Project-wise Reports of Sectorial Monitoring Committee. CSIR- Central Institute of Mining and Fuel Research, Dhanbad

Transcription

1 Project-wise Reports of Sectorial Monitoring Committee 1. Project Title: Development of suitable design methodology for extraction of coal at greater depths (>300m) for Indian geomining conditions (DeepCoal) 2. Project Details: Nodal lab CSIR- Central Institute of Mining and Fuel Research, Dhanbad Participating CSIR- National Geophysical Research Institute, Hyderabad, Labs Hyderabad CSIR-Central Mechanical Engineering Research Institute, Durgapur Nodal Officer Taskforce Chairman Total Man Days 2795 Approved Cost Fund received Fund utilized CSIR-Fourth Paradigm Institute, Bengaluru Dr Gautam Banerjee Dr. Pradeep K Singh, Director CSIR-CIMFR lakh lakh lakh (till ) (Including funds given by CSIR-CIMFR) 3. Periodic Key Recommendations of Task Force/RC/Monitoring Committee S.No Key Recommendati ons of Task Force/RC/Mon it oring Committee Action taken Proposed Deliverables on Key Recommendati ons Revised Deliverable (approved Task Force) by 1 Focusing of investigations in 2-3 locations due to limited budget For Longwall mining method, investigations were conducted in Adriyala of SCCL and Moonidih of BCCL. For CM Technology, investigations were done at VK7 incline and Shantikhani A methodology for analysis, processing and interpretation of insitu stress data and 3D seismic data along with their engineering use in stability analysis belowground; A model for ventilation network analysis 1n deep mines; Technology for high concentration filling at increased rate with low 1L-- 1

2 Mines of SCCL water consumption; Development of numerical models for realistic simulation of support-strata interaction and caving process associated with face advance in different mining methods; A geostatistical classification of rock will be developed for prediction of rock mass behaviour in deep mines, estimation of rock load, design of support system; A methodology for optimum safe mining method for a geomining detail; and Methodology for selection & design of suitable mining method for deep mines. 2 Suitable softwares to be procured for HPC system to realise the objectives Softwares procured MATLAB, ANSYS and INTEL Compiler for software development As above 3 Supplementing the findings from more case studies The study was supplemented by case studies from previously worked out longwall panels from from different mines such as Jhanjra & Khottadih of As above 2

3 ECL Balrampur, of SECL and GDK10A & PVK of SCCL 4 To focus on Addressed As above specific issues the problem with typical geemining of cutter roof/guttering conditions in Adriyala prevailing with Project deep seated Developed a deposits. protocol to tackle the problem of coal burst in Chinakuri Mine 4. Project Achievements: S. No. Deliverables Deliverables Achieved promised at start 01. A methodology for Facility-creation for 3D seismic survey analysis, processing and interpretation of 3D seismic data along with their engineering use in stability analysis below-ground; If not achieved, reasons thereof 02. A model for ventilation network analysis in deep mines; Deliverable achieved 03. Technology for high concentration filling at increased rate with low water consumption; Study of influencing and controlling parameters of high concentration filling technology. Numerical modeling for flow characteristics of filling material in pipe done with ANSYS Fluent software Numerical modeling for strata behaviour and stress distribution due to high concentration filling is in progress. 3

4 04. Development of numerical models for realistic simulation of support-strata interaction and caving associated process with face advance in different mining methods; Creation of a high performance computing facility for solving challenging computational problems of mining and geosciences domain. Strata characteristics and observed caving behaviour in past longwall panels Studied the problem of guttering due to high stresses in deeper horizon during drivages Studied the problem of coal burst due to high stress in deeper horizon during drivages. A numerical model for simulation of joints in rock mass. Numerical simulation of roof reinforcement Defining the properties of caved goat and its simulation. Development of numerical models to predict strata caving behavior and to optimize panel design for longwall mining along with case studies. Development of numerical models to predict strata caving behavior and to optimize panel design for mining method by continuous miner along with case studies. 05. A classification of rock will be developed for prediction of rock mass behaviour in deep mines, estimation of rock load, design of support system; Methodology for classification of roof rocks Methodology for prediction of rockmass behaviour and cavability assessment by numerical modeling Methodology for assessment of load on supports and estimation of support capacity 3D Finite element based characterized model for stress analysis of powered support under different loading conditions. 4

