Pre-feasibility report · dumper mining method is adopted for overburden removal. Medium size electric hydraulic shovels have been proposed in overburden to achieve high degree flexibility

PRE-FEASIBILITY REPORT

Manoharpur and Dip-side Manoharpur Coal Mine Project

ODISHA COAL AND POWER LIMITED Zone-A, Ground Floor, Fortune Towers, Chandrasekharpur, Bhubaneswar – 751023, Odisha

Pre-Feasibility Report Manoharpur & Dip-side of Manoharpur coal mine project

Page 1 of 20

Index

Sl. Description Page No.

1. Introduction of the Project: 2

2. Executive Summary: 4

3. End Use Project 6

4. Land Requirement 6

5. Water Requirement and Sources 7

6. Power Requirement and Supply 7

7. Mining 8

8. Manpower 17

9. Project Benefits 19

10. Project Schedule 21

11. Project Cost 21


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1. Introduction of the Project:

Manoharpur and Dip-side Manoharpur coal blocks were earlier allotted to Odisha

Power Generation Corporation Limited (OPGC) in June 2007. Subsequent to

cancellation of coal blocks by Supreme Court of India, These two coal blocks have

been allotted to Odisha Coal and Power Limited (OCPL) on 31st August 2015 to

supply coal exclusively to the expansion power plants (4x660 MW) of OPGC. These

coal blocks are situated in the IB Valley area of Mahanadi Coalfields Ltd in the

district of Sundargarh, Odisha.

Manoharpur and Dip side of Manoharpur block are contiguous blocks having

common boundary and extension of the Manoharpur coal block. At the time of

allocation Manoharpur block was fully explored and Dip side of Manoharpur block

was regionally explored. In the meantime, the exploration of Dip-side Manoharpur

coal block has been completed and the Geological Report has been prepared by

CMPDI. It is envisaged to start the coal production initially from Manoharpur

coalmine and subsequently from its Dip-side Manoharpur coalmine as an extension

of Manoharpur coalmine. OCPL has obtained all the permits and clearances for

Manoharpur coalmine including Mine Opening Permission. The Mine Operator

appointed by OCPL has commenced the top soil removal engaging its resources.

Requirement of coal has been assessed as 7.6 - 8 MTPA for the expansion power

plants (4x660MW) of OPGC considering the minimum GCV of 3300 Kcal /kg and

90% PLF.


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Page 4 of 20

2. Executive Summary:

Sl. No. Description Details

1. Name of the Project Manoharpur & Dip-side Manoharpur Coal

Mine Project

2. Name of the Coal Block(s) Manohar & Dip-side Manoharpur

3. Name of the Organization Odisha Coal and Power Limited (OCPL)

4. Name and Address of the

Applicant

Odisha Coal and Power Limited

Zone A, Ground Floor, Fortune Towers,

Chandrasekharpur, Bhubaneswar-751023,

Odisha

5. Location of Mine Village: Manoharpur

Taluka: Hemgiri

District: Sundargarh

State: Odisha.

6. Name of the Coalfield Ib Valley Coalfields

7. Particulars of adjacent

blocks

North Meenakshi – B coal block

South Dulanga coal block

8. End Use Project Expansion Power Plant (4X660 MW) of

Odisha Power Generation Corporation

Ltd.,

9. Net Geological Reserve Manoharpur: 252 MT

Dip-side Manoharpur: 726 MT

10. Mining Lease Area 1781.591 Ha


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11. Topo-sheet No. with

latitude and longitude.

Topo-sheet No.: F44 R13 & F44 R9

Latitude: 21o 55’52.168”N to

21o 58’16.871”N

Longitude:

83o 44’41.287”E to

83o 47’42.750” E

12. Peak Rated Capacity (PRC) 8MTPA

13. Estimated Cost of the

Project

Approx. 2720 Cr.

14. Nearest Town Sundargarh

15. Nearest Railway Station Hemgir

16. Nearest Airport Jharsuguda

17. Proposed year of start of

Production

2019

18. Proposed year of reaching

PRC

2023


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3. End Use Project:

4X660MW Expansion power plant of Odisha Power Generation Corporation

limited (OPGC) located at Ib Thermal Power Station, Banharpalli in the district of

Jharsuguda, Odisha.

