LONGWALL

MINING

Venkat
 COAL -
Background
COAL

Most abundant fossil fuel

Major fuel used for electricity
generation world wide

Safe and secure fossil fuel

Cost effective
WORLD ELECTRICITY GENERATION
(% By Fuel-2005)

Consumption by India World

Fuel (%) (%)

Oil 32 37

Natural Gas 8 24

Coal 54 27

Nuclear Energy 1 6

Hydro-Electric 5 6

Total 100 100

(Source: BP Statistical Review of World Energy 2005)

 WORLD SCENARIO
As the International Energy Agency has
commented:

“World reserves of coal are enormous and compared with

oil and natural gas, widely dispersed... The world’s proven
reserve base represents about 200 years of production at
current rates... Proven coal reserves have increased by
over 50% in the past 22 years. The correlation of strong
growth of proven coal reserves with robust production
growth suggests that additions to proven coal reserves will
continue to occur in those regions with strong, competitive
coal industries.”
 INDIAN SCENARIO

Coal accounts for 63% of Country’s

energy needs.

Coal based thermal power generation
capacity presently stands at 61,476MW
and a capacity addition of around 60,000
MW has been targeted in next 7 years.

Total annual hard coal production in India
is about 373.79 million tonnes (2004-05)
out of which nearly 80% is from Opencast
Mines. SCCL share is 10%.
INDIAN SCENARIO
Coal Demand & Production
(in Million Tonnes)

2011-12

Demand 707

Production 550

Gap 157

(Source: Coal Summit 2005)

Proved coal reserves at end 2005
RESERVES - India

As on January 2005 in Billion Tonnes

TOTAL
DEPTH(m) PROVED INDICATED INFERRED (In Bt) (%)

0-300 71 66.5 15 152.5 61.5

300-600 6.5 39.5 17 63 25
0-600 14.5
14 0.5 - 6
(Jharia)
600-1200 18
1.5 10.5 6 7.5

0-1200 93 117 38 248 100

(Source: GSI Report, January 2005)

 RESERVES - SCCL

As on January 2006 in Million Tonnes

DEPTH
PROVED INDICATED INFERRED TOTAL
(m)
0-300 5505.49 2239.12 102.25 7846.86
300-600 2897.69 2900.71 553.05 6351.45
600-1200 0.00 1018.34 1928.95 2947.29
0-1200 8403.18 6158.17 2584.25 17145.60
LONGWALL –
World & India
 Longwall in India

First mechanized powered support longwall
caving face was introduced in August 1978
at Moonidih, CIL.

First Longwall face introduced in GDK.7

Incline in September 1983 in SCCL.

There is no much improvement taken place

in India in respect of Longwall technology
due to various reasons.
 Longwall in India
Reasons for less concentration on Longwalls in India

Serious efforts not made perhaps due to
availability of alternate technologies.

Upgrading not made when most of the world
improved in 90s.

Spares management was poor.

Coal India do not need due to opencast and
flat gradients.

Use of indigenous spares of low quality is
increased, which deteriorated the condition of
faces.
 Australian Coal Industry

World’s largest exporter of coal

230 mt worth Au$ 16 b (Rs. 53,000 crs)
in 2004.

Most of the 74 bt reserves in NSW and QLD

378 mt in 2004, 82 mt from underground.

24 longwalls produced 73 mt in 2004 and
plans to produce 96 mt in 2006.

148 wagons per rake 2 km length, 8,500 t.
 Australian Coal Industry

Less than 25,000 employees.

Each mine has 120 to 200 permanent
and 100 contractors’ men.

Productivity:
 OMY is 15,000 t.
 OMH 5t for UG, 10t for OC
Longwall Geometry - World

Width
Time Length (m)
(m)

1970’s 150 1200

1980’s 225 1800

Today 330 3000

LONGWALL -
METHOD
 LONGWALL GENERAL LAYOUT
TOP Gate

FACE

Dip direction

Bottom
Gate

- Longwall mining method includes drivage of two long

roadways in coal and joining them at the end by a
perpendicular drivage forming a face.
 Different Longwall Methods
1. Longwall Advancing 2. Longwall Retreating
Method Method
Modern Longwall Plans in Australia
Modern
Longwall Plans
in Australia
Gateroad Plans in Australia
Advantages of Longwall Method

High Recovery.

