Support materials should be as per DGMS Cir, no. 3/1996.

Support of Heightened Gallery (Within 9m of face) :

Area within 9m of the working face should be treated as the green roof. The

green roof support should be done as per Reg. 108 of CMR, 1957.

Support of Heightened Gallery:

After heightening of galleries up to 4.6m, the roof shall be re-supported

with roof bolts by roof bolter.

Four bolts in a row shall be installed. The spacing between the bolts in

a row and between the rows shall be 1.2m.

Some additional roof bolts shall be installed to increase the density of

roof bolts, as and when required.

The spacing between the sides of the pillar and the bolts in a row shall

be 0.6m on the both sides of the pillar corner.

Bolts shall not be less than 1.8m/2.4m in length and 22mm in diameter.

Support at Junction: The bolt density should be at least 25% more than the

bolt density of heightened gallery.

Support at Disturbed Places: In addition to the roof bolts, the geological

disturbed area of the Heightening panel shall be supported by cross-bars,

cogs W-straps and other suitable means as and when required.

Supports on Loose Floor: Props shall be set on solid floor and not on loose

packing material. The support shall be kept tight against the roof. Wherever

the props are to be set on sand a flat base piece not less than 5 cm thick, 25

cm wide and 75 cm long shall be used.

For legged steel cogs of 1.2m x 1.2m piece shall be set on solid floor and not

on loose material. They shall be kept tight with timber sleepers against the

roof to ensure maximum contact between the timber and the roof. The

provisions for support on loose floor shall also hold for other working panels of

the mine.

Support Material: The support material shall be as proposed in DGMS Gr

Tech. 3/1996.

Production Proposed

The production proposed from Heightening panel is 0.15 MT i.e. 500 TPD.

Job No: 3507127

X/14

Before going for heightening or widening of galleries in a panel in any of the

seams or section, prior permission from DGMS should be obtained for that. All

the mining operations in the Heightening panel should be in accordance with

the various regulations of CMR 1957 and circulars issued by DGMS for safe

working of the mine.

10.2.3 B & P DEVELOPMENT & DEPILLARING WITH LOW HEIGHT LHD

Bord & Pillar development & depillaring is proposed in Upper Section of Top

Lower Bachra seam and Bottom Lower Bachra seam/section in Benti block.

The proposed pillar size in both the seam/section is 25m x 25m, in both the

seams/sections, width of gallery is 4.2m and height of gallery is 2.4m or the

actual seam thickness leaving 0.3-0.5m of coal in the roof. The development

is proposed in the virgin area of Upper section of Top Lower Bachra along the

roof of the seam & Bottom Lower Bachra seams along the floor of the

seam/section. It is proposed to leave at least 0.3-0.5m of coal in the roof,

since the immediate roof of both the UTLB & BLB comprises of carb. shale,

grey shale, grey wake, alternating bands of shale and sandstone. The reason

to develop the UTLB along the roof is to maintain the parting thickness of

3.0m between the seams/sections for safe working.

Proposal for B & P Development / Depillaring panels with low

height LHD

Bottom Lower Bachra Seam (BLB)

Panels B-1 to B-4, B-13 to B-15, T-1 to T-2 and B-18-B-19.

Upper Section of Top Lower Bachra Seam (UTLB)

Panels B-1 to B-4, and B-13 to B-16.

Layout of Panels

Since both the sections are contiguous, so layout of panels for UTLB & BLB is

proposed in such a way that pillars in both the sections are vertically

coincident. Generally, five headings panels for both the sections have been

proposed for the development of virgin property in Benti block. Vertical

coincident of pillars should be checked by putting boreholes at the alternate

junctions of the development galleries from either of the workings.

Method of work

Development:

Bord and Pillar method with Conventional Solid

blasting. Low height LHD loading on to face

conveyor.

Depillaring: Conventional Bord & Pillar method with caving in both the

seams/sections.(simultaneous)

Manner of Extraction

Development: The virgin property of BLB seam would be developed along

the floor of the seam leaving at least 0.3-0.5m of coal in the roof. Similarly,

Job No: 3507127

X/15

UTLB seam would be developed along the roof leaving at least 0.3-0.5m of

coal in the roof. The details regarding the development of BLB & UTLB seam

s/sections are as below :

Size of Pillar

= 25m x 25m (Centre to centre)

Width of gallery

= 4.2m

Height of gallery

= 2.4m or actual seam thickness

The parting between two sections should be maintained at least 3.0m.

Depillaring: Simultaneous Bord & Pillar depillaring with Caving in UTLB &

BLB has been envisaged. The developed Pillars would be extracted by

splitting and slicing. Each pillar would be splitted into two equal parts by one

dip split of 4.2m wide. There after level slices of 4.2m wide would be driven

leaving 1.8 m (minimum) rib against the goaf so that the area of roof exposure

at any one working place should not exceed 60 m² at any time. On retreat, the

ribs would be reduced judiciously. Driving of a slice would commence only

when the extraction in the immediate in bye slice is completed and goaf edge

support as per approved SSR is erected. Only one slice in a pillar would be

driven at a time and extraction of a half of a pillar shall not be commenced

until extraction of the adjoining in bye half of the pillar has been completed.

Diagonal line of extraction would be maintained. The order of slicing should

be strictly followed to maintain the stipulated area of exposure of 60m² (max.).

In no condition, except with the permission of DGMS, the area of exposure

should be more than 60m².

Coal Evacuation from Panel

It is proposed that the blasted coal shall be loaded by the low height LHD on

to chain conveyors and chain conveyor fed it to the gate belt conveyor for

transportation of coal from panel. This system will be applicable for

development and depillaring panels of both UTLB & BLB. Since the working is

contiguous, simultaneous working is to be done in both the seams/sections.

Panel Ventilation

Two or three headings in the dip side of panel (depending upon the size of

panel) shall be used as intake airway and two or three headings on the rise

side of the panel shall be used as the return airway of the panel. The face

ventilation of the panels in both the conditions while development and

depillaring shall be done with the auxiliary fans as and when required. This

will be applicable for both the UTLB & BLB seams/sections.

Face Equipment and Transport

Electric coal drill, Auxiliary fan, face pump may be the face equipment in

UTLB & BLB workings. Blasted coal would be loaded by low height LHD on to

chain conveyor and chain conveyor will fed to gate belt conveyor.

Job No: 3507127

X/16

Support System

The immediate roof of Lower Bachra seam in the adjoining Churi block is of

fair category. The RMR study for Benti has not been done, so RMR of LBS in

Churi block has been taken for the support design for UTLB & BLB in Benti

block. The support system for the low height LHD working comprises of :

(a)

Support for development.

(b)

Support for depillaring.

Support for Development

There should be a systematic support plan for development workings duly

approved by DGMS in the mine. This shall be effectively complied for all

workings of Churi -Benti Project:

(i)

Support of working face within 9m

All working faces shall be supported by quick setting type full column grouted

bolts. The first row of support shall be at a distance of 1.8m from the face. The

spacing between the rows may be 1.2m. The means of support for the

working faces shall be roof bolts supplemented with conventional support as

and when required.

(ii)

Support of Tramming level

Where required tramming levels shall be supported by cross bars on safari

clamps or in duggis at an interval of

1.2m. In general, roof bolting

supplemented with conventional support as and when required shall support

it. Chocks/cogs shall be set as and when required.

(iii)

Support at Junction

The density of roof bolts at the junction of galleries should be 25% more than

those general galleries. Cross bars, cogs, chocks or other suitable type of

conventional support may also be erected as and when required.

(iv)

Support of Travelling Roadway

In addition to roof bolts, traveling roadway shall be supported by rope stitching

or steel girders or cross bars or vertical props or chocks/cogs at suitable

intervals.

(v)

Support of Airways

In addition to roof bolts, airways may be supported by rope stitching or steel

girders or cross-bars or vertical props or chocks/cogs.

(vi)

Support of geologically disturbed places

Geological disturbed places shall be supported by cross-bars or vertical props

or steel bolts or rope stitching or with chocks/cogs in addition to roof bolts as

and when required.

Job No: 3507127

X/17

Support for Depillaring

While going for depillaring, the systematic support plan should be prepared for

depillaring districts/panels and get approved by the DGMS. It should be

complied effectively for safe working of the mine. The envisaged support for

depillaring panels is as below:

(i)

Support within two pillars of extraction

The support within two pillars length of extraction would be done by roof bolts

at 1.2m spacing in a row and the distance between two rows of such bolts

would be 1.2m. It would be supplemented with the conventional support as

and when required.

(ii)

Split galleries shall be supported with roof bolts at an interval of 1.2m

between the rows and 1.2m between the bolts. Additional roof bolts may also

be provided to increase the density of roof bolts as and when required. It shall

also be supplemented with conventional support as and when required for

safe working of the time.

(iii)

Junction support

Junction will be supported by roof bolts with w-strap chocks/cogs may also be

erected as and when required.

(iv)

Slice support

Goaf side slice will be supported by cogs at 1.5m interval and rib side by roof

bolts with w-strap.

(v)

Goaf Edge Support

Goaf edges will be supported by cogs placed skin to skin with corner props.

Support Material

The specification of support material regarding roof bolts shall be in

accordance with the Cir. Tech 3/1996 of DGMS circulars.

Regarding the conventional support, the specification support material should

be as per the provisions of CMR 1957 and DGMS circulars.

Production Proposed

Production from the B & P development/depillaring with low height LHD is

proposed to be 0.10MTY.

10.3 PRODUCTION PARAMETERS

The production parameters as envisaged in the Churi-Benti Project Report is

as under:

CM Panel

0.50 MTY

Low height LHD panel

0.16MTY

Job No: 3507127

X/18

Heightening Panel

0.15 MTY

TOTAL

0.81 MTY

10.3

SUBSIDENCE

The Project Report for Churi-Benti Project covers area of Churi Re-

organization (CRO) and Benti block. Total area under this project comes to

about 7.68sq. km. For deployment of Continuous Miner, the proposed mining

area is 2.44sq. km. The proposed method of depillaring with CM is by caving..

Earlier, a subsidence study was carried out for the Churi UG mine. However,

the part of mining area for CM under Benti block was not considered. Hence,

It is proposed to undertake fresh subsidence study for assessment of damage

to surface for Churi-Benti project.

10.7

EXPLOSIVES & MAGAZINE

The explosives will be used only for B&P districts with LHDs including remote

controlled LHDs panel. The powder factor presently obtained is around

2.0tonne/kg of explosive. Efforts should be made to improve powder factor to

around 2.5tonne/kg. Blasting study may be undertaken for suitable blasting

pattern.

An explosive magazine of 400 kg explosives and 2000 detonators already

exists in the mine. The magazine would be used for the project. It should be

maintained in accordance with Indian Explosive Act & rules there under. The

adequate arrangement should be made for the safety of the magazine.

10.8

SCHEDULE OF EQUIPMENT PROCUREMENT

The year-wise phasing of P&M is given in appendix-A.3.

