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翻译部分 英文原文Technology for Tomorrow andEquipment Selection for India Coal MinesABSTRACT:The contribution provides a short introduction to economic changes in Indian and consequences to natural energy resources .By the example of coal production there are described the India energy reserves. Next part of contribution describes mining technology from the actual state to the future development. As the conclusion the mining industry has to accept new mining technology and automation systems to implement intelligent mining of 21st century.1. CHANGING ECONOMIC SCENARIOIN INDIA-COMPETITIVE MARKET COMPANYAs we stand today, at the threshold of a Global Market, there are many challenges facing the Indian Coal Industry. Since the beginning of this decade, dramatic political and economic reforms initiated by the Govt. in 1991 mark a watershed in Indias economic thinking and aim at lowering protectionism and integrating the countrys economy with global market. Barriers to import and foreign capital are being lowered. Changes in industrial, foreign trade, exchange rate, and tax policies has led to a paradigm shift towards market forces and competition.The old paradigm that dictated success is being replaced by new rules. The emerging business scenario indicates that there is an urgent need for the Indian coal industry to become proactive, improve its overall performance and understanding of market and customers need. There has to be an increase in the awareness and concern, efficiency improvement and increasing productivity and profitability. Coal India, which produces 90% of coal production of India, has to develop a marketing strategy, which uses its own competition advantages to meet the challenges of growing competition from imported coal and the new entrants in the Indian coal market. With around 60% of the primary energy needs being met by coal and with large reserves available in the country compared to other fossil fuel, the role of coal in the countrys economy will continue to be vital. The liberal economic policies are encouraging the rapid expansion of industry in India, which in turn is creating unprecedented demand for coal to fuel power stations, steel plants, cement and various other industries. Given the above scenario some of the considerations for the long-term strategic objectives for the coal industry has to be to become the cost leader in terms of being the lowest cost provider of a given value and to increase production to meet the challenges of widening gap between demand and indigenous coal availability. It should be noted that liberalization is removing most of the regulatory entry barriers for superior positioning in terms of efficiency by utilizing the best available technology and equipment.2. COAL IN INDIA The primacy of coal in the energy policy planning of the country lies in its relatively comfortable resource position vis-vis that of the hydrocarbons. The present available coal resources going by the reserve to production ratio is expected to last for another 233 years as compared to 15 years for oil and 23 years for Natural Gas, making coal a very secure energy source for the country. The present proven recoverable resources of fossil fuels are:Coal84 billionCrude oil0.715 billion tonsNatural gas692 billion m32.1 Coal Reserve Geological coal resources as per the recent assessment made by the Geological Survey of India (GSI) is around 220 billion tones in seams of 0.9 m and above in thickness and up to 1200m depth. Out of the total coal reserves 38%(844.4 bt) is under the proved category, while the reserves under the indicated and inferred category are 45%J(98.5 bt) and 17%(38.0 bt), respectively. Coal resources in India account for 0.8% of the global coal resources. However, proved reserves are 5.7% of the global coal resources. The share of overall coal resources of different States are:Jharkhand32%Orissa23%Madhya Pradesh/Chattisgarh20%West Bengal13%Andhra Pradesh6%Matharashtra3%Other3%The salient features of Indian coal resources are as follows:About 64% of the total coal resources occur within 300 m depth and 26% occurs in the depth range from 300-600 m depth. Only about 10% resources occur beyond 600 m depth in deep coal basins like Jharia and Raniganj coalfields.Resources of non-coking coals amount to about 85% of the total resources of which only 12% are of superior grade and occurring mostly in Raniganj.Bulk of the coal resources (73%) are inferior grade non-coking coals occurring in thick inter-banded seams and lcated in coalfields like Singrauli, Talcher, North Karanpura, Rajmahal, IB Valley and Korba etc.Coking coal resources are only 15% of the total resources confined to only 10 out of the 62 coalfields in Jharkhand, West Bengal and Madhya Pradesh.The proved reserves (up to a depth of 600 m) is estimate at 71 billion tones out of which only 30 billion tones (42.25%) is