SAFETY IN INDIAN COAL MINES ISSUES AND CHALLENGES WITH SPECIAL REFERENCE TO COAL MINE METHANE CMM RECOVERY AND UTILI

1. SAFETY IN INDIAN COAL MINES � ISSUES AND CHALLENGES WITH SPECIAL REFERENCE TO COAL MINE METHANE (CMM) � RECOVERY AND UTILISATION Dr. M.P. NarayananVice Chairman World Mining Congress

2. Coal Requirement in India

3. Coal potential and possibilities Total coal reserves 260 billion tonnes 25% mined by open cast mining Rest must be mined by underground mining methods Open cast mining may reach its peak/plateau up at 1500 MT/yr by next decade Current underground mining levels 55 MT This needs to be scaled up 10 times

4. Overview of safety Indian Mines

5. Scenario of Coal Mine Disasters Coal Mining is probably one of the most disaster prone industries History of mining globally marred by many disasters Worst: Couriers Mine in France in 1906 when an explosion took toll of 1100 precious lives� In India there were 53 disasters (10 or more deaths) from 1901 and 2000 and 4 disasters between 2001 and 2008

6. Causes of mine disasters in the last quarter of 20th century Indundation Explosion Mine Fire

7. Causewise analysis of mine disasters (%)

8. Reasons for Inundation: In-rush of waters to the mine areas From surface water River Nallah Water course Water reservoirs Low lying areas From adjoining mine having dis-used water logged old workings From the same mine having water-logged old working in other seam/horizon

9. Rescue Operation in MAHABIR Mine The inundation of Mahabir Mine which took place on 13-11-1989 deserves a special mention. This took place during my tenure as Chairman � Coal India Ltd ( a giant holding company, producing 90% coal of the country and employing over 0.6 million workmen). This incident deserves special attention because 65 workmen who would have otherwise lost their lives could be saved. by excellent technological innovation, By excellent communication system in all the nook and corner of the mine, dedicated team effort, and exceptional leadership and guidance from top management

10. The case in detail The drivage of a gallery in one of the heading of Mahabir Mine of Eastern Coalfields situated in eastern part of India, got joined to a old water-logged working of other seem. This phenomena was also coupled with surface subsidence near village pond providing water in-rush to the mine. In total 71 workmen were trapped inside the mine. 6 workers lost their lives due to sudden in-rush of water in the gallery that got joined to the water-log working. 65 workmen were rescued.

11. The case in detail Within few minutes of the incidence, the mine workers trapped inside the mine were directed by mine communication system (CDS System) to a Safe Rise Gallery for further instruction. Three methods were adopted for rescue operations: Approach through near-by mine By driving a tunnel from surface By driving a bore-hole from the surface to join the gallery where workmen were diverted �a� was not possible because of lack of approach and water-logging. �b� was tried but took more time before which operation �c� was accomplished. Large Bore-Hole dia 300 mm)was drilled from the surface to establish ventilation to the gallery. Subsequently the dia was reamed to 850 mm. Food, milk, water and medicines as required were provided to the workmen. An iron capsule was manufactured in the company workshop and all the workmen were evacuated; one by one with the help of winches.

12. Safety monitoring in Coal India Ltd. In order to reduce risk hazard and prevention of accidents and disasters, Coal India/Government of India has since adopted multi-tier safety monitoring system apart from monitoring by Director General of Mine Safety (DGMS). Workmen�s Inspectors� Safety Committee At Mine Level� Area Level Bipartite/Tripartite Committees Subsidiary Level Tripartite Safety Committee Coal India Safety Board Standing Committee On Safety In Coal Mines

13. Technologies adopted to reduce number of accidents Design of support system based on Rock Mass Rating (RMR) studies Increased use of roof bolting Introduction of modern large dia drills Introduction of mass production technologies De-watering of old workings Control of Jharia and Raniganj Fires Use of computerized continuous mine Environmental Tele-Monitoring System (ETMS)

14. Mine disasters by explosions (1) Explosion: is a sudden increase in volume & release of energy in an extreme manner, & generation of high temperatures and release of gases. It creates a shock wave and turns into a coal mine disaster. Methane is main reason behind gas explosion in coal mine. When methane is mixed with air, at 5-15% of the mixture, it is highly explosive and generally responsible for the explosions in underground coal mines all over the world.