10.9

GENERAL PRECAUTION WHILE DEPILLARING

a. The extraction or reduction of pillars should be conducted in such a

way as to avoid the extension of collapse or subsidence of the goaf

over unextracted pillars.

b. During the extraction of pillars, no splitting or reduction of pillars or

heightening of galleries should be carried out for a distance greater

than the length of two pillars ahead of the pillar under extraction. While

starting of pillar extraction, it may be extended up to 4 pillars only.

c. Attempts should be made to allow the roof to cave regularly so as to

avoid the presence of large area uncollapsed. So that danger from air

blast or weighting on pillars could be avoided. If needed, suitable

means should be adopted to bring down the goaf at regular interval.

Adequate number of convergence recorder / load cell should be

installed to predict the roof fall.

d. Rib of not less than 1.8 m should not be left against the adjacent goaf.

Some times, this may also be required in split galleries. So if needed, it

must be left in split galleries also and may be judiciously reduced on

Job No: 3507127

X/19

retreat after setting strong breaker line of cogs or other means of

artificial support adjacent to it.

Adequate precautions against „Air Blast‟ as per Cir. Tech.2/1988

should be taken.

The area of exposure at any depillaring slice should not be more than

60m² at any time.

In case of contiguous working, where the depillaring with caving is

proposed, the extraction in both the seams or sections should be in

such a manner that the line of extraction in both the seams/sections

should be vertically coincident up to each other and in case of any

trouble in one section, persons from both the sections should be

immediately withdrawn.

In case of contiguous workings, the pillars in one seam/ section, should

be vertically above and below the pillars in the other seam or section

unless the strata are inclined at an angle of more than 300 from

horizontal. The partings between two seams/sections should not be

less than 3.0m at any place.

While working in any of the seam/sections, use of CO detector,

methanometer and other safety apparatus must be ensured for safe

working of the mine. The provision for safety apparatus has been made

in this report. Telemonitoring system may also be used at the mine.

Water spraying arrangement to suppress the dust in continuous miner

is an integral part of the machine, so availability of clean water to CM

must be ensured throughout the shift.

The total no. of working panels may be three, and the production

envisaged is 0.81 MTY. So, the ventilation of the mine should be as per

statute and adequacy of ventilation in each panel should ensured. To

check the adequacy of ventilation, ventilation survey for the panels/

mine should be conducted by a scientific body. The provision for

ventilation survey has been made in this report.

As per the geological plan of the blocks, there are too many faults. But

in actual mine operation such no. of faults has not be encountered. But

some minor faults have been encountered as reported by the colliery

management. So, adequate precautions should be taken while working

near the fault. The presence of minor slips cannot be ruled out. So

adequate precautions should be taken while working.

m. Over the leasehold property of Churi-Benti Block, too many important

surface features like nala connected to Damodar River, public road

power line, power trestles, Piparwar rehabilitation site, Piparwar GM

office, DVC substation, etc exists over it. Before working below it, either

it should be shifted/diverted from the proposed mining area or

protective pillars of adequate size considering the angle of draw of 45⁰

of the area to be depillared should be left against such surface features

so that the line of fracture due to caving should not reach to the nala or

other surface features lying over the property and may not affect the

surface features which needs to be protected or may cause danger for

Job No: 3507127

X/20

the person employed there in. Provision of filling of seasonal nala

above the HFL, shifting of trestles has been made in this report.

No working should be conducted within 60m of HFL line without taking

permission from DGMS.

At present, Churi Old mine has the disused isolated working. So

adequate precautions should be taken while restoring the workings in

Churi Old mine in both the seams.

The mine is surrounded by Damodar river, Saphi river, workings of

Ray-Bachra colliery and old abandoned working of Churi which had

been worked in distant past through incline No.2,3,4 & 5. So, adequate

precautions should be taken while working approaches towards these

old workings.

While working both the sections/seams simultaneously, both the

seams/sections shall be under the supervision of same over-man and

one experienced officer should be given for safe working of the mine.

The above provisions will also be applicable for other working panels of

the Churi-Benti project. Provisions for the same have been made in this

report.

In case of any apprehension of danger felt by the supervisor or by any

other official of the mine/project, in any of the panels, the manpower

should be withdrawn for the safety of the workers.

Adequate precautions should be taken to avoid the danger of air blast

and the provision of escape route should be made and kept maintained

in the mine for safety of the mine. The persons should be trained to

deal with any emergency situation, which may endanger the safety of

the mine.

Incubation period of coal for Churi u/g is not known. It should be freshly

determined so that the size of sub-panels can be decided as per the

incubation period. The panel size has been envisaged in this report

considering the incubation period of 9 months.

As soon as the panels are exhausted it should be sealed with the

approved type of isolation stoppings. The competent person to ensure

any leakage from goaved out workings should conduct periodic

inspection of isolation stopping as per Coal Mines Regulation, 1957.

The provision of water seal should be made in these isolation stopping

to prevent the accumulation of water behind the stoppings. The type of

water seal should be of such type that will not allow the leakage of

gases from the goaved out workings.

The earlier subsidence study of Churi underground project clearly

spelled out that the subsidence would reach to the surface so adequate

precaution should be taken to avoid the accumulation of water over the

subsided areas and any surface cracks formed due to subsidence

should be effectively filled with non-combustible material.

Intrinsically safe and flameproof apparatus should be used below

ground. The hydraulic fluid used by the various machines below ground

should be of approved type.

Job No: 3507127

X/21

x. Where blasting is to be done, only permitted explosives should be used

and all precautions as per CMR 1957 with various DGMS Circular

should be effectively complied with for the safe operation of the mine.

y. The working faces in each panel should be supported as per the

approved SSR and if roof bolting is to be done, then full column

grouting should be ensured.

z. Wearing of safety appliance by the workers should be ensured for the

safety of the workers.

aa. The Incline No.1 falls within the HFL line. It is proposed to construct

embankment above 3m HFL to prevent surface inrush of water.

bb. All the safety provisions mentioned together with statutes shall also be

applicable while working in Benti Block.

cc. In addition to above all, such provisions of CMR 1957 and related

DGMS circulars, which attracts attention while carrying out the mining

operation, should be effectively complied for the safety of the mine as

well as the safety of the persons employed therein.

Job No: 3507127

X/22

CHAPTER - XI

MINING SCHEDULE

11.1

PRODUCTION SCHEDULE

Extractable Reserves

The following points have been considered for estimation of extractable

reserves for the project:

 In the Churi block, it has been decided to deploy Continuous Miner in the

western section of CRO & panel E12 & E13, which is free from workable

thickness of UBS.

 In Benti block, the Continuous Miner is proposed to be deployed in Bottom

Lower Bachra seam/section having seam thickness >3.0m, leaving 0.3-0.5m

coal against shale roof, wherever upper seam/sections are not workable.

 The western section of CRO is mostly developed in Lower Bachra seam along

the floor up to 2.4m. It is proposed that the virgin patches falling within the

panels are to be developed and then depillared by Continuous Miner.

 The developed panels in the western section of CRO are proposed to be

heightened up to maximum operating height of roof bolter for deployment of

Continuous Miner.

 It has been considered that the surface features (like GM office, DVC sub-

station, Pvt./Company quarters, trestles, road, etc.) will be shifted to maximize

extraction from the panels.

 Villages are proposed to be rehabilitated.

 No depillaring is proposed below the Piparwar rehabilitation site.

 The pillar size in developed panels has been considered as 25m x 25m and

gallery size 4.2m x 2.4m. The extractable reserves for CM panels have been

estimated considering percentage of extraction as 65% of the in situ coal in

pillars.

 For virgin panels in Benti block, the 5-headings panel with pillar size of 25m x

25m and gallery width of 4.8m has been considered. For virgin area falling

within existing mine boundary & fault F13, has been not been considered.

 The existing connecting panel between Churi & Benti block, i.e panel W6 has

not been proposed for depillaring till completion of extraction in Benti block.

 Provision for protective pillars below the nala flowing over the panels in the

western section of CRO and Piparwar rehabilitation site has been made and

reserve blocked in protective pillars has not been considered in extractable

reserve.

 The reserves for Bord & Pillar in contiguous seams in Churi & Benti block has

been estimated considering leaving parting of 3.0m in from the floor of upper

including actual parting. It includes the reserves in virgin patches in the panels

and in existing developed galleries (i.e, heightening while depillaring) up to

4.0m or the actual seam thickness, whichever is more. Depillaring reserves

has been calculated assuming that the surface features over the panels shall

be shifted. Pillar size has been taken as 25mx25m and gallery width of 4.2m.

Job No: 3507127

XI/1

The summary of extractable reserves in different seams/sections is shown in

Table 11.1. The panel-wise extractable reserves is given in Annexure-A.

Table 11.1 : Summary of Extractable Reserves (MT)

Seam / Section

Churi block

Benti block

Total

Dev.

Dep.

Dev.

Dep.

A. Continuous Miner

Lower Bachra seam (LBS)

0.224

2.979

---

3.203

Bottom Lower seam (BLB)

---

0.464

0.547

1.011

Sub-Total

0.224

2.979

0.464

0.547

4.214

B. Heightening District

Lower Bachra seam (LBS)

0.915

---

0.915

Sub-Total

0.915

---

0.915

C. Bord & Pillar

Upper Bachra seam (UBS)

0.755

2.928

---

3.683

Lower Bachra seam (LBS)

0.242

5.037

---

5.279

Bottom Lower Bachra (BLB)

---

0.521

0.748

1.269

Upper section of Top Lower

---

0.418

0.430

0.848

Bachra (UTLB)

Sub-Total

0.997

7.965

0.939

1.178

11.079

From the above table, the reserves considered for the proposed Churi-Benti project

is as under:

Continuous Miner

(LBS & BLB)

4.214Mt

Heightening District

(LBS)

0.915Mt

B&P development

(UBS, BLB & UTLB)

1.059Mt

It was decided in the FD`s meeting while presenting augmentation report to make

provision of land acquisition for deployment of Continuous Miner only. Hence, B&P

depillaring has not been considered, as surface land is not acquired.

Additional Extractable Reserves:

(i)

Benti block: If the working is extended up to the Fault F13, after statutory

boundary adjustment between Churi-Benti and Ashok project, additional extractable

reserves of 0.784 Mt will be available which may provide longer span of life for the

continuous miner.

(ii)

Additional Extractable Reserves in seam thickness beyond proposed

extraction thickness of 4.6m

In western section of CRO, reserves are blocked in LBS beyond proposed

extraction thickness of 4.6m. It is expected that about 1.0Mt of extractable reserve is

blocked in thickness above 4.6m. While finalizing the specifications of Continuous

Miner, care may be for maximization of extraction thickness.

Job No: 3507127

XI/2

Reserves in panel lying in the eastern section of CRO & Old Churi in UBS &

LBS may be considered for deployment of CM after scientific studies.

Mining Schedule

The following points has been considered for mining schedule of Churi-Benti

UG project:

 It is proposed to deploy Continuous Miner initially in virgin area of Benti block

for B&P development to generate confidence and facilitate learning of the

technical know-how.