Lower Operating Costs.

Easier to Supervise.

Easier to Train Miners.

Works Under Weak Roof.

Clean Coarse Product.

Simple Ventilation.
Disadvantages of Longwall Method

Small Problems = Big Production

Losses.

Dust Control Difficult.

Overloading Conveyor System.

Retreat Longwall Mining
Advantages Over Advance Longwall Mining

Reserves are “Proven” on Development

Gateroads in the “Solid”

Gateroad Development is Separate

Water Easier to Control

Recovering Equipment Easier

Easier Ventilation
Retreat Longwall Mining
Disadvantages Over Advance Longwall Mining

Delay in getting production for the

preparation of first panel.


MAIN GATE WITH SWITCH TRAIN

C
H
O
C
K
S
LONGWALL METHOD

Retreat per day –5 meters/day

Production –3000 Tonnes/day
Thickness of 2.0 m to 3.5 m
POWERED ROOF SUPPORT AT LONGWALL FACE
LONGWALL -
EQUIPMENT
Equipment for Longwall Mining

Powered Face Supports

Shearer

Armored Face Conveyor

Conveyor System

Electricals & Communication
CHOCK SHIELD SUPPORT
Powered Roof Supports (Two legged)
 POWERED ROOF SUPPORT AT
LONGWALL FACE

Capacity -4x450 T to 4x800 T

Thickness of -2.0 m to 3.5 m
Weight -12 T to 20T
Weight -1.5m
Powered
Face
Supports
Armored Face
Conveyor
Armored Face Conveyor
Armored Face Conveyor
Armoured Face Conveyor
(1 pan set)
Shearer working at Longwall Face
SHEARER WORKING AT LONGWALL FACE

Capacity -2x375 Kw
Thickness of 2.0 m to 4.5 m
Web -0.63/0.85
Drum Dia -1.6 to 1.83m
Length -10m
Shearer
Shearer -
Front Half
Shearer -
Rear Half
Shearer Drum
Cutter Bits with Spray
Conveyor Belts
 LONGWALL –
STRATA CONTROL
 STRATA CONTROL PLAN OF
A LONGWALL PANEL
1000 m

120 m
Barrier Pillar

Top Gate 50 L X C L C L
X

RETREAT
INDEX:

GOAF
C Convergence Station
Longwall Panel dimensions
L Load Cell 1000 m x 115 m
X Extensometers
S Stress cell

FACE
S S

Bottom Gate 53 L X X C L C L
1000 m

200 m

120 m

Barrier Pillar
Not to scale
 Strata monitoring of in
a Longwall Panel

• Gate Road ways studies.

• Face monitoring.
• Goaf monitoring.
Gate Road ways studies –
Strata monitoring

• Convergence indicators
• Load cells
• Tell tales
• Stress capsules Cum.CONVERGENCE in Tail gate
of a Longwall Panel
35
30
25

Cum.Convergence in mm
20
15
10
5
0

10.0m

30.0m

50.0m

70.0m

90.0m

110.0m

130.0m

150.0m

170.0m

190.0m

210.0m

230.0m

250.0m

270.0m

290.0m

310.0m

330.0m

350.0m

370.0m

390.0m

410.0m

430.0m
LOCATION in mts
The maximum convergence depends on
the following factors

 Caving properties of the strong bed

causing weightings, indicated by the
Caving Index Number ‘I’ of the strong
bed.
 Thickness of cavable beds forming the
immediate roof in between strong bed
and the coal seam in terms of height of
extraction.
 Resistance offered by the support
system.
 Convergence and Roof Degradation at
Longwall Weightings (GDK.10A)

Maximum Expected Roof

Convergence Condition
Upto 60 mm/m Convergence within permissible
limit

Above 60 upto 100 mm/m Minor roof fracturing increasing

with the value of convergence

Above 100 upto 160 mm/m Significant roof fracturing and

roof degradation. Seriousness
increasing with increase in
convergence

Above 160 mm/m Rock fall zone.

