Workshop on “The Technology Development &

Mechanisation of Mines for enhancing

Coal Production & Productivity ”

20th January, 2015

Presentation by

Western Coalfields Limited

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

WCL contributes more than 7% of the total National Coal Production from its 3.26% of the total National Geological Coal Reserves

2

Western Coalfields Limited

Coal ReservesCoalfield

Resources

Reserves Total

Maharashtra

Wardha Valley 2.90 0.82 3.72Umrer Nand Bander 0.36 0.21 0.57

Kamptee 0.87 0.21 1.08Madhya Pradesh

Pench Kanhan 1.07 0.20 1.27Pathakhera 0.22 0.07 0.29

Total 5.42 1.51 6.93

(in Billion Tonnes)

(As on 01.04.2013) 3

Western Coalfields Western Coalfields LimitedLimited

Unique Feature of WCL • Adverse geo - mining condition• Deep seated Reserve• High stripping ratio• Presence of Black Cotton Soil & Silt• Lower grade Coal• Smaller Capacity Opencast Projects• Very old and extensive UG Mines• Heavy Water seepage (Kamptee Series)

8.7 8.39 8.2 7.73 7.9

34

.95

34

.72

34

.09

32

.00

36

.10

0

10

20

30

40

50

2010-11 2011-12 2012-13 2013-14 2014-15BEUnderground Opencast

43.65 43.11 42.29

Performance at a Glance : Coal Performance at a Glance : Coal ProductionProduction

44.0039.73

Figures in Million Tonnes 5

Growth: 10.7%

Mill

ion

Tonn

es

53

.42

58

.93

52

.54

60

.78

68

.00

62

.40

63

.56

61

.15

59

.30

62

.00

0

20

40

60

80

100

120

140

2010-11 2011-12 2012-13 2013-14 2014-15BE

Hired Departmental

122.49115.82

PerformancePerformance at a Glance : OB Removal at a Glance : OB Removal

113.69130.00120.08

Figures in Million CuM 6

Mill

ion

Cum

Growth: 8.3%

14

4.0

15

0.3

14

1.0

14

5.7

15

8.4

0

20

40

60

80

100

120

140

160

180

2010-11 2011-12 2012-13 2013-14 2014-15BE

Performance at a Glance : Composite ProductionPerformance at a Glance : Composite Production

7

Mill

ion

Cum

Growth: 8.7%

FY 2013-14 CCL BCCL ECL WCL MCLComposite Production (Mcum) 92.57 107.16 109.78 145.7 169.65

17.5

4

18.0

4

21.1

3

22.1

7

22.0

0

20.5

4

18.8

0

15.6

9

13.8

0

18.7

04.48 5.13 4.73 3.98

4.30

0

5

10

15

20

25

30

35

40

45

50

2010-11 2011-12 2012-13 2013-14 2014-15BE

Rail Road Other Means

42.56 41.97

Performance at a Glance : Coal OfftakePerformance at a Glance : Coal Offtake

41.55 39.95 45.00Growth 12.65%

Figures in Million Tonnes 8

Impact of NCWA-IX

Mill

ion

Tonn

es

Crore Rs.

9

Trend Of Coal Production, Offtake & Operating Trend Of Coal Production, Offtake & Operating Profit/ LossProfit/ Loss

Strategy adopted for Enhancement of ProductionStrategy adopted for Enhancement of ProductionCoal Production (MT) 15-16 16-17 17-18 18-19 19-20

BAU 41.85 39.45 33.36 32.75 32.28

Internal efforts : Five projects 1.60 4.60 6.50 9.30 12.50

BG Relaxation : Six projects 0.50 0.80 1.40 1.80 2.37

Revision of CMPDIL norms : Nine projects 1.05 3.15 8.74 11.15 12.85

Total Production 45.00 48.00 50.00 55.00 60.00

10

Year Name of Project Area State Capacity (Mty) Opening Date

2014-15(7.00 MT)

1 Makardhokra-I OC Umrer MAH 2.00 28-Nov-142 Bhanegaon OC Nagpur MAH 1.00 25-Jan-153 Penganga OC Wani MAH 4.00 25-Mar-15

2015-16(15.58 MT)

4 Gokul OC Umrer MAH 1.50 25-May-155 Sharda UG Kanhan MP 0.32 25-Jun-156 Dinesh OC Umrer MAH 4.00 25-Jul-157 Dhau North UG Kanhan MP 0.36 25-Aug-158 New Majri UG to OC Majri MAH 0.80 25-Sep-159 Amalgamated Yekona-I & II OC Majri MAH 2.50 25-Oct-15