5 06. A methodology for optimum safe mining method for a particular geomining condition; and Feasibility study of Longwall Mining technology in deeper horizon: numerical modeling was conducted in Adriyala of SCCL. 15tlh seam of Moonidih Mine of BCCL and RVI seam of Jhanjra Project, ECL. Feasibility in Shantikhani Mine, of SCCL and Chinakuri Mine of ECL is in progress. Feasibility study of Continuous Miner technology in deeper horizon: numerical modeling was conducted in one selected mine of VK-7 Incline of SCCL, where depth of cover varies from 300m to 380m and again at Shantikhani Mine of SCCL has been selected where depth of cover varies between 300m to 600m 07. Methodology for selection & design of suitable mining method for deep mines Two underground mining methods by Longwall and Continious Miner are found to be suitable for deeper horizons. Detailed methodology for selection and design for these two mining methods is in progress. 08. Standardization of instrumentation for monitoring strata and support behavior at Longwall mines. An instrumentation scheme was planned for Adriyala in SCCL and Jhanjra RVI in ECL. Presented the scheme at a workshop in DGMS. 5. Outcomes and outputs from the projects: a. Outcomes 1. Lead(s) identified: Number and names with TRL S.N. Technology Lead identified Current TRL 1 Development of a prototype for TRL 4:Technology validated in on-line data generation of drilling laboratory parameters (penetration rate, RPM, Voltage, Current, Weight on bit, Temp, etc are used to calculate drilling indices such as specific energy and heating rate) to determine various rock the 5

6 properties 2 Wireless communication system TRL 4: Technology validated in the for real time monitoring of strata laboratory. and support behaviour in underground mines 3 Design and manufacture of Longwall Powered Supports TRL 4:Technology simulated in the laboratory. 2. Technology/Product developed: Number and names with TRL level of Development S.N. Technology Lead identified Current TRL Ventilation network simulation for TRL 7: Experimental proof of deep underground coal mines concept tested in actual field with multiseam working condition Software for prediction of load TRL 7: and safety factor of barrier pillar Technology demonstrated in and Design of Mining Method by operational environment and Longwall technology in deeper adopted by SCCL in Adriyala mine horizon and Jhanjra Mine of ECL. At present we are adopting this technology in 15th Seam of Moonidih Mine of BCCL Development of mathematical TRL 7: cum logical m-files in MATLAB Technology demonstrated in environment for identification of operational environment caving layers from borehole lithologs and rock strength parameters Design of Mining Method by TRL 7: Continuous Miner technology in Technology demonstrated in deeper horizon operational environment and adopted by SCCL in VK7 Incline and Shantikhani Mine. Design of support system for TRL 7: mitigation of the effect of Cutter Support system demonstrated in Roof failure in deep underground operational environment and ~oal mines adopted by SCCL 3. Technology/Product transferred: Number and names with name of licensee(s): All the Technology developed in serial number 1-5 are not tangible products. They are of intellectual nature and cannot be transferred to industry but this will help CSIR act as a consultant to the Coal Mining Industry 4. Facility created: Number and names with uniqueness & utility 1) New Laboratory Building. 2) High Performance Computing System 6

7 3) ANSYS Software 4) MA TLAB Software 5) Software development Environment in INTEL Compiler 6) Facility-creation for 3D seismic survey 5. Sponsored projects obtained (with details) Total18 (eighteen) sponsored projects from SCCL, ECL, BCCL and Tata Steel Jamadoba Group of Collieries 6. External Cash Flow (ECF) generated Total cost of all sponsored projects :Rs. 1,55,20, 109/- 7. Societal impact created Valuable augmentation to coal production of our nation from deep mine Underground mine is better in terms of the environmental degradation on surface which in turn may provide higher quality of life to affected population Developed guidelines and norms will enable highly mechanized mine sleading to safer working conditions for the miners b. Outputs: 1. Periodic Reports Submitted 2. Publications i. Total number: 22 (Twenty two) ii. iii. iv. Cumulative IF (as per 2015 f,igures) Average IF Average IF/scientist 3. Patents (or other forms of IP generated such as Copyrights, Designs etc.) i. Filed: Nil ii. iii. Granted: Nil Licensed: Nil 4. Human Resource generated i. PhD fellows (give PhDs completed & pursuing separately): 2 students pursuing 7