Face monitoring–
Strata monitoring

• Leg Pressures
• Leg Closures
• Face Convergence
PRESSURE SURVEY
Continuous Pressure Recorder in Mid Face
of a Longwall Panel
40
Yield Pressure

35

30
PRESSURE (M pa)
25

Setting Pressure
20

15
33.6

39.3

56.2

74.1

95.4

111

119

141

163

180

198

220

237

259

279

305

324

345

369

386

412
FACE RETREAT in mts
Rated Support Resistance

The Rated Support Resistance should

take into account the following
deficiencies during the actual operation.
1. Leakage in leg circuit
2. Setting load deficiencies
3. Miscellaneous (deviation from normal
span, premature bleeding of leg
circuits, etc.)
Goaf monitoring – Strata monitoring

• Remote convergence indicator

• Multi Point Borehole Extensometer
(MPBEx)
CAVING OF THE STRATA WITH RESPECT TO FACE PROGRESS
sensors
SURFACE
SOIL-2.7m

YellowSST 8m

Light Brown Anc4 - 15m

SST-7m 36m

Hard Brown
Anc3 -26m
SST-17m
25m

Anc2 -37.5m
Grey & Brown 13.5m
SST-12m
Anc 1- 45m
6m
Shaly Coal3m

68.0m
80.0m
141m
Face progress Anchor1 Anchor2 Anchor3 Anchor4 Remarks
 Longwall Caving Diagram

Main Overburden

Immediate Roof
Hc F Dc T Cl Ro
A
Gob

Shield
Hs Coal Support

Floor
Hs = Seam Height Dc = Depth of Cut Ro = Rear Overhang
Hc = Caving Height A = Caving Angle T = Canopy Tip to Face
Cl = Canopy Length F = Forward Zone Sw = Shield Width (not shown)
 Longwall Caving

Cut after cut, shear after shear the AFC & subsequently
Chock shield supports will be advanced and the
immediate roof rock above caves in.
 Main Fall

- As the retreat further proceeds substantial area of main

roof rock forms a plate & caves in by imposing load on
supports, known as main weighting.
Periodic Fall
 LONGWALL –
ORGANISATION
Organisation Chart
 MANPOWER

Pre shift General Shift

1. EE/AE 1 1. Overman 1
2. Mech. Charge Hand 1 2. Mining Sirdar 1
3. Overman 1 3. Gate Road Support 6
4. Mining Sirdar 1 4. Face Supporting
5. Shearer F+3 (Bamboo bolting &
6. AFC & BSL F+5 Fore polling etc.) 8
7. Power pack & Chocks F+3 5. Face Cleaning 10
8. Switch train & 6. Slush Tanks cleaning
U/Frame Shifting F+7 along M.G. 6
9. GBC F+4 7. Material transport 6
10. Miscellaneous 9 --------
------------- 38
40
 MANPOWER

Production Shift
1. Under Manager 1 2.
Engineer 1 3.
Overman 1
4. Mining Sirdar 1
5. Shearer Operator 2
6. Multi Job Workmen 9
7. Face fitters 3
8. Face Electricians 1
9. Outbye belt Fitters 1
10. Outbye Electricians 1
11. Helpers 6
12. Conveyor Operators 6
13. Misc/cleaning 4
-------------
37
 LONGWALL –
FACE TRANSFER
 MESHING

Wire meshing is laid in roof from 12 to 15m

behind the face stop line with individual roof
bolts for 5 to 8m and later on along with W-
straps/Channel for balance portion at 1m
interval.

Maximum height will be extracted for the last
8m from face stop line, sothat enough
clearance is there for PRS passing underneath
the line supports.

After stoppage of the face, meshing and
bolting is done to the face also.
 DISMANTLING

All the equipment in the face are dismantled
except chocks and loaded on to the GMT (Gyro
Machine Trolley) and transported to surface of
new face.

Shearer is dismantled into two parts for easy
transport.

AFC pansets were dismantled in such a way
that 5 pansets together forms a unit for
loading onto GMT.

Similarly BSL, Belt sections are dismantled and
loaded on GMT.
 CHOCKS TRANSPORT

PRS turning is done generally from dip to

raise and 2 buttress supports are used as
goaf edge supports at dip most point of the
face.