 Simultaneously, heightening of existing galleries of the panels proposed for

extraction with Continuous Miner will be undertaken.

 After initial development & depillaring by Continuous Miner in Benti block, the

Continuous Miner would be deployed for depillaring of standing pillars in Churi

block. The depillaring is proposed to commence from the extreme panel / dip

most side of western section of CRO.

 At present two B&P development panels/districts are working. The B&P panel

with LHDs is working in Bottom Lower Bachra seam/section in Benti block

while the manual B&P district is working in Upper Bachra seam in Churi block.

 It is proposed that the B&P district with LHDs will continue with development

in Benti block (Bottom Lower Bachra-BLB & Upper section of Top Lower

Bachra- UTLB seam/sections). The manual B&P district is proposed to

phased-out with introduction of Continuous Miner & Heightening districts.

 It is proposed for shifting of surface features (power trestles, road, etc.) and

rehabilitation of villages overlying the proposed panels for Continuous Miner.

The surface features should be shifted well ahead of the mining schedule for

CM production to facilitate extraction. The provision for the same has been

made in this report.

 Panel W-6, considering the entry to Benti section is not proposed for

extraction till completion of final extraction in Benti block.

 Prior to deployment of CM in Churi block, existing panels are to be heightened

as proposed. Heightening of the panels should be sufficiently advanced for

timely deployment of Continuous Miner.

 The Continuous Miner is proposed for introduction in the third year from the

zero date. In the first two years, before commencement of operation of

Continuous Miner, initial preparatory work would be undertaken.

 It has been assumed that all the preparatory work in the including land

acquisition, EMP approval, etc. and procurement & commissioning of

equipment would be completed in two years.

 The existing LHDs in the mine should be replaced with low-height LHDs to

continue with B&P development in low seam /section thickness horizons.

 Available working days in a year has been taken as 300days.

 After completion of heightening district, for the balance life the equipment may

be deployed for depillaring of the reserves standing on pillar in the mine.

Job No: 3507127

XI/3

 In case, reserves considered for Continuous Miner exhausts early, alternative

place of deployment may be suitably identified and arranged for shifting for its

gainful utilization.

 The depillaring of B&P panels of Benti Block in Churi-Benti project has not

been considered, as it would require acquisition of land. As decided in the

FD’s meeting provision for land acquisition is to be made only for Continuous

Miner.

 While working with Continuous Miner in the proposed area of Churi-Benti

project, scientific studies may be conducted for depillaring of standing pillars

in remaining areas of the Churi block by Continuous Miner. If the results of

scientific studies permit, CM may be deployed in the remaining areas after

exhaustion of reserves in Churi-Benti project.

Construction Period

The first two years will be construction period. During this construction period,

the following activities should be completed:

 NIT and Tendering.

 Finalization of contract for supply of CM package

 Scientific studies for selection of appropriate support and method of

work for deployment of CM.

 Permission from DGMS to work with CM

 Permission for heightening of existing panels

 Acquisition of land for depillaring.

 Shifting of Power trestles, road and other surface features .

 Rehabilitation of villages.

 Heightening of existing roadways including inclines for marching of CM

package to underground

 Strengthening of transport system as per requirement of CM

 Construction of UG strata bunker and drifting

 Construction of water reservoir and water filter plant

 Strengthening of workshop as per requirement of CM.

 Strengthening of ventilation system by opening of Churi old workings

and establishing main return through LBS.

 Drivages of roadways below Damodar River to provide additional

approach to Benti block.

The next two years will be production built-up period. Production from

Continuous Miner and Heightening district will commence from 3^rd year

and target production of 0.81 MTY will be achieved in the 4^th year.

Based on above, production schedule from the Churi-Benti project is

proposed as under:

Job No: 3507127

XI/4

Technology

Production from Working Districts/ Technology (Mt)

Continuous

Heightening panel

B&P with low-

Manual

TOTAL

Year

Miner

with remote

height LHDs/

B&P

controlled LHDs

Normal ht LHD

Year 0 /

---

0.10

0.06

0.16

Existing

Year 1

---

0.10

0.06

0.16

Year 2

---

0.10

0.06

0.16

Year 3

0.40

0.10

0.16

---

0.66

Year 4

0.50

0.15

0.16

---

0.81

Year 5

0.50

0.15

0.16

---

0.81

Year 6

0.50

0.15

0.159

---

0.81

Year 7

0.50

0.15

---

0.65

Year 8

0.50

0.15

…

---

0.65

Year 9

0.50

0.07

…

---

0.57

Year 10

0.50

…

---

0.50

Year 11

0.31

---

0.31

11.2 COAL QUALITY

The grade of coal in Lower Bachra seam (LBS) in Churi block varies from ‘A’

to ‘E’. In the panels proposed extraction with Continuous Miner (and heightening

district for CM panels) with seam section of 4.6m, the grade of coal generally is from

‘B’ to ‘C’ (long flame). In Benti block, grade of coal of Bottom Lower Bachra seam

(BLB) in proposed panels for Continuous Miner varies from ‘A’ to ‘C’ (long flame),

generally ‘B’ grade (long flame).

In Benti block, the development reserves for B&P panels with LHDs in Bottom

Lower Bachra (BLB) & Upper section of Top Lower Bachra (UTLB) varies ‘B’ to ‘D’

and ‘D’ to ‘E’, respectively.

The declared grade for Churi UG during past several years of its mine

operation has been grade ‘B’ (long lame), however the geological grade is ‘C’.

Almost entire Churi UG mine has been developed and presently B&P development is

being continued in Benti block. The present declared grade of coal is ‘B’ (long flame).

After discussion in FD’s meeting on 5.12.06 and 22.3.07 at CCL, it has been decided

that declared grade of the mine should be taken for planning purpose instead of

geological grade ‘C’.

Considering the extractable reserves and variation of grade in the property for

CM, B&P & heightening panels, the average grade of coal is expected to be of grade

‘B’ (L/F). Accordingly, grade of coal for financial evaluation has been considered as

Grade ‘B’ (L/F).

11.3 ZERO DATE

Job No: 3507127

XI/5

CHAPTER - XIII

MINE VENTILATION

13.1 DEGREE OF GASINESS

Churi UG is an existing mine in North Karanpura coalfield presently working

Upper Bachra seam & Bottom Lower Bachra seam. The mine has been categorized

as degree-I gassy mine. No active emission of inflammable gas has been noticed

during development in Upper & Lower Bachra seams and in Bottom Lower Bachra

seam in Benti block. Further, it is proposed to continue work in Bottom Lower Bachre

& Upper section of Top Lower Bachra in Benti block and Lower Bachra seam in

Churi block. Hence, gassiness of the mine has been taken as degree-I, for the

purpose of assessment of ventilation requirement & planning.

In conformity with Coal Mines Regulation, 1957 & related circulars issued by

DGMS & standards of ventilation, following criteria have been used:

Restrictions on the maximum velocity in a drivage or mine entries

Fan drift or Ventilation shaft

15m/s

Man winding shaft or haulage roadways

8m/s

Other roadways

6m/s

Conveyor roadways

4m/s

Face

4m/s

Minimum air quantity requirement in a panel at LVC

Based on the production from a ventilation district

2.5m3/min./t

Based on the manpower deployed in the largest shift

- 6m3/min./person,

Which ever is more.

Requirements of minimum velocity at the working faces in the mine

Immediate out bye of ventilation connection from face

30m/min.

4.5m from face on intake side of brattice/partition

30 m/min.

7.5m out bye of the discharge end of an air pipe

15 m/min.

Estimation of aerodynamic resistance of a path/mine

R = k x P x L / A3 R - Aerodynamic resistance in kg sec2 m-8

Where,

k - Coefficient of aerodynamic resistance

P - Perimeter of the path in metre

L - length of airway in m

A - area of x-section in m2

Estimation of pressure requirement for a path/fan

P = R x Q2

Where, P - pressure drop in Pa

Q - air flow through a path in m³/s

Estimation of motor power requirement for the main fan

Q = 1.1 x P x Q/(nf x nt)

P - main fan pressure in Pa

Where,

Q - air flow through the main fan in m³/s

nf & nt - fan & transmission efficiencies

Standards of Ventilation Efficiency in a mine

Ventilation Efficiency Quotient (VEQ) of a mine

60% or more

Operating Efficiency of Main fan (nf)

60%

Transmission Efficiency (nt)

95%

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13.2 AIR QUANTITY REQUIREMENT

The estimated air quantity requirement at the working panels' last ventilation

connections (LVCs) during different stages (refer para 13.3.3) of mine operation as

described above is given in Table 13.1.

Table 13.1 : Estimation of Air Quantity Requirement (in m³) at Panel LVCs

Parameter

Air requirement (m³/s) forProposed Operating panels’ LVC

Continuous Miner Panel

B&P Panel

B&P with remote

with LHDs

controlled LHDs

Production (TPD)

1700

534

500

Manpower (largest shift)

120

100

On the basis of production

22.0

22.5

20.8

(@@2.5m³/min/t

Considering production, air

quantity & velocity in panel

would be very high. Hence, air

requirement at velocity of

1.0m/s has been considered.

On the basis of manpower

7.0

12.0

10.0

@6.0m³/min/ person

On the basis of velocity

11.0

5.8

@0.50m/s (assuming x-

section of 4.8x2.4m/4.6m

On the basis of Temperature

22.0

11.6

(assuming

temprature

exceeds

30.5^oC, taking

velocity of 1.0m/s)

Max. of Air requirement

22.0

22.5

20.8

TOTAL

65.3

On the basis of above, the total air quantity requirement at the panel last

ventilation connection is expected to be about 65.3m³/s. The air quantity would,

therefore, be accordingly regulated so that all the working places / districts get the

required quantity of air as per statute for safe operation of the mine and safety of the

persons employed therein.

One fan (PV-200 type, sec., 79 mm wg) is operating in Churi old section and

catering the existing requirement of the mine. The discharge through the existing fan

is about 50m³/s. Existing fan capacity may not be sufficient to cater the ventilation

requirement of the Churi-Benti Project. However, detailed ventilation survey (

keeping in view that 3 districts would be operated at a time in the Project), should be

carried out to ascertain the actual ventilation requirement for the Project.

For better ventilation in the mine, choking of return, leakage through fan

drifts/shafts, air locks, setting of fan, maintenance of stoppings, etc. should be

examined carefully and adequate steps should be taken for any rise in temperature

Job No: 3507127

XIII/2

and humidity. For better conditions at the working faces, it is desirable to maintain

that the air velocity of air 1.0m/s.

There will be three numbers of panels working at a time. It is suggested that

the colliery management should prepare a ventilation management plan clearly

stating the code of practices and implemented for proper ventilation management in

the mine. In addition to above, various provisions of CMR, 1957 together with

different circulars issued by DGMS should be complied effectively to maintain the

adequacy of ventilation in the working places.