minable by underground and the rest 41 billion tones (57.75%) by open-casting. Presently mining in India is mostly restricted to a maximum depth of about 300 meters. In view of the large availability of indigenous coal and to maintain, its share in the Energy mix, there is a need to increase the production of coal and to improve production is about 300 mt per annum and the domestic production is increasing at a growth rate of about 4-5% per year.3. GROWTH OF COAL PRODUCTIONThe Indian coal industry has come a long way since the nation gained its independence. The growth of the coal mining industry was slow till nationalization. In the year 1974-75, after nationalization of coalmines: the coal production in CIL was 78.99mt and the share of production from opencast mines was only 26percent. Rapid increase in the demand of coal by the power sector has made it imperative for the nationalized coal industry to accelerate its production and expansion program. The underground mining, which dominated the scene before the during the initial period of nationalization days, could not meet the growing needs of the post nationalization period and therefore there was a shift towards increased opencast mining to obtain bulk coal production in shorted time frame .Table below shows the phenomenal growth in production since 1974-75 in CIL。It may be seen from above table that, in the last 28 years period, growth in coal production in CIL has been three fold where as increase in production from opencast mines has been ten fold. The share of opencast, which was a meagre 26% in 1974-75,has gone up to 81%. Underground mining, share in production dwindled from 74% in 1974-75 to only 19%.In the tenth Five-year plan, the production of coal is projected to increase by 77 mt: from a level of 322.74 mt in 2001-02 to 399.73 mt in 2006-07.The demand of coal projection in the terminal year of XI Plan (2011-12) and XII Plan (2016-17) is expected to be 620 mt and 780 mt respectively. Keeping in view the above requirement of coal in the next 15 years a substantial increase in production is envisaged in the coming years to reduce the gap between demand and domestic supply as well as dependence on imports.Plan/YearU/GO/GTotal Cost%UG/%OG4/1974-197558.2220.7778.9974/265/1978-197961.1328.2990.0568/326/1984-198560.5070.31130.8146/547/1989-199058.71119.91176.6233/678/1996-199755.19195.43250.6222/781997-199853.99206.56260.5521/791998-199953.31203.16256.4821/791999-200052.32208.26260.5820/802000-200152.81216.19268.9019/819/2001-2002*54.84224.16279.0019/8110/2006-2007*62.05287.95350.0018/82* Target Production* Projected Production4. MINING THCHNOLGY OPTIONThe mining industry is heading towards a technology driven optimization process.Attaining the twin objectives of accelerated production and lower cost for the Indian coal industry is a challenging task due to the traditionally labor-intensive nature of the industry .All these have called for significant and far-reaching changes in mining technology, in underground as well as in opencast mining methods. It has been realized that the unit operations such as drilling, blasting, excavation, loading, hauling and crushing and interrelated variables in the total cost equation. The development and utilization of the innovative technologies are very important for the mining industry to be cost effective.Surface mining has to improve its level of performance to make inferior quality high ash coal tech-economically viable even in the remote power plants In the foreseeable future, surface mining will continue to dominate the coal production scene with mega-sized mines for economics of scale. The plateau of surface mining expected by the third decade of this millennium has to be supplemented by the u/g mining, which will be under deeper cover and may need strong dose of new technology and heavy capital investment .The underground mining suffering from past legacy has to undertake drastic revision of policy in terms of sinking of shaft or development of incline opening of new deposits and introduction of mew technology at the earliest to meet the rising demand of quality coal.The difficulty of striking a balance between u/g and o/c mining is necessary to avoid total dependence to underground operation in future .It was recognized that the technology to be adopted for coal production would eventually depend on market forces. Market forces are likely to determine the mix of technologies to be followed in the future also as it has been experienced in the recent past. Since the geo-mining conditions very from one coalfield to another, a generalized approach towards one optimal mix of opencast and underground mining cannot be evolved. Generally speaking, u/g mining will be uneconomical in present pricing system if quality of coalmines is lower than grade C. However, liquidation of the better grade of coal locked in already developed u/g working needs to be considered