10 Singhori OC Nagpur MAH 0.80 25-Nov-1511 Amalgamated Pauni-II & III OC Ballarpur MAH 2.50 25-Jan-1612 Tawa -III UG Pathakera MP 1.00 25- Feb-1613 Chincholi OC Ballarpur MAH 0.30 25-Mar-1614 Kamptee Deep OC Nagpur MAH 1.50 25-Mar-16

Year wise Opening of ProjectsYear wise Opening of Projects

11Replacement Project

Year Name of Project Area State Capacity (Mty)

Opening Date

2016-17 (9.20 MT)

15 Mungoli Nirguda Deep OC Wani MAH 4.00 25-Apr-1616 Hindustan Lalpeth Expn. OC Chandrapur MAH 1.00 25-May-1617 Dhuptala Extn. (Sasti UG to OC) * Ballarpur MAH 1.70 25-Jul-1618 Padmapur Deep OC Chandrapur MAH 2.50 25-Jan-17

2017-18(3.14 MT)

19 Niljai Expansion (Deep) OC Wani MAH 3.00 25-Apr-1720 Harrradol UG Kanhan MP 0.14 25-May-17

Grand Total 34.92 (Mah -33.1MP -1.82)

Contribution from above 20 Projects by 2019-20 27.72BAU Production by 2019-20 due to depletion of reserves 32.28

Total Production by 2019-20 60.00

Year wise Opening of ProjectsYear wise Opening of Projects

12Replacement Project

39.7342.00

45.0048.00

51.0055.00

60.0057.78

68.98 69.08 69.28 70.08 70.58 70.58

30354045505560657075

13-14 14-15 15-16 16-17 17-18 18-19 19-20

Production (Now Projected)

Demand

Coal Demand Vis-à-vis ProductionCoal Demand Vis-à-vis ProductionM

ILLI

ON

TO

NN

ES

YEAR

13

Group-wise Future Production ScenarioGroup-wise Future Production Scenario

Existing & Completed Projects

Ongoing Projects

Total Production

Future Projects

Mill

ion

Tonn

es

Year 14

Share of UG and OC production Share of UG and OC production

7.73 7.90 8.00 8.22 8.31 8.77 9.17

32.0036.10 37.00 39.78 41.69

46.2350.8339.73

44.00 45.0048.00 50.00

55.0060.00

0

10

20

30

40

50

60

70

13-14 14-15 15-16 16-17 17-18 18-19 19-20

UG

OC

Total Production

Mill

ion

Tonn

es

Year15

OC Composite Production : Departmental & Outsourcing

178.87

253.56290.69

311.72335.23

Figures in Million CuM 16

17

Opencast : Existing &

Required Equipment

Existing HEMM PopulationEquipment

ModelCapacity Population

Dragline   3

Shovels, Electric Rope

5 Cu.mt 39

Shovels, Hydraulic

More than 2.5 Cu.mt

67

Shovels, Hydraulic

Less than 2.5 Cu.mt

29

Dumpers 35 Ton 55

Dumpers 50 Ton 225

Dumpers 60 Ton 174

Equipment Model

Capacity Population

Dozer Crawler 410 HP 6

Dozer Crawler 320 hp 139

Wheel Dozer 460 HP 12

RBH Drill 250 mm 21

RBH Drill 160 mm 82

Graders 280 HP 24

Cranes 30 -40 Ton 11

TOTAL 887

18

Status of existing major Equipment & their Performance

SN Equipment Capacity Supplier

(No) Performance

1 Dragline 24Cum /96 m

20 Cum /90 m

9Cu Yds /70 Yds

Bucyrus (1)

Uralmash(1)

Marion (1)

• Age – 23 Yrs

• Age – 22 Yrs

• Age - 45 Yrs

2 Electrical Rope Shovel

5 Cum HEC (39) • Delayed supply of spare parts• Inferior quality of spares

19

Status of existing major Equipment & their Performance

SN Equipment Capacity Supplier (No) Performance

3 Hyd. Excavator

4.5/5.5 Cum BEML (28) • Swing pump life –failing at an average life of 7000 Working Hour , against desired life of 20,000 WH

• Power-Take Off–failing at an average life of 8000 WH, against desired life of 20,000 WH

TATA Hitachi(15) • High cost of sub assemblies.

4 Dumper 60/50 T BEML(248 ) • Poor Supply of spare parts• Less Transmission Life

Caterpillar (151 ) • High cost of spares20

HEMM to be procured against replacement

Equipment Model Capacity

Shovel Hydraulic 4.3 / 5.5 Cu.mt

Shovel Hydraulic Less than 2.5 Cu.mt

Dumper 60 Ton

Dozer, Crawler 410 HP

Dozer, Crawler 320 HP

Wheel Dozer 460 HP

RBH Drill 250 mm

RBH Drill 160 mm

Grader 280 HP

Crane 30 - 40 Ton21

Equipment Model Capacity

Shovel Hydraulic 5 - 6 Cu.mt

Shovel Hydraulic 4.3 / 5.5 Cu.mt

Dumper 60 Ton

Dozer 410 HP

Dozer 320 HP

RBH Drill 160 mm

HEMM required for new projects (Dept.)