13.3 VENTILATION SYSTEM DESIGN

13.3.1 Present Ventilation Arrangement

9.2

Present Ventilation System

At present, exhaust system of ventilation is being followed for ventilating the

workings of mine. Presently, Churi UG mine is operating mine with two incline entries

(Inc. 6 & 7) on the rise side working as main intake airways and an air shaft serves

as main return airway with a main mechanical ventilator (PV200 make) installed in

the air shaft. The present air discharge through the main fan is about 50.0m³/s at an

operating fan pressure of about 58mm of WG. The details of main intake & return

airways is as under :

Intake airway

Inc. 6

4.8 x 2.8 m2

Inc. 7

4.8 x 2.8 m2

Return airway

Air shaft 1

4.26 dia. (Fan - PV200 make)

Two standby fans exist, one a Model AF-80 fan in the fan drift parallel to the

existing fan drift and other a Model PV-160 fan in 1A incline. Only the main fan

PV200 make is in operation.

Problems in the existing ventilation arrangement / system: The present

VEQ and the system efficiency of the mine is about 39%. The mine resistance is

about 0.2272gaul, which is very high. Besides, there are several bottlenecks in

ventilation system of the mine. A ventilation study has been conducted for the Churi

UG with the existing extent of workings in October 2006. The deficiencies in the

existing system have been indicated. Further, proposals have been suggested for

improvement in the existing system of ventilation. The recommendations of the

report on ventilation system design for the mine submitted in October 2006 should

be complied.

Presently, working panels in Benti block is being ventilated by the existing

approach through W6 panel. It is proposed to operate two districts in Benti block

including Continuous Miner district. It has been proposed for additional approach for

Benti block through W-11 panel. This would facilitate in improving the ventilation for

the panels in Benti block.

Job No: 3507127

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13.3.2 Proposed Ventilation Arrangement

It is proposed to utilize the existing ventilation system. Certain modifications in

the underground ventilating paths is suggested to reduce the mine resistance as well

as improvement in ventilation efficiency as mentioned under :

 It has been proposed for additional approach for Benti block through W11

panel.

 The zig-zag return is proposed to streamlined by directing the return air

through trunk roadways of Churi old section in Lower Bachra seam.

Besides, the suggestions made in the report ‘Ventilation System Design’, for

Churi colliery should be implemented.

13.3.3 Ventilation Simulation

From the ventilation study carried out for the mine, it appears that the single

existing main fan may not be adequate as the present discharge is about 50m³/s at

wg of about 58mm. Total air quantity required at panels’ LVC is about 65.3m³/s.

Considering VEQ of 60%, air discharge required through the fan is about 108.83

m³/s. The required pressure at the main fan considering present mine resistance of

0.2272gaul works out to 196mm of water gauge, which is very high. Hence, the mine

resistance needs to be significantly reduced.

Ventilation study has been undertaken for the mine. Several deficiencies have

been indicated in the report. By implementing the suggestions, it has been shown

that the mine resistance is likely to reduce to about 0.14gaul. It is further proposed

for modification in ventilating paths as suggested in Para 13.3.2. It involves opening

of old Churi section and drivages of additional approach to Benti block for additional

return paths. This may reduce the mine resistance further and the mine resistance is

likely to be less than 0.1gaul.

Considering mine resistance of 0.10gaul and air requirement at panels’ LVC

and main fan, the required fan pressure will be about 86mm of wg. To meet the

above required ventilation parameters, the existing main fan along with one of the

standby fan or a new main fan with the suitable parameters (higher volume &

increased discharged pressure) would be required. It is proposed to utilize the

existing resources (main fans).

Hence, it is proposed for operating existing main fan along with another

standby fan in parallel. Simply operating two fans in parallel will not meet the

ventilation requirement of the Churi-Benti Project, unless resistance of the ventilating

path is reduced to less than 0.10 Gaul. Hence, it is necessary to reduce the

resistance by implementing the suggestions mentioned above. The proposed

ventilation arrangement is expected to be adequate for the project after incorporation

of suggestions made above and the ventilation study report. Hence, ventilation

simulation for different stages of the mine has not been carried out.

Job No: 3507127

XIII/4

It is expected that depending upon the layout of ventilating paths, sequence &

extent of working panels and leakages, VEQ of the mine can be improved further,

thereby reducing the required air discharge through the main fan.

13.3.4 Proposed Ventilation Layout

Ventilation layout of the main/trunk headings: The fresh air taken into the

mine through mine entries would be taken to the working panels along the

main/auxiliary trunk roadways. These trunk roadways comprises of 4-7headings.

Generally, 2-3 central headings have been considered as main intake airways while

the flank headings on either side have been taken as main return airways, where

working panels lies on either side to trunk headings. Where the working panels lies

on one side of the trunk roadways, the three headings along/adjacent to the working

panels have been taken as intake airways while the remaining headings will work as

return airways. In the auxiliary trunk roadways, the intake and return airways have

been considered based on minimum requirement of air crossing.

While crossing the Damodar river, the existing trunk headings are limited to 3

headings only. In this situation, 2 headings works as intake and 1 heading as return

airway for the existing workings in the Benti section. It is proposed to re-cross the

Damodar river with limited no. of headings through Panel W-11 of western section of

CRO. It will help in improving the ventilation for the workings in Benti section with CM

and low height LHD.

Ventilation layout of the panels: The existing B&P panels comprises of 4-8

headings in Churi block. For the proposed B&P panels in Bottom Lower Bachra and

Upper Section of Top Lower Bachra seams/sections, 5 headings layout has been

envisaged, wherever possible. In all these panels, it is generally proposed for

ascensional system of ventilation, as far as practicable, with 2-3 headings on the dip

side to work as panel intake airways while 2 headings on the rise side to work as

panel return airways.

13.4 FAN SPECIFICATIONS

The existing main fan (along with standby fans) is proposed to be utilized for

the project. The specifications of the present operating main fan is as under :

Paticulars

Fan & its motor

Model

PV200

Make

VOLTAS

Fan type

Exhaust

Impeller diameter (mm)

2000

No. of V-belt grooves

No. of V-belts

Fan pulley diameter (mm)

275

Motor pulley diameter (mm)

440

Fan RPM

880

Installed motor power (kW)

Motor RPM

1440

Total Current drawn (Amperes)

Voltage (V)

550

Job No: 3507127

XIII/5

CHAPTER - XIX

MANPOWER, PRODUCTIVITY & TRAINING

19.1 MANPOWER REQUIREMENT

The manpower for the proposed Churi-Benti UG project has been assessed

keeping in view the existing deployment at surface as well as underground. At

present, total of 905 (nos.) manpower is working at the mine (as on 01.01.2007).

The break-up of the existing manpower is given in Table 19.1.

The manpower requirement for has been estimated for the target

production of 0.81Mty, including existing production of 0.16Mty and incremental

production of 0.65Mty. The total manpower has been as 863 (nos.). Out of this

total manpower, underground manpower has been estimated as 651 (nos.) while

the surface manpower has been estimated as 212 (nos.). For the incremental

production of 0.65Mty, the incremental manpower has been taken 293 (nos.).

For surface manpower, all the existing places of deployment have been

taken into consideration. The same may be continued based on requirement.

Additionally, new places of deployment have been identified. For underground

manpower, manpower assessment is based on the requirement of re-organized

trunk transport, re-organized panels & equipment. The underground manpower

requirement has been worked out keeping in view the mine layout, number of

equipment and statutory requirement. Provision for manpower has been made

considering authorized absence of workers.

The detail of job-wise and category/scale-wise requirement of manpower

has been given in Appendix-B. The break-up of total manpower (group-wise) viz.,

Daily rated workers, Monthly paid staff and Executives proposed project is given

in Table 19.1.

Table 19.1 : Summary of Group-wise Manpower

Sl.

Particulars

Existing Manpower

Proposed Manpower

No.

Piece Rated Workers

177

---

Daily Rated Workers

576

697

Monthly Paid Staff

130

138

Executives

TOTAL

905

863

It may be noted that number and category/scale of persons employed may

be changed in actual practice within overall provision of manpower requirement.

Job No: 3507127

XIX/1

Summary of manpower requirement category/scale-wise along with

wages/scales & annual benefits has been provided in Appendix B.1. Phasing of

manpower during initial stages of mine is given in Table 19.2.

Table 19.2 : Year-wise Phasing of Manpower

Year

Existing

(2006-07)

Manpower

905

863

The retirement profile shows reduction of manpower to the tune of about 150nos.

in the next 2 years and about 235nos. in next 4 years. However, the existing

manpower of 905nos. has been considered during the initial years for the

purpose of present evaluation.

19.2

PRODUCTIVITY & OMS

The target production from the project is 0.75Mty including existing production of

0.10Mty and incremental production of 0.65Mty. The project is likely to achieve

the target production during the year 4. Considering total manpower of 950, the

overall OMS is estimated as 3.32tonnes and EMS is Rs 847.93. Considering

incremental production of 0.65Mty and incremental manpower of 293 (nos.), the

incremental OMS is estimated as 8.5tonnes.

19.3

TRANSPORT OF PERSONNEL

It is proposed for man-riding arrangement for transportation of workmen to the

nearby working places in the mine as the distance of travel is likely to increase

due to increase in the extent of the mine. The same is proposed along the

alignment of trunk roadways. It is suggested for haulage based mine cars for

man riding. However, arrangement / layout and type of man-riding system to be

provided in the mine may be finalized considering the suitability to mine at a later

stage. Lump sum provision for the same has been made in the report.

19.4

TRAINING

The success of Continuous Miner system relies as much on the training

programme and motivation of the management and operators as on the

machinery and methodology. Prior to deployment of CM at Churi-Benti UG

project, a team consisting of executives, supervisors from the mine and Planners

should visit the mines of SECL/WCL where Continuous Miner is in operation. The

supplier should arrange a workshop on operation and maintenance of CM.

Skilled manpower would be required for safe operations of the

machines/equipment and to make the mine a highly productive. The manpower

may be suitably identified and utilized for mine operations. The workers will be

Job No: 3507127

XIX/2

imparted safety & work related training at the V.T.C. Besides, regular refresher

training may be organized for the existing manpower at the V.T.C.

The actual manpower deployment in the mine is generally on the basis specific

job/work requirement. The work-load of the specific job is generally non-

continuous and actual working hours is very low for certain category of jobs. This

requires larger manpower deployment. It is now proposed for deployment of

multi-skilled crew for general services and maintenance purposes (during general

shift) and other works, which are non-continuous and can be clubbed together to

increase the actual working hours and minimise the total manpower. Such multi-

skilled crew is proposed to be developed by in-house training at the area level.

Supplier’s expert should give adequate training on operation of Continuous Miner

and its ancillary equipment to the workers. The education and training for the

electrical & mechanical personnel and operators should be conducted at the mine

site. The operators should be given "on the job" training by skilled, experienced

operator of supplier who will work alongside them for sufficient period until the

trainee is fully conversant with the safe and efficient operation of the controls and

method of work. It is suggested that all persons to be involved in this new

technology should be given a prior general and specific exposure to method of

mining & equipment to be used through theoretical lecture and visual aids, which

may be procured along with equipment.