8 ii. iii. Project fellows: 6 project fellows Skills imparted: Out of 4 students, 2 students have been recruited in CSIR-CIMFR as scientists, 5. External collaborations established: On the process of establishing collaboration with M/s Andhra Pradesh Heavy Machinery and Engineering Ltd, a sister concern of SCCL for development of Indigenous Powered supports for Longwall Mining Method. Lead/Technology /Product (listed above in outcomes) Development of a prototype for online data generation of drilling parameters to determine various rock properties Wireless communication system for real time monitoring of strata and support behaviour in underground mines Salient Features of the Lead/Technology/ Product The drilling parameters penetration rate, RPM, Voltage, Current, Weight on bit, Temp, etc are used to calculate drilling indices such as specific energy and heating rate. These are correlated with the rock properties Technology validated in the laboratory. Useful for strata and support behaviour monitoring in underground mines. Range upto 250m in underground environment and 1500m in surface with a single node. Data from working fac.e can be transferred to the surface using nodes in series as repeaters. Real time plots available for decision making or alert indication. The developed system is a low cost system which can be installed independently and easily in any area of underground without hindering movement of men and machines Technology validated in laboratory. the TRL of the Lead/ Technology /Product TRL4 TRL4 IP Status of Lead/ T echnology/p roduct Status of DPR/Commerci al Technical Report of Lead/ Technology/ Product To be prepared To be prepared Design and Technology simulated in the TRL 4 manufacture of laboratory. Longwall Powered Supports To be prepared

9 6. Sectoral Monitoring Committee Recommendations on Lead/Technology/Product (listed above): For each Lead/Technology/Product prov ~de details separately: Criteria SMC Recommendations Name of Lead/Technology Lead 1. Development of a prototype for on-line data /Product generation of drilling parameters to determine various rock properties Lead 2. Wireless communication system for real time monitoring of strata and support behaviour in underground mines Lead 3. Design and manufacture of Longwall Powered Supports Is the Lead/ Yes with majority funding from stakeholders (e.g. Coal Technology/Product worth India, Ministry of Coal etc.) taking up further? What is the further R&D Demonstration of Wireless communication systems in efforts that need to be put underground mines by CSIR/CSIR laboratories? Global benchmarking of the - Lead/Technology/Product specifically wrt specifications and cost Is the Yes Lead/Technology/Product worthy of commissioning a DPR at this stage? What are the likely Lead 1 - Rs.100 lakh from CSIR resources resources and time duration Lead 2 and 3 - Resources to be generated from required for taking forward Stakeholders the identified Lead/ Technology/Product to the desired TRL? Potential stake holders who Coal India Limited, Ministry of Coal, SCCL, M/s Andhra may be appropriate to Pradesh Heavy Machinery and Engineering Ltd (sister partner technically as well concern of SCCL) etc as financially Suggestion for plausible - road map towards further development of ~ 9

10 lead/technology/product for achieving desired TRL GO/NO GO further GO development Other suggestions, if any, - related to benefits/usage/ commercialization 7. Identified "lessons to be learnt", especially from shortcomings/failures 8. Comments on financial progress on the project - fund availability and utilization of fund in the project: Financial progress is satisfactory and investments made are justified. 9. Sectoral Monitoring Committee Recommendations on Facility creation or other outcomes: 10. Grading of Project Execution: Outstanding/ExcellentNery Good/ Good/ Satisfactory/Un-satisfactory Very Good 11. Additional comments, if any: ~ Shri Ajit Singh /Y_l)~l~ / Pr~ C. banigrahi }~ Prof. S.N. Ojha. }.' -y ~... "" ~ """'-=4 &... Dr. T. Venugopalan Director, CSIR-CIMFR (TF Chairman -Member) Dr.~ ' Director, CSIR-NML (TF Chairman - Member) Dr. S. Srikanth Direc~MMT (TF Chairman - Member) ~~-~~ (Chairman) 10