4. Land Requirement:

a. Abstract of Land Schedule :

Sl.

No.

Classification of

Land

Area Inside the

block (in Ha.)

Area outside the

block (in Ha.)

Total

( in Ha.)

1 Forest Land 476.230 134.887 611.117

2 Agricultural Land 339.364 163.446 502.810

4 Homestead land 14.032 4.438 18.470

3 Barren Land 429.780 122.204 551.984

5 Grazing Land 51.401 15.820 67.221

6 Water Body 27.078 2.911 29.989

Total Land within

proposed Mining Lease 1337.885 443.706 1781.591

Land for Colony for MO & Owner & other outside mining lease area

1 Agricultural Land 13.483 13.483

2 Barren Land 16.425 16.425

Total Land outside

proposed Mining Lease 29.908 29.908

TOTAL PROJECT AREA 1337.885 473.614 1811.499


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5. Water Requirement & Source:

a. Water Requirement:

Water is required for various operations such as Domestic for drinking, dust

suppression, mine operation, green belt development and mechanical workshop.

Total raw water requirement for the mine has been estimated at 3780KLD with

recovery including design margin and losses.

b. Source of Water Supply:

Initially water will be met from ground water through boreholes for construction

and portable use. OCPL has received the NOC for ground water abstraction of

720cum/day from Central Ground Water Authority. Further drawal of 5.55 cuses

water from Hirakud reservoir has been received.

Washery to be designed on zero discharge principle. Thus, all waste water has to be

recycled. In that case, water requirement for washery has to be “Top up Water”.

6. Power Requirement & Supply:

Sources and receiving of power: The total power requirement for mines

operation is around 17 MVA. In order to avail this power in an uninterrupted and

continuous manner, OCPL has arranged power from two different sources.

Source-1: From 132/33 KV Remja GSS OPTCL at 33 KV, by constructing a 22 Km

33 KV single circuit line on RS joist poles and a 33 KV switching station at mines

end. This power supply arrangement shall be used for construction activities till the

CHP is commissioned and in the development stage & operation stage of mines till

the permanent power supply arrangement is ready (source-2). After charging of


Page 8 of 20

permanent power supply arrangement (source-2), this connectivity shall be used

as a back-up power supply arrangement for mining activities.

Source-2: From 765/132/33 KV substation of NTPC, Darlipali at 33 KV, by

constructing two 132/33 KV 31.5 MVA transformer bays at Darlipali STPP. This

connectivity shall be used as a permanent source of power for mining operation

activities.

7. Mining:

a. Mining Technology:

The proposed mining block represents presence of moderately flat multiple coal

seams with intermediate varying parting. Moderately thick to thin seams occur at

shallow to moderate depth in wide area having power grade coal reserve. So this

will make the project most viable by adopting opencast mining method.

The overburden lying between surface and coal seam roof and the partings between

two successive seams are removed before coal is exposed. Fertile top soil of about

0.3m will be removed separately by using hydraulic backhoe & tipping truck

combination. During initial stage, top soil will be stored at a designated place with

appropriate conditions. When Ex-Pit waste dumps are formed to their final

configurations, top soil will be spread over dumps and stabilized by grass

carpeting/plantation. During later stage, top soil will be carried directly from

excavated area to in-pit waste dumps for spreading.

Below top soil, occurs a layer of weathered mantle comprising mostly of laterite.

This layer may not need blasting and may be excavated directly by shovel. Its

thickness varies from place to place.


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Coal seams may be encountered at the floor of weathered mantle wherever

occurring. Hard layers of sandstone, shale or carbonaceous shale occurring above

coal seams will require drilling and blasting for facilitating them to be loaded by

shovel, transported by rear dumpers and be stacked at designated sites of waste

dumps.

After removing overburden or parting, a coal seam is exposed. Coal will be

loosened/ cut by surface miners and loaded onto dumpers by front end loaders to

transport to receiving hoppers located on surface.