through appropriate mass production u/g technology. Besides all this, there are certain problems that require attention.5. SURFACE MINING TECHNOLOGYFuture mining scenario is heavily titled towards surface mining .As mentioned earlier about 57% of the proved coal reserve is amendable to surface mining. The areas with huge reserve of the reserved coal like North Karanpura(8156 mt ), Rajmahal(8933mt), singrauli(6350mt), Korba (7668 mt),Ib River Coalfield (13339mt), Talcher (23355mt), Mand Raigarh (8551mt), AWardha(3420mt) and Godavari Valley (5429mt) may sustain opencast mining for next 50 years, provided proper blend of technology, value addition and resources are made available .Mess production of inferior grade coal at low price is possible only by surface mining ,deploying giant coaling, loading and transporting machines.Surface mining has undergone tremendous change with the development in machine design and growth in information technology. The technology of surface mining has evolved incrementally in search of higher levels of productivity of reduced cost. Apart from achieving economies of equipment ,a new direction of technology development focuses on automation ,cleaner mining systems and improving the reliability of machine performance.The machines used for the purpose are continuous and cycles in nature.Continuous Surface MinersCyclic Heavy Earth moving Machine Heavy Drilling Machines land Blasting CycleShovel-Dipper Shovel /Rope ShovelIn pit Crushing Conveying System6. GLOBAL SCENARIOThe type /size of equipment utilized in coal mining is varying and dependent on the geological and economic condition of the countries where they operate, Dumper /Shovel combination (along or in tandem with draglines) dominate most of the world operations. Due to progressive advancement in the design of new diesel engines, new type of truck has been continuously increasing. While in the early 1980s,the largest truck was designed to carry 170 tones of material, the 1990s ended with manufactures consolidating sales in 240 tones class trucks and establishing commercial acceptance of trucks up to 320 to 360 tones pay loads. By the end of this decade we may witness truck with payload in excess of 400 tones.High capacity excavators (up to 50 cum buckets) are available to load the high size dumpers in 3 to 4 lifts. Large sizes, productivity, reliability and low operating costs combined together make electric rope shovels the traditional workhouse in large surface mining operations. However, due to drawbacks like higher capital investment, lower mobility and reliance on electric power are promoting many operators to select hydraulic machines or wheel loaders. Hydraulic excavator manufactures, have spent the last two decades in trying to catch up with the electric rope shovels in terms of product size and acceptance, In recent years they have gained widespread acceptance in sizes up to 25 cum and their largest models are competing with the electric rope shovels. Wheel loader are regarded as utility as used no coal loaders in large surface mines, Manufactures have developed progressively larger machines(up to 28 cum capacity/1800hp)and they are being used as primary loaders at many locations. High capacity Dozers (up to 860hp) have been successfully operating at many mine sites. The next few years may see the launch of sizes in excess of 1000 hp. Thrust on Drilling and Blasting have helped in reducing downstream costs and boost overall performance. The rapidly changing electronic environment and the information age is driving the need for gathering more data from the drilling operations. As the development of GPS, remote diagnostics and other peripherals are accelerating - drills may be the first piece of equipment to be fully automated.The introduction of walking draglines with greater reach, better maneuverability, better handling capacity and under given condition is the lowest cost overburden handling machine. The Bucket capacity of some of these machines (BE 2570-WS) is 122.3 cum, boom length 109.7 to 128 a maximum digging and dumping height of 60m. The cost of the machine however is very high and demands high productivity to make it economically viable. There are 40 such units under operation in CIL mines with fair improvement in productivity.6.1 Computer ApplicationIn the last decade, information technology has made massive in-roads into surface mines around the world, be it planning or real time control of operations and has opened up existing effort to vistas of future possibilities. Recent advance in computer, communication and GPS technology have renewed effort to develop fully automated, intelligent mining system in which a real time control and management of operations is possible with the objective to optimize mine performance.The technologies related to these include:Data acquisition systems that provide accurate real time information onlocation and