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Reliance Group In Pit Crushing & Conveying Technology for 40 MTPA Capacity Kerendari BC Coal Mine IPCC 2012, Bali, Indonesia 26 th October 2012

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  • Reliance Group

    In Pit Crushing & Conveying Technology for 40 MTPA Capacity

    Kerendari BC Coal Mine

    IPCC 2012, Bali, Indonesia

    26th October 2012

  • Reliance Group

    Reliance Power

    UMPP

    40 MTPA Kerendari BC Coal Mine

    Contents

  • confidential

    Diversified group with presence across key growth areas

    Communications Infrastructure

    Infratel

    Capital Power Entertainment

    Mobile / Fixed Wireless etc

    Multi Tenancy Tower Portfolio Optical Fiber Cable (OFC)

    Mutual Funds, Insurance etc. Generation Fuel Sourcing

    Movies / TV / Music / Gaming Multiplexes FM Radio Stations Broadcasting

    Infrastructure EPC Power Transmission, Distribution

    & Trading

    Slide 3

  • confidential

    Key Financials

    Slide 4

    Assets $40 bn

    Net worth $20 bn

    Revenues $10 bn

    EBITDA $3.2 bn

    Profit after tax $0.8 bn

    One of the largest business houses in India within 5 years of existence

    Over 240 million customers 1 in every 5 Indians

    10 million shareowners the largest in the world

    As on March 31, 2011

  • Reliance Group

    Reliance Power

    UMPP

    40 MTPA Kerendari BC Coal Mine

    Contents

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    A Snapshot

    1540 MW of operational capacity

    5,000 MW to be commissioned by 2012

    Over 20,000 MW under implementation

    Constructing Indias largest gas-based power

    plant of 2,400 MW

    Won 3 of the 4 UMPPs awarded by GoI

    One of the largest capacities of renewable

    energy projects under

    construction in India

    Power Generation Resources

    4 captive coal mines in India with aggregate coal

    reserves of c. 2 bn tonnes

    3 coal concessions in Indonesia with estimated

    coal resources of c. 2 bn

    tonnes

    Planned peak coal production of 95 million

    tonnes

    4 Coal Bed Methane (CBM) blocks with a

    combined area of 3,251

    sq.km.

    An oil & gas exploration block with an area of

    3,619 sq. km in India Reliance Groups brand, experience and position in the Indian Power Sector

    Focus on environmentally friendly

    technologies

    Portfolio well diversified by fuel source,

    geography and offtake

    One of the largest coal reserves amongst

    private power generation companies in India

    Largest portfolio of power projects under

    construction and development in the private

    sector in India

    One of the leading power development

    companies in India

    Slide 6

    Reliance Power

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Project Capacity (MW) First Unit Last Unit Fuel Type

    Land

    Acquisition

    Environment

    Clearance Financing

    Rosa Phase I 600 MW (2 units) Mar-10 Jun-10 Coal

    Rosa Phase II 600 MW (2 units) Dec-11 Mar-12 Coal

    Butibori 600 MW (2 units) Mar-12 Jul-12 Coal

    Sasan UMPP 3,960 MW (6 units) Jan-13 Jun-14 Coal

    Krishnapatnam UMPP 3,960 MW (6 units) Jun-13 Feb-15 Coal In-progress

    Chitrangi 3,960 MW (6 units) Jun-14 Sep-15 Coal In-progress

    Tilaiya UMPP 3,960 MW (6 units) May-15 Feb-17 Coal In-progress In-progress

    Samalkot 2,400 MW Mar-12 Dec-12 Gas In-progress

    Wind 200 MW Mar-12 Dec-12 Wind In-progress NA In-progress

    Solar PV 40 MW Mar-12 Mar-12 Solar NA

    Solar CSP 100 MW May-13 May-13 Solar NA In-progress

    Total 20,380 MW

    Significant Plans to Capitalise on Growth

    Operating Power Portfolio (MW)*

    On-Track Execution of Projects

    Reliance Power has one of the largest pipeline of power projects in the private sector in India.

    Execution of projects is on-track, with key approvals obtained for most of the projects.

