OPENCAST MINE

EXTENSION PROJECT
15-03-2024

OPENPIT MINING.
 ACKNOWLEDGEMENT

We are extremely fortunate to have the opportunity to

visit Singareni colliery, yellandu area of SINGARENI
COALFIELDS LIMITED.

We are privileged to gain knowledge and invaluable

internship experience in this reputed organization.

We wish to acknowledge with gratitude the continued

support given by Dr. B.KARUNAKUMAR Professor, head
of Department of Mining Engineering at Government
Polytecnic College Rudrampur, for organizing our
industrial training at Singareni Colliery Jawarah Khani
OCP yellandu area Bhadradri Kothagudem district,
Telangana.

2
Enhancing Sustainability through
Open-cast Coal Mine Extension Project.
Abstract

The Open-cast Coal Mine Extension Project aims to extend the

operational capacity of an existing coal mine while prioritizing
environmental sustainability, community engagement, and economic
development. This project encompasses comprehensive environmental
impact assessments, advanced mining technologies, and robust
community involvement strategies to minimize ecological footprint and
maximize socio-economic benefits. Through innovative approaches to
rehabilitation, water management, and biodiversity conservation, this
project sets a new standard for responsible resource extraction, fostering
long-term environmental stewardship and social prosperity.

The Open-cast Coal Mine Extension Project seeks to expand the

operational capabilities of an established coal mine, while concurrently
addressing pressing environmental concerns and fostering sustainable
development. Through meticulous environmental impact assessments
and the implementation of cutting-edge mining technologies, the
project endeavors to mitigate adverse ecological effects and minimize
carbon emissions. Additionally, proactive engagement with local
communities and stakeholders ensures their participation in decision-
making processes and facilitates the equitable distribution of benefits
derived from the project. By prioritizing reclamation efforts, water
resource management, and the preservation of biodiversity, this initiative
sets a precedent for responsible resource extraction, advancing the
principles of environmental stewardship and social inclusivity. Ultimately,
the project aims to strike a harmonious balance between economic

3
growth, environmental preservation, and community well-being, thereby
laying the groundwork for a more sustainable future.

METHODS TO BE WORKING:-

 Deep hole drilling and blasting with shovel and

dumper combination.
 Control blasting with shovel and dumper
combination.
 Control blasting with dragline and dumper
combination.
 Control blasting with front Hoe shovels and
dumper combination.
 Soft coal -surface miner combination of loaders
and dumpers. / Bucket wheel excavator.

4
 *ECONOMICAL FACTORS CONSIDER FOR
OPENCAST COAL MINE EXTENSION Project.

 Market Demand and Price Trends: Analyze current

and projected market demand for coal, as well as
price trends. Factors such as global energy
demands, environmental regulations, and
competition from alternative energy sources can
significantly impact coal prices and market demand.

 Cost of Extraction: Assess the cost of extracting

coal from the extended mine site, including
expenses related to equipment, labor,
transportation, and infrastructure. Understanding
these costs is crucial for determining the economic
feasibility of the project.

 Revenue Generation: Estimate the potential

revenue generation from coal sales based on
projected production volumes and market prices.
Considerations should also be given to potential
revenue streams from by-products or co-products
of coal mining operations.

5
  Investment and Financing: Evaluate the upfront
investment required for extending the coal mine
and securing financing options. Considerations
should include capital expenditure for infrastructure
development, equipment procurement, and
operational costs during the extension phase.

 Operational Efficiency and Productivity: Identify

strategies to enhance operational efficiency and
productivity to optimize costs and maximize profits.
This may involve implementing advanced mining
technologies, streamlining processes, and
improving workforce productivity.

 Regulatory Compliance and Permitting Costs:

Factor in the costs associated with obtaining
necessary permits and complying with regulatory
requirements for extending the coal mine.
Environmental regulations, safety standards, and
community engagement initiatives may incur
additional expenses.

6
  Risk Assessment and Management: Conduct a
thorough risk assessment to identify potential
economic risks and uncertainties associated with
the project. This may include market volatility,
regulatory changes, environmental liabilities, and
social license to operate. Develop risk mitigation
strategies to minimize these risks and safeguard the
project's economic viability.

 Community and Stakeholder Engagement:

Consider the economic impact of the project on
local communities and stakeholders. Assess
potential benefits such as job creation,
infrastructure development, and tax revenues, as
well as any potential negative impacts that may
require mitigation measures.

 Stripping ratio: volume of over burden(OB) in

cubic meters to volume of coal / mineral deposits in
tons.

 Slope Stability analysis : It gives the results about

the behaviour of benches and nature of the strata.

7
 Different changes in different weather conditions
and suggest about working methods.

MACHINERY USED FOR OCP

EXTENSION PROJECT

In an opencast coal mine extension project, a variety of

heavy machinery and equipment are typically utilized to
facilitate efficient mining operations. Some of the key
machines commonly used in such projects include:

 Bucket Wheel Excavators (BWEs): These large-

scale excavators feature a rotating wheel equipped
with buckets that scoop up coal and overburden
material. BWEs are commonly employed for
continuous and high-capacity excavation in
opencast mines.
 Draglines: Draglines are massive machines with a
long boom and bucket system used for removing
overburden material in opencast mining operations.
They are particularly effective for large-scale
earthmoving tasks and can achieve high production
rates.