The operators involved with Mass Production Technology, Belt conveyor,

Haulages etc. and electricians and mechanics would be imparted training by

trained staff for operation of the respective equipments as well as to ensure

safety of equipment. The refresher training will also be imparted to supervisory

staff in the Area Training Center as per the requirement and needs.

Depillaring will be introduced & practiced in the mine for the first time. Strata

control, monitoring as well as management, is likely to critical. It is desirable that

a strata monitoring cell may be established under a senior official at the mine with

appropriate instrumentation for monitoring of the strata and caving. The

executives, supervisory staff as well workers involved with the depillaring / strata

control may be given appropriate training for technicalities of strata management.

Strata control, monitoring as well as management, is likely to critical to the

success of the Mass Production Technology in view of proposed method. It is

desirable that a strata-monitoring cell may be established under a senior official

at the mine with appropriate instrumentation for monitoring of the strata and

caving. The executives, supervisory staff as well as workers involved with the

Mass Production Technology may be given appropriate training for technicalities

of strata management.

Job No: 3507127

XIX/3

CHAPTER - XX

SAFETY AND CONSERVATION

20.1

Safety Measures

All precautions stipulated under CMR, 1957 and circulars issued by DGMS

from time to time shall be strictly complied with, for the maintenance of safe

working condition in the mine. Some major identified sources of danger and

their preventive measures have been described in the paragraphs given

below.

20.2

Major sources of Danger

The following are identified as the major sources of dangers:

Surface inrush of water from Damodar River, Saphi River, Benti Nala and

other seasonal Nala passing over the leasehold property.

Workings of Ray-Bachra colliery and old abandoned workings of lower Bachra

seam which have been worked in distant past through incline no. 2, 3, 4 & 5.

along with old and abandoned workings of adjacent Manki colliery

Strata problem

Fire, spontaneous heating, dust and other inflammable gas.

Geological disturbances.

Blasting in roof of already developed galleries for Heightening of existing

galleries and side blasting for widening of existing galleries to facilitate the CM

operation.

20.3

Preventive Measures

The suggested preventive measures are as under:

Surface Inrush of Water: The sources for water inrush into the underground

workings are anticipated from the following sources: -

(a)

Damodar river

(b)

Saphi river

(c)

Benti Nala

(d)

Seasonal Nala passing over the leasehold property.

(e)

Surface cracks due to caving operation.

(f)

Geological disturbances.

(g)

Unplugged exploration Boreholes.

(h)

Potholes created due to caving of the overlying seams at surface.

To guard against the above-mentioned causes, the following measures have

been envisaged.

A solid barrier of 60m has been left against the Damodar & Saphi Rivers.

No working has been proposed within 60m of HFL line, except with the

permission of DGMS.

No depillaring is proposed below Piparwar Rehabilitation site, Seasonal Nala,

Benti Nala. Provisions for protective pillars to protect the important surface

features have been made in the report.

Job No: 3507127

XX/1

The filling of seasonal nala and low-lying area above H.F.L should be done

before going for depillaring operation. If possible, nala may be shifted/diverted

from the existing working. The existing topography compels that nala and low

lying area which comes under HFL line, is to be filled up with OB or other

suitable material above HFL. Since the construction of embankment against

the river Damodar may cause the creation of water reservoir over the

workings, therefore filling of seasonal nala and low lying area above H.F.L

have been proposed. If all the above is not possible, no depillaring operation

should be commenced below this area except with the permission of DGMS.

As subsidence progresses, surface cracks should be filled up effectively with

earth and the ground should be given adequate slope towards the water

bodies for natural drainage, so that surface cracks may not provide the way

for surface water to percolate below ground.

Garland drains should be made around the caved out area to prevent water

accumulation over the caved area.

The surface position of all the faults and geological features should be clearly

marked on the working plan and adequate precautions should be taken

against them.

The HFL line of Damodar River and Saphi River has been drawn as per

survey of 1976. The HFL of these rivers may have changed. So fresh survey

should be conducted to draw the correct HFL line as on date. While

approaching the workings below or near HFL, adequate precautions should

be taken to avoid any danger to the mine.

Effective protective measures should be taken against danger from

accumulation of rainwater, particularly over silted subsidence cracks, shallow

workings etc. as well as against the embankment if any.

10.

Effective measures should be taken against any obstruction in the normal

drainage of the area.

11.

Exploration boreholes, which are unplugged due to any reason, should be

effectively plugged.

12.

Potholes should be effectively filled up.

13.

Constant vigilance to be exercised during rainy season by the competent

person (Manager/ safety officer with senior most mine official & surveyors) to

check vulnerable points and effectiveness of safety measures. In case of any

doubt, persons should be withdrawn safely.

In addition to above, the provisions of Reg. 126 of CMR 1957 together with

circulars issued by the DGMS time to time should be complied effectively for

safe operation of the mine.

Underground Inundation: The sources of irruption of water from

underground to the workings are anticipated from the following sources:

(a)

Adjoining Ray-Bachra mine and old abandoned workings of inclines 2,

3, 4 & 5.

(b)

Workings approaching towards geological disturbances (faults, slips

etc).

(c)

Working below goaved out workings.

(d)

Unknown/ hidden water bodies in the overlying strata

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To guard against the above-mentioned causes, the following measures have

been envisaged -

The provisions of Reg. 107 of CMR 1957 (Working near mine Boundaries)

should be effectively complied with.

Sequence of panel extraction should be such as to avoid working below water

bodies.

The worked out panels isolated with stopping should be provided with water-

seals to prevent accumulation of water under high hydrostatic head behind

the stoppings, without leakage of the noxious gases from the goaved out

area.

Before commencement of extraction of pillars in a seam, the workings/ goaf of

overlying seams should be dewatered and made dry.

Hydro-geological studies should be conducted to locate the unknown/ hidden

water bodies, which might become potential source of inundation in future and

for safe drivages below Damodar River.

While approaching towards river and/ or any accumulated water bodies

advance boreholes should be made by the safety-boring machine. The

provision of the safety-boring machine has been made in this report.

Adequate parting should be left against the fault plane or any other geological

disturbances, if encountered.

All exploration boreholes drilled from the surface should be correlated and

plotted accurately on the working plan and all other plans. The boreholes

should be plugged with cement from bottom to top (full column) wherever

possible, to prevent direct inrush of water through such boreholes.

Any UG workings approaching within 60m of the water bodies, adequate

precautions should be taken as per the statute.

In addition to above, the provisions of Reg. 127 of CMR 1957 together with

circulars issued by the DGMS from time to time should be complied effectively

for safe operation of the mine

Precautions Against Spontaneous Heating

(a)

Underground Measures

Where development has been done without giving due consideration to

formation of panels, Isolation stoppings should be constructed to create

artificial panel.

ii)

Caving of seams should be done only in descending order. The crossing point

temperature should be freshly determined (if it is not known) for deciding the

size of the panels/ sub-panels.

iii)

Wherever possible, extracting of the pillars should be done soon after the

development of galleries, to prevent the crushing of pillars. Hence, there will

be minimum time gap between formation and extraction of pillars in each

panel.

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iv)

Regular and rapid advance of coalfaces should be maintained to ensure rapid

consolidation of the goaf.

Method of mining should be selected in such a manner that the minimum

coal is left in the goaf.

vi)

After completion of depillaring operation, the panel should be sealed off by

construction of approved type isolation stopping.

vii)

Ventilation pressure on the stopping should be kept balanced to prevent

inward leakage of air, which may cause spontaneous heating in the goaf.

viii)

Approved type Hydraulic fluid and fire resistant materials should be used in

the underground.

ix)

The roof coal is bound to left in the panels proposed for CM deployment in

CRO, since only 4.60m is to be extracted. There may be the chances of

spontaneous heating of coal in the goaved out panels. So isolation of panels

should be done with approved type of isolation stopping and regular

monitoring should be done to avoid any dangers in the mine.

(b)

Surface Measures

Surface cracks propagated up to the surface due to depillaring of the

seams should be filled with non-combustible material to prevent the air

leakage into the goaved out areas, which may cause spontaneous heating

in goaf.

ii)

The filling of cracks may be done with earth, clay and non-combustible

material of 1.5m thick nesses. The mutti (earth clay) should be placed in

thee layers of 50 cm each in succession, with proper consolidation. The

mutti seal should be kept moist for a period of 5 years.

iii)

It is observed that fireclay bands exist in the strata overlying the coal

seams in Churi mining block. The fire clay material, being plastic in nature,

may form a natural seal to the cracks caused due to mining. This will

provide additional support in filling the cracks. Hence it is proposed that

fire clay mining should not be permitted in that area.

iv)

In no condition, any combustible material or sand should be used for filling

up the cracks.

In addition to above, the provisions of Reg 117 and Reg 118A of CMR 1957

along with DGMS circulars should be strictly complied for safe operation of

the mine.

Precaution against fire

The sources of fire in the mine may be as under:



The spontaneous heating of goaved out panels in both the seams.



The existing fire in the same seams or section.



The existing fire in the near by mine which is connected with the working of

Churi UG by any means.



Due to presence of any source of ignition.

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Adequate precautions should be taken to prevent the spontaneous heating of

coal. When the UG working approaches to any old working or adjacent

workings, which is under fire, then adequate precautions should be taken as

per statutes for safe working of the mine.

In addition to the above, the provisions of Reg. 118, 119, 120, 121 & 122

together with various circulars of DGMS should be effectively complied with

for safe working of the mine.

Precautions due to contiguity of the seams:

Although, this Production augmentation report doesn’t envisages the workings

in the contiguous part but it may have to be done in future. The following

precautions may be adopted in the contiguous part :

(i)

Working in both the seams should be vertically coincident.

(ii)

Vertically should be checked by putting holes at the alternate junctions

of the gallery.

(iii)

The thickness of parting should be not be less than 3.0m in any case.

(iv)

If working is to be done in both the seams independently, prior

permission should be obtained from DGMS and upper seam to be

depillared first.

(v)

For working both the seams simultaneously, the line of extraction in

both the seams should be vertically coincident.

(vi)

In addition to above, the provisions of Reg. 104 of CMR, 1957 and

circulars issued by DGMS should be strictly complied with.

Precautions against Noxious gases and Inflammable gases

The Churi UG mine has its underground workings in both the seams namely

Lower Bachra and Upper Bachra and is almost fully developed by Bord and

Pillar method of mining with SDL/LHD loading and manual loading of coal.

During development of both the seams, no incidence of abnormal make-up of

gas was noticed and the mine is declared Degree-I mine. Two main

mechanical ventilators of adequate capacity to cater to the ventilation

requirement as well as for dilution of various gases including inflammable

gases of the mine has been installed at the mine. Presently one fan PV-200 in

air-shaft is operating in Churi Old mine area and is catering to the ventilation

requirement of whole mine. Continuous Miner have in-built methane indicator

along with the other safety instruments, so as to warn in advance before any

apprehended danger. The other following precautions should also be taken:

(i)

Churi underground is degree-I gassy mine. Adequate provisions have

been made in the report towards building up and maintenance of

standards of ventilation as per Reg 130 of CMR-1957.