    *Capacity includes only those projects under current construction

    600 3,140 5,100

    9,820 15,580

    18,400 20,380

    FY11 FY12 FY13 FY14 FY15 FY16 FY17

    Slide 7

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Reliance Powers project portfolio is well diversified by fuel type and location

    Power Operation/ Implementation

    Project No. Capacity (MW)

    Coal based 6 17,640

    Gas based 1 2,400

    Solar 2 140

    Wind 1 200

    Power Development

    Project No Capacity (MW)

    Hydroelectric 12 5,292

    Resources

    Asset No Resources

    Coal mine-India 4 ~ 2 bn tonnes

    Coal mine-

    Indonesia 3 ~2 bn tonnes

    CBM blocks 4 193.92 BCM

    Oil & gas blocks 1 204 MMT; 76 BCM

    Mizoram

    Note: # represents Operating Projects; ^ represents Projects Under Construction; * represents Projects Under Development

    Butibori^ (600 MW)

    Rosa # ^

    (1,200 MW)

    Tilaiya^

    (3,960 MW)

    Krishnapatnam^

    (3,960 MW)

    Chitrangi^ (3,960 MW)

    Sasan^ (3,960 MW)

    Samalkot^ (2,400 MW)

    Sohagpur

    Kothagudem

    Barmer 4

    Barmer 5

    Coal Gas Coal Mines CBM blocks Oil & Gas

    Solar CSP ^

    (100 MW)

    Solar PV ^

    (40 MW)

    Wind ^

    (200 MW)

    Renewable

    Hydro Projects * (672 MW)

    Hydro Project * (400 MW)

    Hydro Projects * (4,220 MW)

    Hydro

    Slide 8

    Reliance Power: Projects Portfolio

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 9

    Allotted Coal Blocks

    Madhya Pradesh

    (Moher,Moher-

    Amlohri &

    Chhatrasal Blocks)

    Orissa (Rampia

    Block)

    Jharkhand

    (Kerendari B&C

    Block)

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 10

    Shahpur I (1,200 MW)

    Butibori

    (300 MW)

    Rosa I (600 MW)

    Rosa II (600 MW)

    Coal Based Power Projects

    Chitrangi Power

    (660x9 MW)

    Sasan

    (660x9 MW)

    Krishnapatnam

    (4,000 MW)

    Domestic coal

    based projects

    14,700 MW

    Imported coal

    based projects

    5,200 MW Orissa Coal

    (1,320 MW)

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 11

    India Coal Reserves

    Chhattisgarh

    (10%)

    Maharash

    tra (5%)

    Madhya

    Pradesh

    (8%)

    Orissa (19%)

    Jharkhand

    (37%)

    Andhra Pradesh

    (9%)

    Total reserves

    106 Billion

    tonnes

    West Bengal

    (11%)

    Over 85% of total coal reserves concentrated in just five states

    Source: Ministry of Coal, Annual Report 2008-09

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Coal Production

    12

    Mill

    ion

    To

    ns p

    er

    an

    nu

    m

    Financial Year

    4

    11

    24.5

    38

    51.5

    90

    100 MTPA

    FY Moher Chhatrasal Kerendari

    B &C

    Indonesia Total

    2013 4 4

    2014 10 0.5 0.5 11

    2015 15 2.5 4 3 24.5

    2016 20 5 8 5 38

    2017 23 5 16 7.5 51.5

    2019 23 5 30 32 90

    2020 23 5 40 32 100 0

    20

    40

    60

    80

    100

    120

    2013 2014 2015 2016 2017 2019 2020

    Indonesia

    Kerendari B &C

    Chhatrasal

    Moher

  • Reliance Group

    Reliance Power

    UMPP

    40 MTPA Kerendari BC Coal Mine

    Contents

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Ultra Mega Power Project UMPP (4000 MW)

    UMPPs are of national importance

    All initial development and approvals by Government of India

    Ministry of Power to provide land, fuel linkage to captive mine block, water and environment

    & forest clearances

    Government of India regularly monitors the progress of the UMPPs to ensure that they are built

    on time

    MoP has awarded projects at Mundra (Gujarat) to Tata Power and Sasan (MP), Krishnapatnam

    (AP) and Tilaiya (Jharkand) to Reliance Power

    Slide 14

    Electricity Buyers are identified upfront and entire capacity is contracted with the Electricity