15. Mine disasters by explosions (2) Other two important factors are: presence of explosive mixture of Methane - Oxygen and source of ignition. Once ignited flame will self propagate throughout the mixture independently and away from source of ignition. In the case of explosion, it is normally associated with coal-dust explosion as the temperature rises up to 700 degree centigrade and it can cause explosion in the air-coal-dust mixture. For ignition of Methane explosion, there should be a spark or heated-surface for a definite time. For electrical spark, the current must be more than 750 /1000 ma

16. Mine Fires Mine Fires are consuming coal seams in major coal producing countries including China, United States, India and Indonesia Numerous seams have been burning for decades and some in China for several centuries Environmentally catastrophic effects for the coal fires include the emission of noxious gases particulate matter into the atmosphere for air pollution condensate products responsible for water and soil pollution There are 3 major coal fires in the world Coal fires in Northern China Coal fire in Pennsylvania of USA Coal fire in Jharia coalfields in India In India major coal fires in Jharia and Raniganj have killed people forced entire communities to abandon their homes and business

17. MINE FIRE IN JHARIA COALFIELDS (JCF) (1) Most fires in JCF were caused by the spontaneous combustion of coal subsequent to open cast and/or shallow underground mining. Jharia Coal Fire started in the year 1916 and by 1970 it spread up to an area of 17.32 sq. km. affecting around 41 collieries and burning 37 Million Tons of coal. Around 1.8 billion tons of coking coal was locked in by coal fire. Enormous effort and thrust was made by the nationalized coal company and Government of India to deal with the fire.

18. MINE FIRE IN JHARIA COALFIELDS (JCF) (2) Strategy adopted: Dozing and leveling the ground to fill-up surface cracks and prevent air/oxygen to subsurface fires Blanketing surface fires with sand to extinguish it Cutting trenches around fire to prevent spreading Removal of burning coal by open cast method wherever possible by using remote control equipment

19. The Present Status of JMF Ten mine fires have been successfully dealt-with. The locations with blazing fire is now having green forest The fire is now contained to an area of 8.9 sq. km. and only 1.4 billion tons of coal is locked in Master Plan has been prepared to deal with the fire effectively/completely which includes inter-alia: Rehabilitation and re-settlement of the entire population and township (Jharia, Kathras, Karkend, etc.) effected by the coal fires to non coal bearing areas. Re-alignment of Dhanbad � Sindri, Dhanbad � Chandrapura and Dhanbad - Gomoh Railway Lines. Re-location of coal sidings. Construction of peripheral road (ring road) and diversion of all the public road to ring road to avoid vehicular movement to the coal fires except for the purpose of mining. Mining of the entire coal of affected seams by the method of open cast.

20. COAL BED METHANE (CBM) and COAL MINE METHAN (CMM) When coals beds are formed through the high compression and heating of organic materials over geologic time spans, methane generated in the process is entrapped Methane gas trapped in coal seams is often termed as Coal Bed Methane or CBM As the coal seam is exploited, the equilibrium pressure in coal pores goes down and part of methane gas released Methane gas is a very powerful green house gas (GHG) 21 times more potent than CO2 Methane is remarkably clean fuel when burnt and its combustion produces no SO2 or particulate The environmental, technical and economic advantages of CBM has made it a global fuel of choice

21. CURRENT DEVELOPMENT OF CBM RECOVERY IN INDIA India has 4th largest proven coal reserve and is 3rd largest coal producer in the world. India holds significant prospects of commercial recovery of CBM. In India Godwana Basin contribute about 99% of total coal resource of about 254 billion tons. Estimated CBM resource from various source have been reported in the range of 0.8 to 1.5 TCM. From recovery point of view CBM is classified into 3 main categories: Virgin Coalbed Methane (VCBM) or pre-mining degasification. Coal Mine Methane (CMM) Ababdoned Mine Methane (AMM) While VCBM is the activity area of natural gas industry, capturing of CMM and AMM is practiced by coal mining industry