(ii)

Regular monitoring of atmosphere i.e the presence of noxious and

inflammable gases in the goaf of UBS should be made.

(iii)

The auxiliary fans should effect brisk ventilation of headings/workings.

(iv)

The provisions of Reg 124, 142 and various circulars issued by the

DGMS should be effectively complied with.

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In addition to that other provisions of CMR 1957 related to gas and ventilation

shall also be complied effectively for safe working

Precaution against Dust

Due to operation of Continuous Miner, coal dust may be formed in

appreciable quantity at the face, which may cause health hazards. In order to

prevent it to be air bone, the Continuous Miner cutter head is equipped with

powerful water sprays. An optional integral dust collector is also available with

the machine, which controls the dust in the machine vicinity. The adequate

provision for water arrangement is made in the report. The adequate

precautions should also be taken for preventions of accumulations of dust

particles for safe operation at face. The provision of stone dust barrier should

also be implemented in the gate belt in in bye ends and out bye end. The

other following precautions should also be taken:

(i)

Adequate provisions have been made in this report for supply of water from

surface for dust suppression in CM-panel, LHD panel. Provisions have been

made in this report for adequate ventilation of the workings. Steps should be

taken for effective compliance of the various provisions.

(ii)

It is suggested that regular and systematic sampling of air-borne dust is to be

made for control of air bore dust to safe concentration level.

(iii)

In addition to above, the provisions of regulation 123, 123A and 123B together

with various circulars issued by the DGMS from time to time should be

effectively complied with for safe working of the mine.

Precautions for strata control

(i)

While development or depillaring of the panel, the supporting should be done

as per the approved SSR.

(ii)

Since the immediate roof predominantly comprises of carb shale, shaly coal

shale, alternate bands of shale and sand stone, so while development in any

of the seam a coal of 0.3-0.5m thickness should be left against the roof.

(iii)

In case of roof bolting, it must be supplemented with the conventional support

as and when required.

(iv)

The scientific body should conduct the fresh cavability study of the strata for

Churi UG mine.

(v)

Adequate no. of convergence recorder, load cells etc. should be installed

while depillaring in any panel to protect from danger of air blast.

(vi)

Record of local fall and main fall should be properly maintained and analyzed

in the safety committee meeting, so that the general awareness regarding

local fall and main fall can be created among the workers and officials.

(vii)

All other steps as needed by the situation in accordance with the provisions of

regulations and circulars should be taken to avoid any mishaps due to roof

fall.

(viii)

In addition to above, all other provisions of CMR, 1957 which is attracted by

strata problems together with various related circulars should be effectively

complied for safe working of the mine.

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(ix)

As and when required, induced blasting may also be used to bring down the

roof regularly.

The provisions of Reg 108 of CMR, 1957 and various circulars related with it

should be effectively complied.

Working below PWD road and Power trestles

The PWD road between Bijupara & Hazaribagh together with other roads and

many power trestles are passing almost through the Churi mining area and it

has to be shifted to facilitate depillaring operation in the proposed area. The

provisions for shifting of trestles, road, basti, filling of low lying areas and other

infrastructure belonging to company have been made in this report

Development under these roads and power trestles has already been done. In

case of non shifting of power trestles and the roads, two nos of pillars or

distance considering angle of draw of 45 deg. of the workings (which ever is

more) should be left un-extracted on both sides of the roads and power

trestles to protect it. This should also be applicable for all those surface

features like nala, DVC Sub station, and any other important surface features

which is to be protected and may cause any danger in future.

While working below surface features, the various provisions of CMR

1957 related to that together with various circulars should be effectively

complied with for safe operation.

Signalling & Lighting

Sufficient lighting as per standards will be provided at all the required places

i.e. at coal transfer points, loading points, working faces, along trunk and gate

belts, feeder breaker, switch gear and maintenance area. Adequate lighting

provision has to be made at underground workings, workshop and coal

dispatch area to avoid accidents and to maintain safe working condition. Good

communication between face, conveyor drives, key points in underground,

surface control rooms, offices, workshop etc., is essential for efficient

operations. Intrinsically safe signaling equipment of audio- visual type should

be installed in underground for smooth and efficient communication between

various points. In addition to above, the provisions of CMR, 1957 together

with related circulars should be complied.

Precautions against subsidence due to depillaring by caving

The following control measures have been suggested.

(i)

As subsidence progresses, surface cracks should be filled up effectively with

earth and the ground should be given adequate slope towards the water

bodies for natural drainage, so that surface cracks may not provide the way

for surface water to percolate below ground.

(ii)

Garland drains should be made around the caved out area to prevent water

accumulation over the caved area.

(iii)

It is suggested that mine management should form a team that will be

responsible for the proper and regular filling of surface cracks developed due

to subsidence. The team will also maintain record of the development and

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filling surface cracks. Mine management at the site should arrange adequate

supply of filling materials.

(iv)

Surface drains should be made outside the subsidence area to prevent the

surface water of adjoining area to come into active subsidence area.

(v)

The topography of the mining area is uneven and the ground elevation varies

from 402 to 468m, i.e. a difference of elevation of 66m. For such terrain, the

maximum anticipated subsidence of 3.655m (for both seam working) is

unlikely to extensively affect the drainage pattern in the area. However,

subsidence may result in the formation of depressions over the center of the

panels where water may accumulate during rains. So, adequate precautions

against accumulation of water may be taken..

(vi)

The surface features, such as rivers, surface structures and PWD road,

existing over the mining area are likely to be affected by subsidence. So either

it should be shifted or adequate precautions to protect surface features may

be taken.

(vii)

The nala flowing over the mining area are likely to be affected by subsidence.

It is to be protected by leaving coal pillars un-extracted vertically below and

within the subsidence influence area. Tenancy land over the mining area is

likely to be affected by subsidence. Thus, if any cultivation is being done in

such land, crop compensation to be paid to the tenancy land owners during

the year when depillaring operation will be carried out in the panels below it

and subsequent reclamation by filling and consolidation of the land.

(viii)

The HT lines over the mining area are likely to be affected by a maximum

amount of 1.908m subsidence. Thus, pylons of HT lines need to be protected

by leaving coal pillars un-extracted vertically below it or HT lines should be

shifted from the subsidence zone.

(ix)

An abandoned quarry on the northern side of the mine boundary is unlikely to

be affected by subsidence as it is away from the subsidence area. It is

recommended that while carrying out extraction in the panels of Upper Bachra

seam, close subsidence monitoring should be done and their impacts and

effectiveness of the mitigative measures should be reviewed before starting

depillaring in lower seam.

Precautions against Blasting in Heightening District.

Since the entire mine is developed up to 2.4m only and it is to be heightened

up to 4.60mto facilitate the CM operation for depillaring of standing pillars.

This type of heightening experiences will be totally new for the project. So,

before going for heightening, the permission from DGMS for Blasting,

Support, Ventilation and other workings should be obtained. The entire mining

operation should be in accordance with the provisions mentioned in the

permission. In addition to above, other provisions as per statute should be

strictly complied with.

Environmental Monitoring

To ensure the safe operation of the mine, the following aspects should be

measured periodically and adequate precautions as per statutes should be

taken.

ii)

Fire damp (CH4)

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iii)

Carbon-Monoxide (CO)

iv)

Temperature

Humidity

vi)

Coal dust concentration

The various provisions regarding monitoring and remedial measures for each

of the above as per CMR, 1957 and other related circulars should be

complied with effectively.

Conservation

In Churi Block, two coal seams namely Lower Bachra and Upper Bachra exist

with a parting ranging from about 0.47-18m. The thickness of Lower Bachra

seam generally varies from 3 to 5m and gradually increases to 9m in the

western part. The thickness of Upper Bachra varies from 2 to 3m in the major

part of the area.

In Benti block, the Lower Bachra seam is splitted in two parts Bottom Lower

Bachra & Top Lower Bachra. Top Lower Bachra further splits into two parts

Upper section of Top Lower Bachra & Lower section of Top Lower Bachra. In

part of the areas these two section merges and forms combined Top Lower

Bachra. Two sections namely, Bottom Lower Bachra & Upper Section of Top

Lower Bachra / Combined Top Lower Bachra is workable through out the

property in Sector-A of Benti Block.

The mine is developed up to 2.4m in most part of the property in Churi

Block. Presently development is in progress in bottom lower Bachra seam in

Benti Block. The development height is 2.4m.

The maximum cutting range of the proposed Continuous Miner (which

has been successfully deployed at Anjan Hill Mine, SECL) is about 4.6m.

Continuous Miner having cutting height more than 4.6m. is also available. But

it requires gallery width of 5.5m. But LBS has been developed with gallery

width 4.2m. So, it limits the choice of the machine. The percentage of

extraction achieved may be about 65% of the coal in standing pillars,

considering the average thickness of coal in the area proposed for mining. In

general, coal seams exhibit variable thickness. The seams having thickness

greater than 3.0m has been proposed for continuous miner working. The use

of continuous miner will increase the percentage of recovery as compared to

conventional Bord and Pillar Method. The layout of panels and the extraction

of pillars have been envisaged in such a manner to result minimal losses of

coal in the goaf.

General

All underground workers will be provided with self-rescuers and all such

resources will be examined and maintained by competent person. Where

formation of coal dust is more than permissible limit, approved type of dust

respirator will be provided to the workers. The various provisions of CMR,

1957 related with the safety of the mines and persons employed there in

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CHAPTER-XXI

ENVIRONMENT MANAGEMENT

21.1 GENERAL

The present report covers part of area under Churi & Benti (partly) blocks.

Upper & Lower Bachra seams are presently being worked at the mine. Presently

development is in progress in Bottom lower Bachra seam of Benti block (Sector-A)

and upper Bachra seam of Churi Block. It is proposed to introduce Continuous Miner

technology in the mine. The method of mining proposed is Bord & Pillar with caving.

The average seam thickness within proposed mining area of the workable seams is

about 5.5m. The range of extraction height in the seams will be restricted to 4.6m.

The maximum depth of mine workings in the mining area is likely to vary from about

21m to 121.68 m.

A study for subsidence prediction and management for Churi U/G was carried

out at CMPDI (HQ) considering 4.6m of extraction and extraction for both the seams.

It has been estimated that the maximum possible subsidence over the mining is

3.784m. The estimated tensile strain values in the forest area due to extraction of

Upper and Lower Bachra seams individually and after extraction of both the seams

are exceeding the limit prescribed by MOEF, i.e. 20mm/m. In the forest area such

amount of tensile strain is likely to develop surface cracks more than 300mm wide.

Part of the Benti block was beyond the scope of the study for subsidence. Churi-

Benti project consists of part of Churi Block and part of Benti Block.

The method of extraction proposed for Churi-Benti Project is B & P with

caving. Previously, no depillaring activities have been undertaken within the mining

area. Major area under the project lies at moderate depth of cover. It is expected that

caving in underground may cause subsidence at surface. Hence, it is proposed to

undertake fresh subsidence study for appropriate evaluation.