    Buyers by signing a common 25 year PPA

    Powergrid Corporation of India Limited, the Central Transmission Utility, is responsible for

    developing and providing the transmission grid

    Slide 14

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Tilaiya UMPP

    One of the largest pit head power projects in the world, Mining Plan 40 MTPA

    Tilaiya UMPP awarded to Reliance Power through international competitive bidding process

    4000 MW capacity Power Project based on Super-Critical Technology

    Power Plant

    Ash Dyke

    Coal Block

  • Reliance Group

    Reliance Power

    UMPP

    40 MTPA Kerendari BC Coal Mine

    Contents

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Coal Mine Location

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Geological Details

    Geological formation

    Geological structure

    Dip

    Faults

    GSI 2 968.05

    CMPDI 287 50529.70

    TOTAL 289 51497.25

    Agency Boreholes Meterage

    Borehole Density -11 boreholes /km2

    Blocks are occupied by exposure of Barakar formation and

    mostly covered by soil/weathered mantle. Predominant rock

    strata is sandstone/ shale

    Strike of the strata is almost E-W in general but in the central

    part it swings to WNW to ESE and again to E-W in the eastern

    part

    The general dip of the strata/coal seams is southerly and varies

    from

    10-19 degrees, average dip being about 14 degrees

    Coal block contains 11 faults having throw in the range from 10-

    130 m

    Exploration details

    18

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Sequence of Coal Seams

    Particulars Thickness Range (m)

    Surface RL 414 489

    Weathered Mantle 6 28

    Top OB 6 361

    Seam IV D 0.23 5.67

    Parting 0.32 13.25

    Seam IV C 0.19 3.01

    Parting 0.50 28.05

    Seam IV B 0.10 5.37

    Parting 1.08 38.03

    Seam IV A 0.13 2.91

    Parting 0.32 18.32

    Seam IV 3.26 19.42

    Parting 1.34 45.90

    Particulars Thickness Range (m)

    Seam III T 0.08 3.75

    Parting 0.10 26.87

    Seam III B 0.08 4.12

    Parting 0.36 21.80

    Seam II T 1.02 19.54

    Parting 0.00 4.99

    Seam II B 1.66 14.35

    Parting 0.65 11.78

    Seam I T 0.15 5.76

    Parting 0.17 11.69

    Seam I M 3.66 20.54

    Parting 0.49 12.63

    Seam IB 0.07 4.93

    19

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Geological Cross Section

    20

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Coal Reserves

    Total Net Geological

    Reserves 1,229.12 MT

    Total Extractable Coal

    Reserves 834.65 MT (68%)

    Coal Losses

    Under Barrier 60.81 MT (5%)

    Under Batter 291.95 MT (24 %)

    Mining Loss + Devolatized 41 .71 MT (3%)

    Total Losses 394.47 MT (32%)

    Volume of OBR 3055 Mm3

    Average Stripping Ratio 3.66 m3/T

    21

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Present Final Pit

    Coal Loss in West

    43 Mill. tonne Coal Loss in East

    89 Mill.Tonne

    Coal loss in South

    221 Mill. tonne

    Kerendari BC Block

    Kerendari A Block

    (NTPC)

    Pakri Barwadih

    Coal Block

    (NTPC)

    Coal Loss

    Area Barrier Batter

    Total

    Reserves (Mt.)

    East 16 73 89

    West 12 31 43

    South 33 188 221

    TOTAL 61 292 353

    Devolatisation 16

    Mining Loss (@3% of reserves) 26

    GRAND TOTAL 395

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 23

    Geological Faults (11 Nos) from East to West: F2-70m;F10- 50m;

    F9-10m to 40m;F8-100m to 130m; F7-5m to 60m; F6-10m to 80m;

    F4-10m to 40m; F3-5m to 30m; F1-0m to 60m; F5-60m

    Pit Floor, Floor Contour of IB Seam

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Depth (m) Coal (Mt.) Volume of

    OBR(Mm3)

    Stripping

    Ratio(m3/t) Lead(Km)

    Peak Capacity

    (MTPA)