22

Equipment Model Capacity

Shovel Hydraulic

3.1 Cum

4 Cum

10 Cum

Dumper

18.7 Cum

19.5 Cum

100T

Surface Miner

Proposed HEMM required for new projects (Outsourcing)

23

24

Underground : Existing

& Required Equipment

24

Underground : Existing Major Equipment

25

SN Equipment Population

1 Continuous Miner Package 1

2 SDL ( 1.0 Cum) 72

3 LHD (1.5 Cum) 113

4 UDM 45

5 Man Riding System 09

SN Equipment Supplier (No) Performance1 Continuous

MinerJoy Global (1) • Inadequate performance of Quad Bolter

2 SDL ( 1.0 Cum)

Eimco(57)BEML (14) • Design flaws in the machine

• Delayed supply of spares• Inadequate Service support

Simplex (1)

3 LHD( 1.5 Cum)

Eimco (101)Simplex (12) • Delayed supply of spares

• Inadequate service support

4 UDMEimco (36)Simplex (9) • Delayed supply of spares

• Inadequate service support

Status of existing major Equipment & their Performance

26

Replacement Equipment To Maintain Existing Production

Machine Capacity

SDL 1.0 Cum

LHD 1.5 Cum

UDM

27

Underground: New Projects

• Introduction of Continuous Miner Package on hiring basis

• Mass Production Technology package @ 1 MTY of coal production on Turnkey basis (MDO Route)

• Manriding system28

Continuous Miner Package on Hiring Basis

S.No. NAME OF MINE Potential Production (MTPA)

Estimated Year of Production

1. Tawa-II Expn. 0.36 2016-17

2. Waghoda 0.39 2016-17

3. Tawa-I 0.70 2016-17

4. Naheriya 0.34 2017-18

5. Dhau North 0.36 2017-18

6. Sharda 0.315 2018-19

29

Turnkey Projects through MDO Route

S. No. Name Of Mine Proposed Technology

Potential Production

(MTPA)

Estimated Year of

Production

1. Tawa-III Mass Production technology(LW/CCT) 1.00 2018-19

30

Installation of Manriding Systems in UG Mines

15-16 16-17 17-18 18-19 19-20

Nandgaon Rajur Mahakali Saoner III AB Incline

Adasa Naheriya HLC-1 Mathani Patansaongi

Saoner II Vishnupuri II Ghorawari

Silewara (Winder)

Ambara

2 2 3 3+1(Winder) 4

31

32

Coal Evacuation &

CHP Required

32

Coal Evacuation Year-wise, Mode-wise

2015-16 2016-17 2017-18 2018-19 2019-20

Production 45.0 48.0 50.0 55.0 60.0

Rail 23.29 25.29 26.79 32.06 35.61Road 17.03 17.11 17.60 18.31 19.26MGR 1.10 1.10 1.10 1.10 1.10Despatch 3.60 4.50 4.52 3.53 4.03Offtake 45.0 48.0 50.0 55.0 60.0Rakes/day 16.3 17.8 18.8 22.6 25.0

Fig. in MT

CoalCoal Evacuation of 60 MT by 2019-20 Evacuation of 60 MT by 2019-20

• Presently WCL is maintaining evacuation arrangement for 45 MT through 19 no. of Railway sidings

• Additional 7 MT will be evacuated by utilizing spare capacity of existing sidings

• Silo arrangement for 2 OC projects (8 MT) & Rail Connectivity (15 Km) up to silos by 2019-20

34

CHP : Existing Crushing Equipment

35

SN Equipment Population

1 Feeder Breaker/Crusher (-200mm) 42

2 Crusher(-100mm) 4

CHPs : Plan for 2015-16

Machine Capacity

Secondary Crushers-100mm output

Feeder Breaker/ Crusher-100mm output

36

Major area of concern

• Availability of experienced Contractors• Availability of required Excavators,

Dumpers/Hauling Trucks and matching support equipment in a span of four years for existing and new projects.

• Trained Manpower for both Departmental & Outsourced equipment

Dept HOE TotalExcv 71 114 185

Dumpers 282 467 749

37

Suggestions• Workshop for Outsourcing Agencies with

participation of all Subsidiaries.• Year-wise schedule may also be drawn by

Suppliers/Manufacturers• Skill Development Centers at Subsidiary level to

tap in-house as well as external (PAPs) potential.

38

ThankYou