22. CBM RECOVERY POLICY/INCENTIVE BY GOVERNMENT OF INDIA No participating interest from Government of India Allotment of CBM Blocks through open international competitive bidding Exploration and Development of CBM under confessional type of agreement through Model contract Seven years tax holiday from the date of commencement of commercial production Nominal commercial bonus of US$ 0.3 million on declaration of commercial assessment Freedom to sell gas at market driven price in the domestic market 35% income tax for Indian companies and 48% for foreign companies Provision of 100% cost recovery

23. Objectives of CBM Recovery CBM Gas Recovery is a clean source of energy If CBM Recovery is not done in advance of mining, this CBM will be discharged to the atmosphere during course of mining contributing to Global warming Subsequent to CBM Recovery, the coal mining operations are much safer due to much reduced incidence of methane Production and Productivity after CBM Recovery will be greatly enhanced The cost of mining considerably reduced on account of saving in ventilation and equipment. It will provide added revenue The impact of CBM Recovery will be known on the future coal mining which follow. CBM recovery will help future planning of coal mining activities of replicated projects Projects under this group are eligible for CDM benefits/carbon trading

24. CURRENT CBM EXPLORATION/ PRODUCTION ACTIVITIES Area opened Up for CBM Exploration 13600 Sq Km Blocks Awarded 26 Nos CBM Resources in Awarded Blocks 1374 BCM Production Potential in Awarded Blocks 38 MMSCMD

25. Exploration Activities Phase-I exploration activities completed in 5 blocks and have entered into Market Survey & Pilot Assessment Phase (Phase-II). Phase-I exploration activities in progress in remaining 11 blocks The exploration activities have established encouraging CBM resources in some of the awarded blocks. There has been significant finds in eastern and central part of India. CBM gas being flared in the test wells bear ample testimony in the stories of success Commercial assessment is completed in 4 blocks. The total established reserves in these blocks is 6.24 TCF Commercial production of CBM in India is now a reality and is to commence from 2009

26. PILOT PROJECT OF CMM RECOVERY AND UTILIZATION While VCBM is the activity area of natural gas industry, as per MOU signed between of Ministry of Coal and Ministry of Petroleum and Natural Gas, the coal producing companies will have the right of CMM exploitation in their working mines including pre and post mining operations With a view to develop indigenous capacity in the field of CMM recovery and commercial utilization, a GEF/UNDP aided demonstration project is under implementation by GOI at Moonidih and Sudamdih mines of BCCL The objectives of the project: Reduce the potential adverse social, environmental and economic consequences of global climate change. Improve the health and safety of underground miners who are required to mine coal from gassy coal deposits. Improve the local and regional environment by introducing technology to recover and use, an otherwise wasted clean energy source that is presently being vented to the atmosphere. Promote the development of indigenous enterprises engaged in recovery, transportation, conversion and use of coal mine associated coal bed methane.

27. Objectives of the Pilot Project for CMM recovery and utilisation Reduce the potential adverse social, environmental and economic consequences of global climate change. Improve the health and safety of underground miners who are required to mine coal from gassy coal deposits. Improve the local and regional environment by introducing technology to recover and use, an otherwise wasted clean energy source that is presently being vented to the atmosphere. Promote the development of indigenous enterprises engaged in recovery, transportation, conversion and use of coal mine associated coal bed methane

28. FUNDING OF THE PROJECT GEF Funding: 9.20 million USD � Procurement of International Equipment for CBM Recovery; Cost of Project Professionals UNDP Funding: 1.21 million USD � Mainly for cost of International Expert; Study Tours; Official Travel; Information Internet equipment GoI (Cash): Rs. 18.06 crores � Procurement of CBM Utilization equipment (FE Component); Cost of Drilling; Costs in-country training, etc. GoI (Kind): Rs. 7.00 crores � Mainly for the cost of Project Personnel (Admin & Executive manpower) of CBM Project ONGC (50:50) Co-funding of Hydrofrac & cementing equipment by Rs. 12.15 crores (2.7 mill. USD)

29. PRESENT STATUS OF THE PROJECT. The Pilot Scale Demonstration Project at Moonidih & Sudamdih is successful to be completed by December 2008. Commercial utilization by generating 500 kw has been demonstrated with cost of production of Rs. 2.63 per kwh i.e. 5.5 cents per unit. This cost is for the 1st well. In latter wells the capital cost would be reduced to half and cost of power generation would be less than Rs. 1.50 per unit i.e. around 3.0 cents per unit.