The surface topography of the mining area is uneven. The ground elevation varies

from 402 to 468m above MSL. The general slope of the area is towards east and

west sides. Damodar and Saphi rivers flowing on the western and eastern boundary

of the Churi block respectively and control the surface drainage of the existing mine

area. Major portion of the surface over the proposed mining area is under forest and

remaining is tenancy land. PWD road, few kutcha, Power trestles & forest roads are

passing over the mining area. Accordingly, these surface features are proposed to

be shifted and villages are proposed to be rehabilitated / resettled

Provision has also been made for compensatory afforestation, anti-pollution

measures, base line data generation, and for earth filling over subsidence area

caused by depillaring with caving

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Sufficient storage capacity has also been provided in the main underground

sump, so that the suspended dust particles generated due to underground mining

operations settle down and comparatively cleaner water is discharged on the

surface. Capital provision for settling tank has also been made in this report. Oil &

grease trap would be constructed near workshop to treat effluents.

The solid waste debris due to excavation of inclines/drifting, etc. would

be utilised for making the haulage embankment and surface levelling. So, any

adverse effect on environment is not expected. Plantation at industrial site may be

done for aesthetic look.

The noise level at the transfer points of coal in the underground workings as

well as at the face and on surface, would be kept within the permissible/

recommended level of 85dBA. The general ecology comprising flora/fauna/general

environmental and air, water, noise etc will be protected and improved.

21.2 COMMUNITY DEVELOPMENT

For better relation with the neighboring villages and as corporate social

responsibility, it is required that community work like play ground, park, drinking

water, road etc. may be provided. Churi UG mine is an existing mine and several

works have been undertaken in the past for community development. However,

provision of lump sum additional capital for community development has been

envisaged.

21.3 EMP CAPITAL

The total additional capital under EMP head has been estimated and is shown

in appendices. Further, provision has been made for EMP related activities from

revenue account @Rs. 4.0/tonne, as ‘Environmental Protection Cost’.

EMP of Churi UG Project was prepared in the past considering the technology and

production target of approved Feasibility Report. Since the technology and mining

area has changed and boundary has also been re-adjusted, there is a need for

preparation of a new EMP considering all the aspects of the Churi-Benti Project.

A comprehensive EMP report dealing with the impact of mining on

environmental attributes & various mitigative measures will be prepared separately.

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CHAPTER-XXII

MINE CLOSURE PLANNING

22.1 PREAMBLE

Mining is a hazardous operation as it offsets the equilibrium of natural

depositional environment viz. in-situ stress field, ground water, surface drainage

system as well as the socio-economic condition. Although mining activities are

usually short-term phenomena, they are liable to leave long lasting impacts on

landscape, ecology and on the mind set of local inhabitants. Thus, it is imperative

that any mining venture should have adequate closure plan addressing issues viz.

reclamation and environmental protection, rehabilitation of disturbed area.

Community implementation of mine closure plan will incur some extra cost,

neglecting this aspect will lead to future problems of attending compensation or

expensive socio-economic problems.

Hence, efforts have been made to identify the likely impacts on geo-

environmental and socio-political set-up due to closure of the proposed Churi-Benti

UG project during the planning stage itself, so that it will offer an opportunity to

generate resources for mitigative measures during closure of the mine.

22.2 LIFE CYCLE CONCEPTS

Mining Projects have a definite life cycle. All the mines have to eventually

close their operation. The reasons for the closure may be many including economic

conditions, depletion of mineable resource or any other unforeseen safety reasons.

In the present project proposal the mine life cycle planning is governed by the

reserves content in the proposed mining area. Here, it is planned to exploit Lower

Bachra seam in Churi block and Bottom Lower Bachra seam & UTLB in Benti

section. As per mining schedule, the project life is estimated as 11 years. It is

suggested that the activities for closure will be initiated at an early stage of project

life in a gradual/planned manner.

22.3 MINE CLOSURE PHASE

The mine closure phase is supposed to be closed when the mine is de-

commissioned, facilities at site are removed, the mine entries are sealed / fenced off,

the management of waste dump/tailing is completed and the site is released in

ecologically sustainable suitable for proposed land use.

The likely impacts due to closure of the mine in so far as the geo-technical/

safety/ environment and socio-political aspects are concerned and the suggested

mitigative measures are elaborated as under:-

A) Technical aspects:-

i) Mine Entries : It is suggested that mine openings & workings will be

properly closed & sealed so as to prevent any danger to post-mining uses of area.

ii) Service Buildings : The service buildings/structures will be removed/

demolished or may be used for some offices and the land covered under them

restored for productive uses.

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iii) Hazardous substances : Prior to surface demolition/restoration, a surface

audit will be undertaken on all surface structures, spoil heaps, lagoons etc. to assess

whether there are any hazardous materials that could cause problem i.e. explosive,

asbestos, chemical oil etc.

iv) Disposal of assets : A list of surface and UG assets (P&M) will be

prepared and made available to potential purchasers or transferred to other

new/working mines of the company. This will ensure that the assets perform till its

economic life and have better utilisation of assets.

B) Environmental aspects

i) Post closure Env. monitoring : It is suggested that the air & water quality

parameters in the mined out area is monitored by some agency even after closure of

the mine.

ii) Land reclamation and rehabilitation : The area on surface is mainly

covered by forest, tenancy, cultivable & Govt. land. The method of mining is

depillaring by caving under low to moderate depth of cover. The degradation of

surface is expected due to caving. If any cracks / voids are created due to

underground mining activities, it will be restored to original profile by filling up cracks

/ voids. The post-mining surface profile should ensure no accumulation of water and

to maintain the general drainage pattern. It is suggested that the site restoration is

progressive so that the restoration is more or less similar to the rate of mining.

The objective of restoration of post-mining area will be determined through

consultation with local community and the govt. authority, so that the potential/

required end use of the mined out land is determined in advance. Such usage may

be agriculture, forestry, amenity development or nature reserve. Necessary capital

provision in the revenue account is indicated in the report.

C. Socio-political aspects

i) Mining Community : Due to closure of mining operation persons directly

employed in the mine will be surplus. It is suggested that suitable manpower plan

may be formulated by the mining company sufficiently before closure of mine for re-

deployment of the work force in other units of the company.

The community in the region is highly dependent on agriculture, forest and

other activities. The existence of mine is providing employment or other indirect

benefits to the community. The mine closure is likely to create negative impact on

the socio-economic condition of the region. It is suggested that the mine owner will

interact with the local govt. to establish strategy for supporting the project affected

community of the region by promoting investment in non-mining related enterprises.

ii) Mining Township and Water supply : It is suggested that the civic

facilities developed during the mining phase will be transferred to the local

govt./municipality so that, the region transforms smoothly into post mining phase.

The plan of closure shall be implemented in consultation with all

stakeholders including state government.

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CHAPTER XXIII

LAND & PROJECT IMPLEMENTATION SCHEDULE

23.1 LAND ACQUISITION

23.1.1 Mining Area

The distribution total area within mine boundary is as under:

Existing area within mine boundary

7.68 sq. km

Churi block

5.89 sq. km

Benti block

1.79 sq. km

Area where CM is proposed

2.44 sq. km

Churi block

2.03 sq. km

Benti block

0.41 sq. km

23.1.1 Quantum & Type of Land

Land-use within mine boundary: The proposed mining area under the project

covers area of existing Churi reorganization (CRO) mine and part of Benti Block. The

northern limit of the mining area in Benti block is up to the existing adjusted

boundary with Ashoka OCP of Piparwar Area. The limits of developed pillars in Churi

block and adjoining virgin area in Benti block up to existing mine boundary

constitutes the mining area for the project. Major part of the area within the proposed

mine boundary is forest land. Power trestles and roads are passing over the

property, which needs to be shifted. Many villages like Pahan Tongari, Sakhuwa

Tola, Jobia Sarna, Manu -Tand, Barwatand, Amba-gram, etc. are situated over the

proposed property. Villages & other surface features falling over the mining area

needs to be shifted / rehabilitated. The quantum and type wise land use of the area

within the proposed mine boundary is shown in Table 23.1. This detail of land is as

per the land use plan supplied by the project.

Table 23.1: Summary of Land-use over Total Area within mine boundary

Usage of

Existing Land Area (Ha)

Total

Land

Churi block

Benti block

(Ha)

Forest

443.48

49.98

493.46

Non-Forest

145.38

129.14

274.52

Total

588.86

179.12

767.98

Within the existing mine boundary, the land over the mining area is to be acquired for

extraction of coal (development & depillaring). The area lying on south of fault F10

has been excluded as extent of mining is not known. Only the area lying on the north

of fault F10 in Churi & Benti block (within existing mine boundary) is available for

extraction and is about 6.04 sq. km. The land use for the above area considered for

mining is shown in Table 23.2.

Table 23.2 Details of actual mining area are as under

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Usage of

Existing Land Area (Ha)

Total

Land

(Ha)

Churi block

Benti block

Forest

382.34

49.98

432.32

Non-Forest

58.42

113.56

171.98

Total

430.76

171.98

604.30

If the total area is to be depillared then surface land of 604.3 Ha of land is to be

acquired. It comprises of 432.32.Ha forestland and 171.98 Ha non-forest land. Total

amount of rupees required for the acquisition of this total land will be around 5533.22

lakhs (i.e. 55.33 Crores). As decided in the FD’s of CCL, it was directed to make

provision for land acquisition only for CM deployment.

Land-use for CM Deployment: Out of the total mining area as mentioned above,

only part of the area is proposed for CM deployment. Area of the western section of

CRO (up to W-15 panel) including panels E12 & E13 and part of the Benti block up

to its existing boundary in Benti block. Major part of the area proposed for CM

deployment is forest. The quantum and type wise details of land for the proposed

area for CM deployment are as shown in table 23.2.

So, out of the above 604.3 Ha, only 229.10 Ha of forest land & 15.5 Ha of non-forest

land will be required for CM deployment and provision for the same has been made

in the report which amounts to 28.94 Crores.

Table 23.2 : Summary of Land-use for CM Deployment over Mining Area

Type of Land

Within Existing Boundary

Total Land

Churi

Benti

(Ha)

Forest

203.5

25.6

229.1

Non-Forest

15.5

Total

203.5

41.10

244.6

The above delineation of land is based on the land use plan supplied by the

colliery authority. Considering possibility of subsidence, it is proposed to acquire land

on surface taking into account the NPV of forestland and compensation of

private/govt./other type of lands.

If CCL management makes boundary adjustment up to Fault F-13 in Benti

block, the additional 31 Ha of land will have to be acquired. Presently, diverted

Benti nala, haul road of Ashoka project & other important road are passing over this

additional property. This 31 Ha land comprises of 24.2 Ha of forestland and 6.7 Ha

of non-forest land. The boundary adjustment can provide a longer development life

for CM. Since Area officials have not agreed for boundary adjustment, this extended

part is beyond the scope of this project report.

Land requirement for other infrastructure of the mine: Major infrastructure

for the project / mine already exists on surface including residential colony & other

welfare measures. The surface land other than the mining has not been proposed for

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acquisition. The land acquisition for the project has not been done till today. It has to

be acquired for the project for the exploitation of the developed and virgin reserves.