    Upto 200 344 894 2.6 3.0 14

    Upto 250 423 1164 2.8 3.5 17

    Upto 300 493 1529 3.1 4.0 20

    Upto 350 619 2033 3.3 4.5 25

    Upto 400 745 2663 3.6 5.0 30

    Upto 435 835 3055 3.7 5.5 40

    Depthwise Coal Reserves & Ratio

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Block

    Boundary

    Public Road

    Conveyor Coal

    Conveyor

    OB/IB

    Conveyor for

    Coal and OB

    North-1198 Ha P-208 ha,G-43 ha & F-947 ha

    South-728 Ha P-524 ha, G-72 ha & F-132 ha

    Coal Block-2574 Ha P-1677 ha,G-234 ha & F-663 ha

    Total Land Requirement (40 MTPA) Mtpa)

    25

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Dump area and Hills

    26 of 19

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Concept of Barriers

    27 of 36

    East Pit 15 m from Outer Edge

    West Pit 15 m from Outer Edge

    Southern Boundary 7.5 m from Block Boundary

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Coal mine: Challenges

    Multi-seam mining - Total 12 coal seams of

    splitting & merging nature

    Geologically disturbed property - Occurrence

    of 11 faults having throw up to 130 m

    Steep gradient of coal seams Up to 19O

    Occurrence of three Rivulets / rivers within

    the property

    High hillocks on the north side of Block

    28

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Target Production Plan

    Particulars Value

    Total Coal Production 834.65 M Tonne

    Peak Coal Production 40 MTPA

    Peak Coal Volume 25.0 M m3

    Peak OB (OB+IB) 152.11 M m3

    Peak Annual Workload (OB Rock + Coal) 177.11 M m3

    Target year for reaching 40 MTPA 5th Year

    Largest coal mine in India & 3rd largest in the world

    29

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 30

    Mining Sequence RWE vs Internal

    West side to East Side East side to West Side

    Box Cut

    Dump

    Box Cut

    Dump

    RWE Internal

    Merit De Merit Merit De Merit

    1. Coal is at shallow depth 1. Diversion of Nala is

    required immediately

    1. Coal is at shallow depth 1. Immediate shifting of

    Mata Temple

    2. Mine working will be

    easier for initial 10 years

    2. Mine working will be

    difficult when mining is

    started in eastern part

    2. More dump can be

    accommodated in the east

    pit

    2. Rehabilitation

    requirement is more

    3. Land acquisition will be

    easier as less population to

    be displaces

    3. Dump height is more

    than 90m

    3. After mine closure more

    land is available for

    agriculture

    3. Total Land requirement is

    more

    4. Shifting of Mata Temple

    not required immediately

    4. Huge void will be left after

    mine closure

    4. Smaller void is left after

    mine closure

    4. Initial mine working will be

    difficult

  • Confidential

    Mining Methodology

    Coal Seams

    Shovel (35 m3) -> Dumper (350t) -> Crusher -> Conveyor -> Stacker -> Stockyard

    Shovel (15 m3) -> Dumper (100t) -> Crusher -> Conveyor -> Stacker -> Stockyard

    Peak System Capacity 40 million tonnes per year

    Overburden

    Shovel (35m3) -> Dumper (350t) -> OB dump area Shovel (15 m3) -> Dumper (100t) > OB dump area

    Shovel (60 m3) -> Dumper (350t) -> Crusher -> Conveyor -> Spreader -> OB dump

    Shovel (35 m3) -> Dumper (350t) -> Crusher -> Conveyor -> Spreader -> OB dump

    Peak System Capacity 152 million cubic meter per year

    Thin Interburden Ripping and dozing -> Loader -> Dumper -> OB Dump

    IPCC

    IPCC

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Mining Technology Selection

    HEMM Size / Capacity No. Required

    Electric Rope Shovel 60 65 m3 8

    Hydraulic Shovel (BH) 30 35 m3 7

    Front End Loader 10 15 m3 8

    Rear Dumper 350 ShT 92

    Rear Dumper 100 ShT 51

    OB Removal

    Top OB Benches: Fully Mobile IPCC with three 60- 65 m3 Rope Shovel

    units

    Other Top OB Benches: Semi-mobile IPCC with 30 - 35 m3 Hydraulic

    Shovel and 350 Tons Rear Dumpers

    Thick Partings: Semi-mobile IPCC with 30 - 35 m3 Hydraulic Shovel

    and 350 Tons Rear Dumpers

    Thin Partings: Semi-mobile IPCC with 10 - 15 m3 Front End Loaders

    and 100 Tons Rear Dumpers

    Coal prodn.