status of all pieces of mining equipment and facilities.Digital ore body models with ability to interact with mining equipment and control its advances on one side and interacting with the computerized mine planning on the other.Vital signs monitoring systems that allow collection of reliable equipment performance data on one side and provide equipment health diagnostics on the other.Wide band, high speed bi-directional communication systems that facilitate fast transmission of voluminous data.Computerized fleet management and dispatch systems are common features in most mines today. These allow for optimization of truck assignments and achievement of production objectives at significantly lower overall costs. Truck dispatching has now become an integral part of any large surface mine for improving machinery availability and utilization, management control, real time control and has proven its economic viability in over 100 installations in the world.6.2 Indian ScenarioThe surface mining segment of the Indian Coal industry can claim to be leader with many success stories in recent years. Some of the technological milestones are as follows.Inpit crushing and conveying at Padampur project of WCL1993-94 Commissioning of 25m3 shovel & mobile crusher at Pipawar mine1994-95 Inpit crushing and conveying at Ramagundam opencast PH-1998-99 Surface miner (in MCL)The contribution of open cast technology in overall production mix continues to be dominant. The CIL proposes to produce 80% of coal from opencast mines and SCCL 54% during 2006-7. Opencast mining, in India, at present is done max up to a depth of 160m. However, few mines have been planned for working even for depths up to 29m. Some of these mines on further extension on the dip side are likely to be worked at greater depths subsequently.Shovel dumper combination is the most prevalent system of coal extraction and overburden removal. Draglines have been deployed whenever conditions are conducive. So far as equipment size is concerned: Draglines up to 30 cubic meter bucket capacity, roper shovels with bucker size up to 20 cubic meter, 170 T year dumpers, 770 HP dozers and 311 mm dia blast hole drills are in use in Indian mines. Techno-economic considerations may allow deployment of rope shovels of sizes even up to 42 cubic meter with 240 tons rear discharge dumpers in some open cast mines where large overburden to coal ration exist.Due to advances made in information technology, introduction of diagnostics and GPS based systems for greater control over operations and monitoring of production and performance indices need critical consideration. In other coal producing developed countries for large size equipments with fully computerized automatic operational control systems competitive advantage on cost of production per ton of coal. Usually the equipment in use has the following sizes:(a) Trucks with big payloads of 400T.(b) High capacity excavators up to 50 cubic m buckets.(c) Hydraulic excavator up to 25 cubic m.(d) Wheel loader up to 28 cubic m capacity / 1500 HP.(e) Dozer of 860 HP and likely launch of 1000 Hp.There appears to be ample scope for improvement in the surface mining system. The future of surface mining will hinge on its ability to manage the environmental impact in a cost-effective manner.However, use of high technology equipment is only when used in conjunction with efficient production practices. Thus, the focus in indigenous coal sector is on increasing the overall efficiency of HEMM by better utilization for equipment through use of information technology, and better management practices.7. UNDERGROUND MINING TECHNOLOGYThe Indian underground coal sector, though the fifth largest underground producer in the world with 70 million tones per year, still has a low level of mechanization and massive scope for improvements. Recently India has introduced semi-mechanized mining with SDLs and LHDs. The scope to introduce new fully mechanized continuous mines system is existing. The cost of coal from u/g mines in India is US 30.09/ ton is rather prohibitive. The same for opencast mine is 9.39/ ton. The cost in US per billion calories from underground and opencast mines in India works out to 5.47 and 2.18 respectively, against global mining cost of 2.42 to 3.54. The 2000-01. Keeping in view long -term energy requirement of the country-there is an urgent need to systematically build up underground production capacity and production potential. Size of mining operations and introduction of appropriate technology is key to success of underground mining.Bulk of the total underground coal production in India comes from board and pillar workings. The share of mechanized board and pillar operations, i.e. with loading of coal by SDL/LHDs, has gradually been increasing. In the past 3 its years its share has gone up from 37.8 & 42.6%. The contribution from
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