This process of clearing the top soil, removing overburden and extraction of coal

will be done in layers simultaneously with formation of benches to maintain safe

angle of slope and adequate working width for deployed machineries. These

benches will be aligned along strike of the seam and cut from one end of mine to the

other end. Thus, mine will advance from incrop side of lowest seam to dip side of

the property. Height of bench will be restricted to maximum safe digging height for

excavator deployed in that bench.

As mine progresses towards dip, waste material will be backfilled in de-coaled area.

Thus the opencast excavation will be closed continuously, after providing channels

for transport of coal from face to surface.

Proper planning of transport network, dumps and drainage, adequate lighting and

ventilation are required as the mining progresses beyond depth of 200m. As the

depth and stripping ratio increases, the percentage accommodation of dump within

the quarry will also be limited.


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b. Choice of Technology

For continuous feeding of coal to the OPGC’s thermal power plant, coal quality is to

be regulated within a specified range of GCV. It needs more flexibility in mine

operations to extract coal at different locations from different seams to maintain

that average quality. So, shovel-dumper system is chosen. Draglines could have

been cheaper but mine operations become rigid by deploying dragline. Large size

draglines are highly cost intensive. Its availability, maintenance and utilization

casts a shadow of doubt about projected gains against risks involved. However, the

technical considerations of deploying dragline does not support due to presence of

multiple seams with varying thickness & varying intermittent parting & band.

Shovel-dumper system is very flexible and also offers convenient mining operations

to deal with sudden occurrences of unworkable or poor quality patches and change

of floor position due to varying seam gradient and thickness. It also offers flexibility

for easy transition to any other technology or equipment configuration. The

technology is well known and advantageous to get skilled manpower. So shovel-

dumper mining method is adopted for overburden removal. Medium size electric

hydraulic shovels have been proposed in overburden to achieve high degree

flexibility & reduce pollution.

Coal will mostly be cut by surface miner in windrowing method. There are many

advantages in this technology including the avoidance of drilling, blasting, crushing

of coal and related environmental hazards, improvement in grade of ROM coal by

removing thin bands i.e. selective mining, clean surface for transport etc. It is

estimated that coal at two ends of a bench & comparatively thinner seams (about


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15%) may have to be extracted by conventional drilling- blasting method and this

will vary according to actual geological and geotechnical conditions.

Part In-pit conveying of coal may be opted in later years for coal transportation from

quarry bottom. Initially Blast free coal from bottom sections will be transported

along benches and then along main haul road along floor upto the receiving hopper

on pit top by rear dumpers. Coal from upper seams will be transported along haul

road on southern or northern slope slope after year7-8 when mine will be developed

along its full strike. This system may continue upto year25. After year 25 as the mine

depth increases beyond 200m there will be extreme shortage of space for

accommodating overburden internally due to higher depth & stripping ratio, during

this period central haul road & haul road on southern slope will be filled up & main

haul road will be developed along northern slope, main conveyor may be aligned

along part of this flank haul road . Then coal will be transported along benches by

rear dumper and the same will be loaded onto inpit conveyor on northern quarry

slope via reclaim feeder. This system will optimize the transport fleet, which in turn

reduce the environmental pollution & savings in fuel & manpower. High angle

conveyor system may also be adopted in future. Decision regarding inpit conveying

or high angle conveyor may be taken at future date.

c. Equipment Selection

Hydraulic shovels have been preferred over rope shovels due to their higher

productivity, faster marching, higher manoeuvrability and ease of maintenance.

They are cheaper but have shorter life than rope shovels.

Choice of excavator size is dictated by optimum utilization of these excavators and

efficiency of loading thin benches up to 3m. In view of that, 10 to 12 cum hydraulic

shovels/ backhoe (175-205 T/950 to 1050 HP) are proposed for overburden


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excavation and 6-7cum hydraulic shovels/ backhoe (450 to 550HP) are proposed

for comparatively thinner partings. These shovels will also load part coal which will

be drilled and blasted.