PRS are being marched with self hydraulic

power upto loading station and shifted on
to GMT for further transport to surface or
to new face.
SCCL – A Review
Strut Pit, Yellandu
 Singareni

• Presently operating 47 Underground

and 11 Opencast mines.

• Godavari Valley Coalfields spread out

over 350 Kms.
L
O
C
A
T
I
O
N
The Godavari Valley Coalfield

L
O
C
A
T
I
O
N
 Mile stones - Technology
1975: Opencast mining
1979: Side Discharge Loaders
1981: Load Haul Dumpers and Road
Headers
1983: Longwall mining
1986: Walking Dragline
1989: French Blasting Gallery method
1994: In-pit crushing and conveying
2004: Phasing out manual Coal filler
launched.
 Technology-Wise production- 2005-06

Opencast :23.42 mt
(64.8%)

Underground :12.71 mt
(35.2%)

Manual mining :7.12 mt

Longwall :0.85 mt

Intermediate mech. :4.74 mt
(LHD, SDL, BG & RH)
 PROJECTIONS

TECH 2006-07 2011-12 2016-17 2021-22

PROD % PROD % PROD % PROD %
(M.T) (M.T) (M.T) (M.T)
HS 6.005 16 5.225 13 3.780 8 3.620 8
SDLS 3.30 9 2.865 7 1.610 4 1.280 3
LHD 1.655 4 1.110 3 1.12 2 0.680 1
LW 1.205 3 3.900 10 5.600 12 8.500 18
CM 0.400 1 1.800 4 1.770 4 2.000 4
BG 1.210 3 1.150 3 0.920 2 0.920 2
TOTAL UG 14.251 37 16.050 39 14.800 33 17.000 36
OC 21.749 63 24.750 61 30.200 67 30.500 64
TOTAL 37.500 100 40.800 100 45.000 100 47.500 100
 General Organisation of SCCL
C&MD

SO Marketing

Dir/ Fin. Dir/ P&P Dir/ Oprs. Dir/ PAW Dir/ E&M
Finance Areas Areas Personnel E&M, UGM
Int. Audit Forestry Civil Medical E&M, OC
SO Safety R&D Estates PH&WS
Co. Secy. CP&P Qual. Mgt IE Central WS
Corp. Plg HRD Purchase

Cap. budget Edn. Stores

Proj. Plg. Vigilance

Explrn. Security

Survey IT

Environ. Law
 General Organisation of Areas
GM

SO

Mines Safety

IE Civil

Finance IT

Survey Medical

HRD Purchase

Qual.Mgt. Coal handling

Personnel E&M

Township Workshop

WM Comn. Stores
General Organisation in the Mines

Mine Manager

Pit Office

Safety Ventilation

E&M Mntnce Min. Mntnce.

Survey Welfare
Production
Shifts
Drilling, Blasting
Loading, Transport,
Mine support,
Coal handling etc.
Organisation of statutory personnel

Owner Directors
on the Board
Corporate HoDs
(Deemed Agents)

General Manager
(deemed Agents)

Named Agent
(group of mines)
Mine Manager
Officers
For various
disciplines

Supervisors

Competent
persons
 STATUS OF
LONGWALLS AT SCCL
 INTRODUCTION

The first Longwall was commissioned in SCCL

at GDK.7 Incline, RG-II in September, 1983.

Till now 10 sets of Longwall were purchased

by SCCL. Mainly the equipment was
purchased from UK and China.

Till now 70 Longwall panels have been

completed in SCCL and presently 4 Longwall
units are in operation in 4 Underground
mines.
EXISTING LONGWALL MINES OF SCCL
2006-07

S Name of the mine No of

No Units
1 PVK-5 Incline,KGM Area 1 unit
2 GDK-9 Incline,RG-II Area 1 unit
3 GDK-10A Incline,RG-II Area 1 unit
4 JK-5 Incline, YLD Area 1 unit
 LONGWALL PRODUCTION TREND-SCCL
25