    Thick Seams: Semi-mobile IPCC with 30 - 35 m3 Hydraulic Shovel and

    350 Tons Rear Dumpers

    Thin Seams: Semi-mobile IPCC with 10 - 15 m3 Front End Loaders

    and 100 Tons Rear Dumpers

    32

  • Confidential

    Mining Methodology

    33

    Coal Seams

    Shovel (35 m3) -> Dumper (315t) -> Crusher -> Conveyor -> Stacker -> Stockyard Shovel (15 m3) -> Dumper (91t) -> Crusher -> Conveyor -> Stacker -> Stockyard

    Peak System Capacity 40 million tonnes per year

    Overburden

    Shovel (35m3) -> Dumper (315t) -> OB dump area Shovel (15 m3) -> Dumper (91t) > OB dump area

    Shovel (60 m3) -> Dumper (315t) -> Crusher -> Conveyor -> Spreader -> OB dump Shovel (35 m3) -> Dumper (315t) -> Crusher -> Conveyor -> Spreader -> OB dump

    Peak System Capacity 155 million cubic meter per year

    Thin Interburden Ripping and dozing -> Loader -> Dumper -> OB Dump

    33

    IPCC

    IPCC

  • Confidential

    Mining Activities

    34

    Year 5

    40 Mtpa

    Fourth OB Crusher to be erected in first half of year 5

    Fifth OB crusher to be ready in second half of year 5

    Year 1 - 3

    16 Mtpa

    Waste to be trucked to north ex-pit to prepare decks for spreaders

    First OB Crusher to be erected in second half of year 3

    First Coal crusher to be erected in first half of Year 3

    Preparation of Coal stock yard and secondary crushing plant in Year 1

    Year 4

    30 Mtpa

    Coal and OB being mined using both IPCC and S&T operation

    Second OB Crusher to be erected in first half of year 4

    Third OB crusher to be ready in second half of year 4

    Second Coal crusher to be erected in first half of Year 4

    34

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Production Profile

    Production Year Year Coal (MTPA) Waste

    (million m3)

    Strip Ratio

    (cubic

    metres/MT)

    1st 2016-17 4 27.25 6.81

    2nd 2017-18 8 50.96 6.37

    3rd 2018-19 17 72.78 4.28

    4th 2019-20 30 91.55 3.10

    5th 2020-21 40 (Target)

    118.46 3.01

    6th 2021-22 40 149.36 3.75

    7th to 15th year 2022-30 40 x 9 1466.04 4.07

    16th year 2031-32 40 158.44 3.96

    17th -20th year 2032-35 40 X 4 566.6 3.54

    21st year 2036-37 28.02 72.38 2.58

    22nd year 2037-38 26.02 72.38 2.78

    23rd-27th year 2038-42 16.5 X 5 211.8 2.56

    Coal production 40 MTPA from 5th to 20th year

    35

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Project Year Yr 1 Yr 2 Yr 3 Yr 4 Yr 5

    ROM Coal, MMT 4 8 17 30 40

    Hydraulic Shovel, 30 35 m3 1 1 1 2 2

    Front End Loader, 10 15 m3 1 3 3 5 8

    RBH Drill, 160 mm 3 5 5 8 10

    Rear Dumpers, 350 Sh T 5 5 10 10 10

    Rear Dumpers, 100 Sh T 6 23 23 29 29

    Dozer with Ripper, 850 HP 2 3 4 5 5

    Wheel Dozer, 450 HP 2 3 4 5 5

    Equipment Scheduling for Coal Removal

    36

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 37

    Tilaiya Coal Mine - Year 1

    Mining Sequence from West to East instead of East to West as planned earlier

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 38

    Tilaiya Coal Mine - Year 3

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 39

    Tilaiya Coal Mine - Year 4

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 40

    Tilaiya Coal Mine - Year 5

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 41

    Tilaiya Coal Mine - Year 10

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 42

    Tilaiya Coal Mine - Year 15

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential 43

    Tilaiya Coal Mine - Year 20

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Semi-mobile Crushing Unit

  • DRAFT FOR DISCUSSION PURPOSES ONLY Confidential

    Fully-Mobile Crushing Unit

  • Thank You