8
  Dump Trucks: Heavy-duty dump trucks are
essential for transporting excavated coal and
overburden material from the mining area to
designated dumping sites or processing facilities.
These trucks come in various sizes and capacities to
accommodate different hauling requirements.
 Dozers and Shovels: Bulldozers and hydraulic
shovels are used for various tasks such as stripping
overburden, grading roads, and pushing material.
They play a crucial role in preparing the mining area
for excavation and maintaining haulage roads.
 Wheel Loaders: Wheel loaders are versatile
machines used for loading coal and overburden
material onto trucks for transportation. They are
also employed for stockpiling and handling
materials at various stages of the mining process.
 Drilling Equipment: Drilling rigs are utilized for
pre-splitting, blast hole drilling, and exploration
drilling in opencast coal mines. These machines are
essential for creating blast patterns and accessing
coal seams efficiently.
 Conveyors: Conveyor systems are employed for
transporting coal and overburden material over
long distances within the mine site. They help

9
 streamline material handling processes and
minimize the need for truck transport over uneven
terrain.
 Graders and Rollers: Graders are used for leveling
and grading the mining area, while rollers are
employed for compacting roads and surfaces to
enhance stability and safety.
 Water Trucks: Water trucks are used for dust
suppression and road maintenance within the mine
site, helping to mitigate environmental impacts and
improve working conditions.
 Crushers and Screens: Crushing and screening
equipment are used for processing coal and
separating it into different sizes and grades. These
machines are integral to the coal processing plant
and ensure efficient coal preparation for market
sale.

These are just a few examples of the machinery and

equipment commonly used in opencast coal mine
extension projects. The selection and deployment of
specific machines depend on factors such as the scale of
the operation, geological conditions, production
requirements, and budget constraints.

10
HAZARDS OCCUR/ CHANCES –

In an open-cast coal mine extension project, various

hazards and risks may arise throughout the different
stages of operations. Understanding these hazards is
crucial for implementing effective risk management
strategies to ensure the safety of workers, protect the
environment, and maintain operational continuity. Here
are some hazards and potential occurrences in such
projects:

 Slope Instability: Excavation of overburden and

coal can lead to slope instability, causing landslides,
rockfalls, or slope failures, which pose risks to
personnel and equipment.

11
  Equipment Accidents: Heavy machinery used in
mining operations can result in accidents such as
collisions, rollovers, or equipment malfunctions,
endangering workers and nearby personnel.

 Fires and Explosions: Presence of combustible

materials like coal dust and methane gas increases
the risk of fires and explosions, particularly during
blasting or equipment operation.

12
  Respiratory Hazards: Exposure to coal dust, silica,
or diesel exhaust can lead to respiratory issues such
as pneumoconiosis or exacerbate existing
respiratory conditions among workers.

 Noise and Vibration: Mining operations generate

high levels of noise and vibration, potentially
causing hearing loss, musculoskeletal disorders, or
structural damage to nearby structures.

 Water-related Hazards: Flooding, drowning, or

contamination risks arise from water accumulation
in open-cast mines, affecting worker safety and
environmental integrity.

13
  Chemical Spills and Contamination: Storage,
handling, or transportation of hazardous chemicals
can lead to spills or leaks, causing soil or water
contamination and health risks for workers and
nearby communities.

 Community Impacts: Mining activities can disrupt

local communities through noise, dust, or traffic,
leading to social conflicts, displacement, or loss of
livelihoods.

 Confined Spaces: Enclosed areas within equipment

or infrastructure pose risks of asphyxiation,
engulfment, or entrapment for workers entering
these spaces.

 Weather-related Hazards: Extreme weather events

like storms or heavy rainfall can exacerbate existing
hazards, causing flooding, landslides, or equipment
damage.

 Health and Ergonomic Hazards: Manual handling

tasks, repetitive motions, or awkward postures can

14
 lead to musculoskeletal injuries or ergonomic issues
among workers.

 Psychosocial Hazards: Long working hours, shift

work, or job insecurity can impact worker mental
health, leading to stress, fatigue, or depression.

 Wildlife Encounters: Working in natural

environments may expose workers to wildlife
encounters, such as snake bites, insect stings, or
animal attacks.

 Security Risks: Theft, vandalism, or sabotage can

occur in remote mining locations, posing risks to
personnel, equipment, or infrastructure.

 Emergency Response Preparedness: Lack of

adequate emergency response plans or training can
delay or hamper effective responses to incidents
like fires, explosions, or injuries.

By identifying these potential hazards and implementing

appropriate control measures, open-cast coal mine
extension projects can prioritize worker safety,

15
environmental protection, and operational continuity.
Regular risk assessments, safety training, and
compliance with regulations are essential to mitigate
these hazards effectively.