20

15
PROD (LT)

10

0
1983- 1984- 1985- 1986- 1987- 1988- 1989- 1990- 1991- 1992- 1993- 1994- 1995- 1996- 1997- 1998- 1999- 2000- 2001- 2002- 2003- 2004- 2005-
84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 2000 01 02 03 04 05 06
LW PROD 1.33 2.47 5.75 6.18 6.12 6.12 4.62 6.32 12.17 13.2 16.1 10.4 20.19 22.9 19.3 16.42 15.79 13.66 11.27 10.1 11.17 11.19 8.5
 INTRODUCTION OF LW SETS

S Mine where LW sets No.of sets Support

No introduced & Yr. capcities
1 GDK.7/9 Incline, RG-II 1, 1983 4 x 360T
2 VK-7 Incline, KGM 1, 1984 4 x 360T
3 GDK.11A Incline, RG-I 3, 1990-92 4x450T(2),
4x430T(1)
4 JK-5 Incline, YLD 1, 1990 4x450T
5 GDK.9Extention, RG-II 1, 1996 4x800T
6 GDK.10A Incline, RG-II 1, 1994 4x800T
7 Padmavathikhani, KGM 2, 1995-96 4x760T
 GDK.7 INCLINE

Longwall equipment introduced in no.3 seam

bottom section in September 1983.

After completion of two panels, due to non

availability of the property the equipment
was shifted to adjacent GDK.9 Incline.

Main Problem - Strength of coal is high for

Shearer cutting & sand stone bands running
across the panel.
GDK.7 INCLINE

Borehole Section
showing
3 seam Top & Bot
Section.
 GDK.7 INCLINE

Two panels have worked with 4x360T

supports in No.3 seam bottom section
with a face lengths of 110m and 96m.

The production achieved is 0.8LT with

an average production of 1900T/day.
 VK.7 INCLINE

Longwall equipment with 4x360T Conventional
supports was introduced in Top seam in 1985.

With 4x360T supports, 8 panels of 120m face length
and 7 panels of 60m face length have been worked
successfully.

Second set (4x450T IFS) shifted from GDK.11A Inc in
1994 & is presently in operation.

Experience in – varied face lengths, up hill transport,
crossing the developed gallery, working in between
goaves, fault running across the panel.

Main Problems – Underrated capacity of supports,
Cavity formation.
Depth Thickness Strata Description

VK.7 INCLINE

Borehole Section
showing Top seam
(Middle Section)
 VK.7 INCLINE

8 panels of 120m face length have completed

With 4x360T supports by producing around
3.6MT and daily production varied from 400
to 1800T.

7 panels of 60m face length have completed

With 4x450T supports by producing around
1.6MT and daily production varied from 1000
to 1300T.
 GDK.11A INCLINE

Two longwall sets were introduced with
4x450T/4x430T supports during 1991, followed by 3rd
Longwall unit with 4x450T supports during 1992.

First time longwall was introduced in No.1 Seam of

Ramagundam.

Main Problems – Underrated capacity of supports,

Oblique fault running across the panel, high water
seepage, improper geo-technical investigations.
GDK.11A INCLINE

Borehole Section
showing No.1 seam
(Bottom Section)
 GDK.11A INCLINE

Longwall unit –I : 2 panels worked producing around
0.5MT of coal.

Longwall unit – II : 4 panels worked producing around

1.3MT of coal.

Longwall unit – III : 3 panels worked producing

around 0.96MT of coal.

While working with Longwall unit-II & III, experienced

more strata problems and cavity formations, due to
underrated capacity of supports.
 PADMAVATHIKHANI

First time Chinese longwall was introduced in

PVK in 1995 in Queen Seam (Top seam).

2 sets were introduced, One in 1995 and the
other in 1996 with 4x760T supports.

11 panels have been completed by producing
around 5 MT.

Experience in – varied face lengths,
negotiation of fault, deviation of gate
roadways.

Main Problems – Non-availability of Spares.
PADMAVATHIKHANI

Borehole Section
showing Top seam
(Middle Section)
 JK-5 INCLINE

Longwall with 4x450T supports (IFS) was
commissioned in June 1990.

Longwall panels were extracted in both, Top and
bottom sections of Queen (Top) seam after
allowing for goaf settlement.

2 panels in Queen seam bottom section and 8
panels in Queen seam Top section have been
completed by producing around 2.7MT of coal.

Experience in – varied face lengths, negotiation
of fault, in between goaves, steep gradient (1 in
3.6).