Optimum dumper size for larger shovel is 90 to 100 T and that for smaller size

shovel & pay-loaders is 50-60T.

Surface miners having 3.8m drum width with engine power of 900-1100HP are

proposed for coal cutting in windrowing method. Loose coal will be heaped & loaded

on to 50-60 Tonne dumpers by 6-7 cum front end loaders.

250mm diameter drills are proposed for thick partings and top overburden while

160 mm diameter drills are to be deployed for other partings and coal which need

to be blasted.

Crawler dozers of 850HP with ripper attachment are proposed for pre-mining land

preparation and loosening of bands and partings below 3m where good

fragmentation is not expected with 160 mm drills.

Supporting equipment like crane, grader, water sprinkler, tire handler, compactors

etc. of suitable sizes have been provided. However if required, in coal & in inseam

band/ parting smaller size eqyuipment may be deployed for operational efificiency.

The application of In-Pit Crushing and Conveying (IPCC) of coal can be introduced

during the later part of the mine life of the project after conducting the detailed

viability studies. Introduction of any new technology at a future date may be studied

at that time for improved performance, productivity and safety in the mine.


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d. Production:

Production Program: The year wise Coal and OB Production Schedule are as

follows:

YEAR

COAL OB Stripping Ratio

(in Mt) (in Mcum) (in cum/t)

Cons(Year-1) - - -

P1(Year-2) 1.00 3.32 3.32

P2(Year-3) 2.50 6.27 2.51

P3(Year-4) 5.00 13.83 2.77

P4(Year-5) 8.00 18.44 2.31

P5(Year-6) 8.00 18.44 2.31

P6(Year-7) 8.00 18.44 2.31

P7(Year-8) 8.00 18.44 2.31

P8(Year-9) 8.00 18.44 2.31

P9(Year-10) 8.00 18.44 2.31

P10(Year-11) 8.00 16.78 2.10

P11(Year-12) 8.00 16.78 2.10

P12(Year-13) 8.00 16.78 2.10

P13(Year-14) 8.00 16.78 2.10


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P14(Year-15) 8.00 16.78 2.10

P15(Year-16) 8.00 16.78 2.10

P16(Year-17) 8.00 16.78 2.10

P17(Year-18) 8.00 16.78 2.10

P18(Year-19) 8.00 16.78 2.10

P19(Year-20) 8.00 16.78 2.10

P20(Year-21) 8.00 16.78 2.10

P21(Year-22) 8.00 16.78 2.10

P22(Year-23) 8.00 19.73 2.47

P23(Year-24) 8.00 19.73 2.47

P24(Year-25) 8.00 19.73 2.47

P25(Year-26) 8.00 19.73 2.47

P26(Year-27) 8.00 19.73 2.47

P27(Year-28) 8.00 19.73 2.47

P28(Year-29) 8.00 19.73 2.47

P29(Year-30) 8.00 19.73 2.47

P30(Year-31) 8.00 18.07 2.26

P31(Year-32) 8.00 18.07 2.26

P32(Year-33) 8.00 21.02 2.63


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P33(Year-34) 8.00 23.97 3.00

P34(Year-35) 8.00 23.97 3.00

P35(Year-36) 8.00 23.97 3.00

P36(Year-37) 8.00 23.97 3.00

P37(Year-38) 8.00 23.97 3.00

P38(Year-39) 8.00 23.97 3.00

P39(Year-40) 8.00 23.97 3.00

P40(Year-41) 8.00 23.97 3.00

P41(Year-42) 8.00 23.97 3.00

P42(Year-43) 8.00 23.97 3.00

P43(Year-44) 8.00 23.97 3.00

P44(Year-45) 8.00 26.92 3.37

P45(Year-46) 8.00 26.92 3.36

P46(Year-47) 8.00 26.92 3.36

P47(Year-48) 8.00 26.92 3.37

P48(Year-49) 8.00 26.92 3.36

P49(Year-50) 8.00 26.92 3.36

P50(Year-51) 8.00 28.58 3.57

P51(Year-52) 8.00 28.58 3.57


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P52(Year-53) 8.00 28.58 3.57