-SAFETY PROCEDURES TO AVOID

HAZARDS AND HIGH PRODUCTION
RATE
Safety procedures in an opencast coal mine are crucial
to minimize hazards and ensure the well-being of
workers. Here are some key safety measures typically
followed in such environments:

 Risk Assessment and Management: Regular risk

assessments should be conducted to identify
potential hazards in the mine. Adequate measures
must be implemented to mitigate these risks
effectively.
 Training and Education: All personnel, including
miners, supervisors, and managers, should receive

16
 comprehensive training on safety procedures,
hazard recognition, emergency response, and
equipment operation.
 Personal Protective Equipment (PPE): Miners
must wear appropriate PPE such as hard hats, safety
goggles, gloves, boots, and respiratory protection
to safeguard against various hazards like falling
debris, dust, and harmful gases.
 Safe Work Practices: Clear guidelines should be
established for safe work practices, including proper
use of equipment, safe handling of materials, and
adherence to operating procedures.
 Equipment Inspection and Maintenance: Regular
inspection, maintenance, and servicing of machinery
and equipment are essential to prevent
malfunctions and accidents.
 Traffic Management: Well-defined traffic routes
and signage should be in place to regulate the
movement of vehicles and machinery within the
mine, minimizing the risk of collisions and accidents.
 Emergency Preparedness: Comprehensive
emergency plans must be developed and
communicated to all personnel. This includes

17
 procedures for evacuations, medical emergencies,
fire incidents, and rescue operations.
 Monitoring and Control of Environmental
Factors: Continuous monitoring of air quality,
ground stability, and other environmental factors is
essential to detect and mitigate potential hazards
such as gas leaks and ground collapses.

 Communication Systems: Reliable communication

systems should be established to facilitate
coordination and rapid response during
emergencies or unforeseen events.
 Regular Inspections and Audits: Routine
inspections and audits should be conducted to
assess compliance with safety regulations and
identify areas for improvement.
 Safety Culture: Fostering a strong safety culture
within the organization is crucial. This involves
promoting a mindset where safety is prioritized by
all employees, and proactive measures are taken to
address potential hazards.

18
  Regulatory Compliance: Ensure compliance with
relevant regulations and standards set forth by
government agencies and industry organizations.

By implementing and strictly adhering to these safety

procedures, opencast coal mines can significantly reduce
the risk of accidents and ensure the well-being of their
workforce.

PROJECT OVERVIEW
A project overview of an opencast coal mine extension project would
typically include the following key components:

Project Title: Opencast Coal Mine Extension Project

Project Objective: The objective of the project is to extend the

existing opencast coal mine to extract additional coal reserves efficiently
and sustainably to meet the growing demand for coal.

Project Location:Specify the location of the opencast coal mine

extension, including details such as the geographical coordinates,
nearest town or city, and any specific geological features of the area.

Project Scope:Outline the scope of the project, including the area to

be mined, the estimated quantity of coal reserves to be extracted, and
any associated infrastructure developments such as access roads,
stockpiles, and water management facilities.

19
Project Timeline: Provide an overview of the project timeline,
including key milestones and phases from planning and permitting to
construction, mining operations, and reclamation.

Project Stakeholders: Identify the main stakeholders involved in the

project, including the project owner, regulatory authorities, local
communities, environmental organizations, contractors, and suppliers.

Environmental and Social Impact Assessment: Summarize the

findings of the environmental and social impact assessment conducted
for the project, including potential impacts on air and water quality,
wildlife habitat, local communities, and cultural heritage sites. Outline
the mitigation measures planned to minimize adverse impacts and
enhance environmental and social benefits.

Regulatory Compliance: Describe the regulatory framework

governing the opencast coal mine extension project, including permits,
licenses, and approvals required from relevant government agencies.

Health and Safety Considerations: Highlight the health and safety

measures implemented to ensure the well-being of workers and the
surrounding community during all phases of the project, including
hazard identification, risk assessment, training, and emergency response
planning.

Technological Innovations: Discuss any innovative technologies or

best practices adopted to optimize coal extraction efficiency, minimize
environmental impacts, and improve operational safety and productivity.

Community Engagement and Consultation: Outline the community

engagement and consultation process undertaken to solicit input from
local stakeholders, address concerns, and build positive relationships
with the surrounding community.

20
Financial Considerations: Provide an overview of the project’s
financial aspects, including estimated costs, funding sources, financial
projections, and economic benefits to the local and regional economy.

Sustainability and Reclamation: Describe the sustainable mining

practices and reclamation plans designed to restore mined areas to a
safe and environmentally sound condition after coal extraction is
complete.

Monitoring and Reporting: Detail the monitoring and reporting

mechanisms established to track project progress, environmental
performance, compliance with regulatory requirements, and ongoing
stakeholder engagement.

Economical stripping ratio:

Shovel and dumper combination –1:4 to 5

With Dragline – 1: 8 to 10

Bucket wheel excavator – 1:3 to 4

By presenting these key components in the project overview,

stakeholders can gain a clear understanding of the opencast coal mine
extension project’s objectives, scope, impacts, and benefits, facilitating
informed decision-making and effective project management.

21
22