Main Problems – Geological disturbances, Cavity
formation, underrated capacity of supports.
JK-5 INCLINE

Borehole Section
showing Top seam
Top & Bottom section
 GDK.9/9E INCLINE

Longwall equipment (4x360T) introduced in

no.3 seam bottom section in 1986 which was
shifted from GDK.7 Incline.

New Longwall set with 4x800T capacity was
introduced in No.1 seam in 1996.

Main Problem – underrated capacity of
supports for 3 seam, Cavity formation,
Insufficient geological data, slow progress in
development of panels, more water seepage,
spares mgmt.
GDK.9/9E INCLINE

Borehole Section
showing 1 seam
 GDK.10A INCLINE

Longwall equipment (4x800T IFS) was introduced in
no.1 seam in 1994.

GDK.10A longwall produced daily, weekly and

monthly record output in India. In the year 1997-98,
the mine produced 8.67LT.

GDK 10A produced 5.40 LT of coal against

the target of 5.38 LT in the year 2005-06.

Main Problem –more water seepage, non-availability

of good quality spares, Cavity formation.
GDK.10A INCLINE

Borehole Section
showing 1 seam
 FUTURE
LONGWALLS AT SCCL
 FUTURE LONGWALL PROJECTS
• Adriyala Shaft Project
– Extension of GDK.10A dip side

• Jallaram Shaft Project

– Extension of GDK.9 Inc Dip side

• Peddampet Shaft Project

- Extension of GDK.11A Inc Dip side

• Kakatiya Longwall Project, Bhupalpally

- Steeply inclined, New mine.

• Shanthikhani Longwall Project, Bellampalli

- Extenstion of existing mine
 STATUS OF APPROVAL OF LW PROJECTS

S. Project FR Status of EMP Status of GOI approval

No approved
by SCCL
Board
1 Adriyala July’ 2003 EC obtained Sanctioned from GoI in Sept 06
11.10.2004
2 Shanthikhani Dec’ 2003 EC obtained Submitted to GOI on 26.02.04.
24.01.2006 In principle approval received.
PIB note submitted on 01.01.05
3 KTK LW June’ 2005 EMP to be prepared Submitted to GOI 5.08.2005
4 Jallaram Oct’ 2004 Public hearing completed. Submitted to GOI 11.11.04
Application for EC under
preparation.
5 Peddampeta Dec’ 2003 Public hearing completed. Submitted to GOI 26.02.04
Application for EC under
preparation
ADRIYALA SHAFT PROJECT

1. Location : Ramagundam coal belt

Ramagundam Area
2. Geological Block : RG SB-II & RG SB-III
3. Geological Reserves : 109.59 Mt
4. Extractable Reserves (Apr.) : 43.38 Mt
5. Area (in Sq.Km) : 3.40
6. Capacity (MTPA) : 2.14
7. Life of the Mine : 31 years
8. Face length : 150m
9. Panel length : 700 - 1300 m
10. Depth range : 294 – 644m
11. Gradient : 1 in 6.0 to 1 in 7.8
:
 ADRIYALA SHAFT PROJECT

Details of seams:

Seam Avg. Height of Geological Extractable Grade

Thickness Extraction Reserves Reserves
(m) (m) (Mt) (MT)
I 5.64 3.5 27.99 10.98 E
II 3.27 2.0 15.24 6.07 D
III 9.40 3.5(Top)/ 43.09 23.31 D
3.5(Bot)
IV 3.66 3.5 15.56 11.28 C
SHANTIKHANI LONGWALL PROJECT

1. Location : Dorli - Bellampalli coal belt

Bellampalli Area
2. Geological Block : Shantikhani Extn Block
3. Geological Reserves : 8.87 Mt
4. Extractable Reserves (Apr.) : 17.78 Mt
5. Area (in Sq. Km) : 6.81
6. Capacity (MTPA) : 1.17
7. Life of the Mine : 23 Years
8. Face length : 150m
9. Panel length : 450 - 2000 m
10. Depth range : 309 – 596m
11. Gradient : 1 in 3.5 to 1 in 5
 SHANTIKHANI LONGWALL PROJECT
Details of seams (Phase-I)