30. Saving of CO2 emissions using CMM for power generation in Moonidih 32000 cm/day of CH4 production will safe 160151 tons CO2 from going to atmosphere (CH4 is 21 times more potent than CO2) Current CH4 production is 1/6th i.e. 5400 CM/day, so 27025 Ton per year of CO2 is being saved from going to atmosphere. 1 MW of power generation using 9000 cm/day of CMM replaces 8750 litres of diesel and contributes a saving of 8585 tons of CO2 per year. Current 500 kw of power generation by CMM is thus contributing a saving of 4293 tons of CO2 per year. Though this project is not entitled for carbon credits under CDM as the funding is from grant by UNDP/GEF and GOI, otherwise the project would earn 140000 USD per year.

31. Conclusions (1) The improvement in safety standards in coal mining across the globe may be attributed to all the stake-holders viz. public/private mining companies, trade unions, government and public at large. Though China hogs the lime-light so far as mining related accidents are concerned, such mishaps are not un-common in other countries like Mexico, India, Canada, Columbia and Russia. In India coal is produced mainly by Coal India Limited a Public Sector Holding company. Coal India produces over 85% of India`s total coal production and employs over 4.5 lacs man-power.

32. Conclusions (2) India`s safety record in coal mining has improved in the last 3 decades particularly since the nationalization of coal mines. Coal India`s 0.33 per thousand per year and 0.26 per million tons coal produced fatality rate is comparable with any developed countries. However, this figure is stagnant over past few years and efforts to be made to bring the figure to zero. Need to focus on improving safety aspects will increase many-folds as India`s coal production is set to double in the next 10 years from the present level of 460 million tons and up to 2.00 billion tons by 2030.

33. Conclusions (3) Challenges on safety requires, technological shift in mining methods, training and re-training of work-men, continuous tele-monitoring of mine environment and strata as well as institutional frame-work from safety enforcing authorities, research institutions and Government of India. R & D efforts both for equipment design and mining technology need to be speeded up. The successful mass production technologies, especially for underground mines should be adopted in all underground mines . Government, while introducing several and severe legislative measures regarding mining accidents, it is incumbent to ensure proper implementation by empowering various implementing agencies.

34. Conclusions (4) Use of information and communication technologies including remote sensing for correct mapping for prediction and prevention of mine accidents should be deployed in almost all the mines. EPR System should be adopted for safety, health and environment monitoring. Apart from punitive action for violating mining law/regulation/methods leading to mining accidents, authorities responsible for safety monitoring should keep provision of lucrative rewards at national, regional and mine levels to encourage improvement in safety standards and achieve goal of ZERO accident. This applies for both India and China.

35. Conclusions (5) Jharia and Raniganj coal fires in India has to be dealt effectively with support from the Government, coal producing companies, trade unions and public at large. Issues of rehabilitation and re-settlement requires dealing with liberally and compassionately. However, the matter requires very positive bureaucratic support and political will.

36. Conclusions (6) It has been well acknowledged that coal mine methane gas is main hazard leading to mine explosions, apart from being a source of green house gas. As such extraction of Virgin Coal Mine Methane (VCMM), Coal Mine Methane (CMM) and Abandoned Coal Mine Methane (ACMM) in many coal producing countries and utilizing it for commercial purposes is right and positive direction in not only addressing mine safety issues, but also environmental issues. Commercial benefits and carbon credits are added advantages. Steps have also been taken in India to allocate blocks to public and private operators for extraction of VCMM. Pilot projects under UNDP Aid for extraction of CMM and its commercial utilisation has produced successful results in Sudambih and Monidih mines of BCCL.