As directed by FDs, it is proposed to acquire land (all rights / surface rights) only for

the purpose connected with introduction (development & depillaring) of Continuous

Miner only. Accordingly the provision has been made in this report.

23.1.2 Status of Notification & acquisition

The entire area within the proposed mining area is already notified under

section 9 of CBA Act. The details of the land acquisition (as provided by the CCL

authorities) status for Churi-Benti UG project is as below:

a) The revised forest application in new format was submitted to the DFO,

Ranchi (East) on 13.7.05.

b) DFO has forwarded to CF on 27.10.05.

c) Latest development in the process of acquisition of land as communicated by

CCL management is that the proposal for land acquisition is pending with

RCCF.

The actual status for the land acquisition for CM deployment in Churi-Benti

project has been assumed that it is not acquired till today, so the provision for its

acquisition has been made in this report.

The cost of forest land has been taken as Rs 12.60 lakhs/Ha and non-forest land

has been taken as Rs 0.50 Lakhs per Ha. Forest land includes GMK (jungle-

jhari).

23.1.2 Time-frame for acquisition with capital provision

The phasing of the quantity of land and its capital provision is shown in

Appendix-A.1.

23.2 PROJECT IMPLEMENTATION SCHEDULE

The activity for project / mine development will commence only after the

acceptance of De-rating cum completion report (foreclosure) report of Churi UG

project and sanction of the present report. As most of the surface infrastructure

exists, initially efforts would be made to commence the trunk roadway development

in Bottom Lower Bachra seam and undertaking various activities required facilitating

introduction of Continuous Miner. Simultaneously, efforts would be made for timely

procurement & commissioning of the Continuous Miner. Efforts would be made for

consolidation of existing coal evacuation system, man-riding arrangement, pumping

& ventilation re-organization, etc. The schedule for procurement of additional Plant &

Machinery (P&M) & other infrastructure along with their capital phasing have been

detailed in appendices

Zero Date: The zero date for the project has been considered as the date of

sanction of PR and/or EMP approval, which ever is later. The project construction

activities would start from Year 1. It has been assumed that the activity of PR/EMP

approval and land acquisition for CM deployment would be completed in the first two

(2) years, i.e. by the end of Year 2.

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For timely implementation of project, it is essential that all activities related to

construction of the project are properly scheduled, closely monitored and effectively

supervised. All departments will have their own implementation schedule to get the

project constructed within the time frame. The resources should be made available in

time as soon as the project report gets sanctioned to prevent time & cost overrun.

The construction activities are required to be identified in detail for appropriate

monitoring and timely implementation of the proposed project so that the project

achieves its target output within time frame.

Construction Team: It is proposed to appoint a Project Officer (mining) of M-

1 rank and Colliery Manager of E-5 level along with a group of Asstt. Managers of E-

4/E-3 level for the mine. It is proposed that each of the units will have a dedicated

team of electrical and mechanical engineers to take up the project development

activities for timely execution of the work.

23.3 YEAR OF COMMENCEMENT OF PRODUCTION

The existing production from the Churi-Benti project is about 0.16Mty. It is

proposed to enhance the production level of the project to 0.81Mty. The target year

to achieve the rated production is Year 4. Year-wise production schedule during

initial years in shown in the Table 23.3.

Table 23.3 : Production Schedule during Initial years

Technology / Year

Year 1

Year 2

Year 3

Year 4

Year 5

Manual B&P district

0.06

---

B&P with low-height LHDs

0.10

0.16

B&P heightening district with

---

0.10

0.15

remote controlled LHDs

Continuous Miner

---

0.40

0.50

Total Production (Mt)

0.16

0.66

0.81

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CHAPTER- XXIV

FINANCIAL EVALUATION

24.1

TOTAL CAPITAL INVESTMENT

Churi UG is an ongoing project in CCL. With the aim of CCL to augment coal

production this PR has been envisaged with production augmentation of

Churi-Benti UG to 0.75 MTY. Accordingly the economics has been worked out

considering introduction of Continuous Miner Technology (for the first time in

CCL). The estimated economics have been discussed in the subsequent

paragraphs.

Initial capital investment has been provided in the report till the year of

achieving rated coal production i.e 4^th year. The capital requirement both

Initial as well as beyond target year, has been proposed from the own

resources of the Company. The estimated capital requirement is given below:

Rs.Crores

Sl.

Particulars

Initial Capital (Up to target year)

163.41

Additional Capital (upto target year)

145.44

Existing Expenditure upto 31.3.06

17.97

considered in this PR

Capital beyond target year.

2.39

Specific Investment Rs./t

2178.81

Foreign Exchange: Foreign Capital will be involved in this project. The

estimated foreign exchange requirement is shown in Appendix-A.3.5.

The details of capital investment under various heads viz. Land (A.1),

Buildings (A.2), Vehicles (A.6), Prospecting & Boring (A.7) and Development

(A.8), are given in the appendices mentioned against each of them.

24.2

CAPITAL INVESTMENT ON P&M

Capital investment on P&M is given in Appendix-A.3. The detailed break-up

for P&M, Electrical, Pump & Pipes, Workshop and Other P&M etc. are given

in Appendix-A.3.1 to A.3.5. The estimated capital investment on P&M is given

below:

Rs. Crores

Sl.

Particulars

Additional P&M (up to target year)

111.59

P&M (beyond target year)

CMT Package (up to target year)

66.80

CMT Package (beyond target year)

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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. Price of Continuous Miner has been based on the price of equipment in

a recently concluded agreement between ECL & supplier for CMT introduction

at Jhanjra mine, ECL. The 100% payment to the supplier will be on the basis

of outright purchase.

Estimated Cost of Civil Construction

The basis for the estimation of the cost of civil construction viz. residential

buildings, service buildings, roads etc. has been given in Appendices - A.2.1,

A.2.2 & A.8.2.

Capital Investment on Vehicles

The additional capital investment on vehicles is estimated as Rs. 10.00 Lakhs.

The details are given in Appendix- A.6.

Development

Under this head, estimated investment is given for (a) capital outlay in mines

(Appendix A.8.1), (b) Roads and culverts, including haul roads (A.8.2), (c)

Water Supply & Sewerage (A.8.3). The details of each item are given in the

respective Appendix indicated in bracket.

Opening of Revenue Account

Churi UG project is an existing ongoing project.

24.3 COST OF PRODUCTION

The overall estimated average cost of production of this proposed Project

comes to Rs.1261.01/t and Rs. 1404.94/t at 100% and at 85% operation

levels respectively. The break-up of different cost elements is shown in

Appendix-C1 & C2. Salient points regarding estimation of revenue costs are

mentioned below:-

Salary/Wages : There is no additional requirement of manpower.

However for the purpose of its impact on CPT, the requirement of

manpower is estimated category wise/ scale wise and details of

manpower are given in Appendix - B1.

Prevalent pay scales for executives and non- executives (NCWA-VII)

are adopted. Mid points of the relevant pay scales of executives & non-

executives have been considered in estimating the salary and wages

cost. EMS works out to be Rs. 847.93. The average wages cost per

tonne works out to Rs. 346.40.

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Store :

Repair and Maintenance : As per standard norms formulated by

CMPDI for underground mine.

ii)

Explosive and Timber/Roof Bolting : Based on approximate

consumption pattern of underground mines in the Area.

iii)

POL & Miscellaneous store cost : As per CMPDI norms.

iv)

Spares & Maintenance (for the life of project) for CM (refer to

Appendix A.3.5 for details), has been considered as per the

agreement for Jhanra mine, ECL. These are however subject to

change upon finalisation of agreement with supplier during

implementation.

The average store cost including all the above works out to Rs.

309.61/t.

Power : Detailed calculation of specific energy consumption per tonne

of output is given in the chapter for power supply, illumination, etc.

Power cost per unit kWh is considered as average Rs.3.20/unit. The

average power cost per tonne works out to Rs. 56.84.

Misc.expenses including workshop debit : 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 major equipment, insurance and taxes for vehicles,

normative contractual cost of major maintenance. The average misc.

cost at 100% capacity level works out to be Rs. 64.08 /t.

Supervision Charges for CM : This cost is for a period of five years of

initial operation of CMT package and has been considered as per the

agreement for Jhanra mine, ECL. These are however subject to

change upon finalisation of agreement with supplier during

implementation. This works out to Rs. 138.24/t.

This would involve operational supervision by suppliers’ personnel with

other overheads. The incidence of income tax on salary of such

personnel and service tax on services provided has been included in

these charges.

Depreciation: Depreciation on assets is computed as per the prevalent

norms. The straight-line method of charging depreciation has been

adopted. The average depreciation cost per tonne at 100% level works

out to Rs. 246.29 /t.

Administration charges: It is taken as Rs. 54.46 per tonne of annual

output based on average cost per tonne of CCL .

Interest on Working capital @ 12.5% works out to Rs. 40.59/t.

24.4 GRADE OF COAL SELLING PRICE & PROFITABILITY

The present declared grade is ‘Gr. B’. The same has been considered for the

purpose of present economic evaluation. Considering the above and overall

estimated average cost of production of Rs.1261.01/t and Rs. 1404.94/t at

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100% and at 85% operation levels respectively, the project is likely to earn a

profit of Rs. 179.99/t and Rs. 36.06/t, respectively. The profitability at different

level of operation is presented in Appendix-C.1&2.

24.5 BREAK-EVEN PRODUCTION

It is estimated that the project would break-even at 36.86% of production

capacity.

24.6 INTERNAL RATE OF RETURN

The overall financial Internal Rate of Return (FIRR) of the Project works out to

9.33% and 0.08 % at 100% and at 85% level of production respectively. The

year-wise production and present declared grade ‘B’ selling price of Rs.

1441.00/t has been considered for IRR calculation. However, with a slippage

of grade by one stage i.e Grade C, the IRR will not be positive.

24.7 SENSITIVITY ANALYSIS

The following parameters have been identified for assessing their impact on

the profitability of the project.

Capital investment

Operating cost

Capacity utilisation

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:

Variable Parameter

IRR at different stages of

10%

15%

20%

25%

Increase in Capital

9.33

8.34

7.40

6.51

5.66

4.85

Increase in Cost of Prodn.

9.33

6.24

3.10

tive

Decrease in Capacity

9.33

9.12

4.73

0.08

tive

Decrease in Selling Price

9.33

5.00

0.42

tive

24.8 INCREMENTAL SCENARIO

An option has been included, which shows the incremental impact of the

introduction of CMT in Churi-Benti for an incremental production of 0.65 MTY.

The salient features of the incremental analysis is tabled below:

Sl.

Particulars

Incremental Capital (Up to target year) Rs.Crores

145.44

Incremental Average cost of production Rs./t

827.16

Incremental IRR at 100% of incremental Prodⁿ. %

21.17

Incremental IRR at 85% of incremental Prodⁿ. %

13.35

Incremental Specific Investment Rs./t

2237.55

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