Seam Avg. Height of Geological Extractable Grade

Thickness Extraction Reserves (Mt) Reserves
(m) (m) (Mt)
SJ Top 1.88 1.5 18.96 3.91 F
SJ Bot 3.18 2.5, 3.5 29.91 13.87 D
 KAKATIYA LONGWALL PROJECT

1. Location : Mulug coal belt

Bhoopalpalli Area
2. Geological Block : Gollapalli block & Peddapur block
3. Geological Reserves : 67.45 Mt (Phase-I)+ 60.06 Mt (Phase-II)
4. Extractable Reserves (Apr.) : 40.02 Mt (Phase-I)+ 35.99 Mt (Phase-II)
5. Area (in Sq. Km) : 9.71
6. Capacity (MTPA) : 2.16
7. Life of the Mine : 24 + 22 Years
8. Face length : 250m
9. Panel length : 1200 - 2900 m
10. Depth range : 35 – 412m
11. Gradient : 1 in 2.8 to 1 in 3.3
 KAKATIYA LONGWALL PROJECT

Details of seams (Phase-I)

Seam Avg. Height of Geological Extractable Grade

Thickness Extraction Reserves Reserves (Mt)
(m) (m) (Mt)
IA 2.02 2.0 12.16 7.62 E
I 2.66 2.5 17.18 9.45 F
II 2.72 2.5 17.55 9.71 F
III 3.05 3.0 20.53 13.24 B
 JALLARAM SHAFT PROJECT

1. Location : Ramagundam coal belt

Ramagundam Area
2. Geological Block : RG SB-II
3. Geological Reserves : 206 Mt
4. Extractable Reserves (Apr.) : 79 Mt
5. Area (in Sq.Km) : 7.29
6. Capacity (MTPA) : 2.28
7. Life of the Mine : 53 years
8. Face length : 200m
9. Panel length : 500 - 1800 m
10. Depth range : 123 – 579m
11. Gradient : 1 in 5 to 1 in 8
 JALLARAM SHAFT PROJECT
Details of seams

Seam Avg. Height of Geological Extractable Grade

Thickness Extraction Reserves Reserves
(m) (m) (Mt) (Mt)
I 5.09 3.0 53.99 14.13 E
II 2.99 2.0 27.43 12.17 E
III 8.79 3.0 (Top)/ 85.04 36.91 D
3.5 (Bot)
IV 3.00 3.0 29.19 16.21 B
PEDDAMPETA SHAFT PROJECT
1. Location : Ramagundam coal belt
Ramagundam Area
2. Geological Block : GDK-6B Integrated Mine Block
3. Geological Reserves : 112.62 Mt
4. Extractable Reserves (Apr.) : 41.40 Mt
5. Area (in Sq.Km) : 7.25
6. Capacity (MTPA) : 1.46
7. Life of the Mine : 32 Years
8. Face length : 150m
9. Panel length : 470 - 1200 m
10. Depth range : 118 – 443m
11. Gradient : 1 in 6 to 1 in 10
 PEDDAMPETA SHAFT PROJECT
Details of seams

Seam Avg. Height of Geological Extractable Grade

Thickness Extraction Reserves (Mt) Reserves
(m) (m) (Mt)
II 2.64 2.0 24.27 7.06 E
III 8.69 2.0 (Top)/ 65.69 21.39 D
3.5 (Bot)
IV 2.50 2.5 22.66 12.95 B
Variants of Longwall Mining
(NEW CONCEPTS)
Punch Longwall
- Developing longwall panels directly off high walls of OC
Punch Longwall Field site operations
Punch Longwall
Advantages

Step change in cost and productivity

More production capacity

High productivity & low cost

Longer term and higher % of reserves extraction

Easy logistics – near surface

High gate road development rates feasible

Higher and faster returns on investment

Total investment ~ $100 million – compared with >
$300 millions UG
Longwall Top Coal Caving (LTCC)

Technical Principle Of Top Caving

Rock stress 1st pressure Low stress Stress 2nd pressure Compact
peak abrupt drop peak stress

Pressure curve of top coalseam

Fracture
Virgin
5600

Coal Broken Coal

coal goaf

caving
2800

Working
Height

Front AFC Rear AFC

back
Longwall Top Coal Caving (LTCC)