P53(Year-54) 8.00 28.58 3.57

P54(Year-55) 8.00 28.58 3.57

P55(Year-56) 8.00 28.58 3.57

P56(Year-57) 8.00 28.58 3.57

P57(Year-58) 8.00 28.58 3.57

P58(Year-59) 8.00 28.58 3.57

P59(Year-60) 8.00 28.58 3.57

P60(Year-61) 8.00 28.58 3.57

P61(Year-62) 8.00 28.58 3.57

P62(Year-63) 8.00 25.63 3.20

P63(Year-64) 8.00 25.63 3.20

P64(Year-65) 8.00 25.63 3.20

P65(Year-66) 8.00 22.68 2.84

P66(Year-67) 8.00 22.68 2.84

P67(Year-68) 8.00 22.68 2.84

P68(Year-69) 8.00 22.68 2.84

P69(Year-70) 8.00 21.02 2.63

P70(Year-71) 8.00 21.02 2.63


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P71(Year-72) 8.00 21.02 2.63

P72(Year-73) 8.00 21.02 2.63

P73(Year-74) 8.00 21.02 2.63

P74(Year-75) 8.00 21.02 2.63

P75(Year-76) 8.00 21.02 2.63

P76(Year-77) 6.00 14.34 2.39

P77(Year-78) 4.68 8.69 1.86

TOTAL 595.18 1656.35 2.78

8. Manpower:

The development of the Manoharpur Mine will take place during the first three to

four years of operation. During year-1 to year-2, the mine will not reach at its rated

production, and the larger size equipment will not be deployed. Accordingly, the

manpower builds up as production increases, and the full equipment fleet is

commissioned. The mine will be developed and operated by the Mine Operator, it

is envisaged that the required manpower shall be engaged by the Mine Operator for

the development and day to day operation of the mine, coal handling plant

including other allied activities.

Departmental manpower has been assessed by OCPL for the mining operation

which is summarized below:


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Manoharpur Manpower (Departmental) for MO Mode

Exe. Non-Ex. Total

Co. Office 18 3 21

Site 73 36 109

TOTAL 91 39 130

The company has prepared a statutory and non-statutory requirement of manpower

taking into consideration lead time for training and external hiring.

Company will also have 15 persons for the initial 3 years of CHP construction &

operation for the supervision (2 years construction & 1-year operation on

contractual basis). After initial two years of operation of CHP, the Mine Operator

will operate & maintain the CHP.

Coal extraction, loading, transport, overburden drilling & blasting, excavation and

transportation and other auxiliary activities in the mine will be done by the Mine

Operator. Assessment of same will widely vary as per contract and Mine Operator.

However, a tentative assessment of operation manpower for the above activities

have been done by OCPL and are summarized below:

Mine Operator’s Manpower

OBR Operations 300

Coal Operations 175

Common Operations 275

TOTAL 750


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Security & Canteen Services will be outsourced.

*N.B: These figures are indicative only and may vary as per actual requirement.

9. Project Benefits:

The proposed project is expected to bring significant socio-economic and

environmental benefits both at local and global level as listed below:

1. Infrastructural Improvement

2. Employment Potential

3. Revenue Generation

4. Indigenous People Development Plan (IPDP)

5. Peripheral Development Plan (PDP)

a. Providing Job Opportunity

b. Vocational Training to Local Youth

c. Providing Medical Assistance

d. Education

e. Infrastructure Development

f. Social Afforestation

g. Games, Sports & Culture.

6. Other Benefits: Beside above, indirect benefits have also accrued to the

region by way of increase in agricultural and industrial production.

Overall there will be positive impact in socio0economic area due to increased

economic activities, creation of new employment opportunities, infrastructural

development, better educational and health facilities.


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10. Project Schedule:

The coal production will start from April 2019 onwards and will reach the rated

capacity in the year 2023.

11. Project Cost:

The total project cost is approximately Rs. 2720Cr.

Documents

Pre-feasibility report · dumper mining method is adopted for overburden removal. Medium size electric hydraulic shovels have been proposed in overburden to achieve high degree flexibility