Supports used
Longwall Top Coal Caving (LTCC)
Advantages of LTCC

• Increased resource recovery in thick seams (> 75%)

• Lower face working height (better face control)
• Improved spontaneous combustion control
• More efficient capital utilisation/ financial
performance
• Reduced operating costs
• Improved production consistency
• Less gate road development requirements
• Some dust and gas issues
 LONGWALL –
INDIAN
PERFORMANCE
 INDIAN LONGWALL
- PAST EXPERIENCE:
- Introduction of advanced technology system in Indian
coal mining industry marked a major step with the
installation of first mechanized Longwall Powered support
face at Moonidih in August 1978.

- In between 1978 to 1985, a major number of first

generation Longwall faces started through out India in
various mines of CIL such as Moonidih, Jhanjra, Seetalpur,
Dhemomain and Pathakhera Colliery and in SCCL at GDK-
7 & VK-7 Incline.
 INDIAN LONGWALL
- PAST EXPERIENCE:

- Churcha Longwall face failed due to dynamic

loading.
- Jhanjra with shallow depth Longwall working face
ran into acute spares problem.
- Kottadih face failed after successful completion of
two Longwall panels due to dynamic loading and
underrated capacity of supports.
- GDK.11A failed due to underrated capacity of
supports.
 LONGWALL- SCCL
- PAST EXPERIENCE:
Longwall technology was introduced in
Seven mines of SCCL. Their performance
has been:

• GDK-10A, JK-5 and VK-7 Incline gave

consistently good results, and

• The other four mines GDK-7, GDK-9, GDK-

11A and PVK suffered mainly due to non
availability of sufficient geological data.
 INDIAN LONGWALL

MAIN REASON :
Insufficient geo-technical investigations
resulted in surprises by encountering major
geological disturbances while working the
longwalls. Thus effecting the performance of
Longwalls to the maximum extent.
 INDIAN LONGWALL
- PRESENT & FUTURE :
- With the likely reduction of contribution from Open
cast and the more or less stagnant production from
Underground by Conventional methods, it is time
that an impetus is given to boost Long wall
Technology to able to meet the future energy needs
of the country.

- On the positive side, coal companies have now

gained sufficient experiences right from senior
executive level to front line workforce to be able to
plan, execute and work longwall faces. What are
required are proper geo-technical
investigations for effective layout of longwall
panels.
REASONS FOR POOR PERFORMANCE
OF LONGWALL

>Large expansion in opencast mining in the past

two decades provided cheaper and safe method
for bulk coal production and as a result long wall
had to take back seat.

>Clear strategies were not pursued for its

sustenance as there was mixed results from long
wall in the early years of its introduction.
REASONS FOR POOR PERFORMANCE
OF LONGWALL
>Long walls were introduced mostly in the blocks
left over by working Bord and pillar method.
Clean and extensive blocks have not been
identified. Even the smaller blocks, which were
identified, were of inferior grade coal.
>Long wall had to co exist with the conventional
mining in most of the mines, which caused
management problems.
>There were some deficiencies in the imported
spares management and the supplies were not
reaching in time.
REASONS FOR POOR PERFORMANCE
OF LONGWALL

>Coal companies were sensitive to the failures of

a few long wall faces and were not prepared to
risk huge investments.

>Development could not keep pace with the

extraction of Long wall panels, slow progress in
dip has delayed the formation of Long wall
panels and affected the performance.
FUTURE REQUIREMENTS

- Longwall should be promoted as a

technology mission.

- A high level thrust group could be constitute

at national level to promote, coordinate and
interact different aspects related to Longwall
technology.
FUTURE REQUIREMENTS
- Huge investments incurred on different
operations for extraction of coal from greater
depths in future can be attained by imposing
a special cess on present OC production or
from other sources.

- R&D efforts are to be doubled.

- Efforts are required by the policy makers to

transform ideas into actions.
FUTURE REQUIREMENTS
- Foreign participation is required for
extraction of thin seams and steeply
inclined seams.

- The manufacturing companies of India

such as MAMC and Jessop are to be
reconstructed/ re-organized.

- More number of longwall blocks are to be

identified to assure the market for
manufacturers.
THANK YOU