Longwall Mining

1. LONGWALL 
MINING
Venkat 

2. COAL 
-
COAL 
-
Background

3. COAL
C
Most abundant fossil fuel
C
Major fuel used for electricity
generation world wide C
Safe
and
secure
fossil
fuel
C
Safe
and
secure
fossil
fuel
C
Cost effective

4. WORLD ELECTRICITY GENERATION
(% By Fuel-2005)
Consumption by 
Fuel
India 
(%)
World 
(%)
Oil 32 37 Natural
Gas
8
24
Natural
Gas
8
24
Coal 54 27
Nuclear Energy 1 6
Hydro-Electric 5 6
Total 100 100
(Source: BP Statistical Review of World Energy 2005)

5. WORLD SCENARIO
As the International Energy Agency has
commented: “World reserves of coal are enormous and compared with
oil and natural gas, widely dispersed... The world’s proven
reserve
base
represents
about
200
years
of
production
at
reserve
base
represents
about
200
years
of
production
at
current rates... Proven coal reserves have increased by
over 50% in the past 22 years. The correlation of strong
growth of proven coal reserves with robust production
growth suggests that additions to proven coal reserves will
continue to occur in those regions with strong, competitive
coal industries.”

6. INDIAN SCENARIO
C
Coal accounts for 63% of Country’s
energy needs.
C
Coal based thermal power generation
capacity presently stands at 61,476MW
and
a
capacity
addition
of
around
60
,
000
and
a
capacity
addition
of
around
60
,
000
MW has been targeted in next 7 years.
C
Total annual hard coal production in India
is about 373.79 million tonnes (2004-05)
out of which nearly 80% is from Opencast
Mines. SCCL share is 10%.

7. INDIAN SCENARIO
Coal Demand & Production
(in Million Tonnes)
Coal Demand & Production
(in Million Tonnes)
2011-12
Demand 707
Production 550 
Gap 157 
(Source: Coal Summit 2005)

8. Proved coal reserves at end 2005

9. RESERVES -India DEPTH(m)  PROVED  INDICATED  INFERRED 
TOTAL 
(In Bt)      (%)
0-300 
71 66.5 15152.561.5
As on January 2005 in Billion Tonnes
300-600 
6.5 39.5 176325
0-600
(Jharia)
14 0.5 -
14.5
6
600-1200 
1.5 10.5 6
18
7.5
0-1200 93 117 38248100
(Source: GSI Report, January 2005)

10. RESERVES -SCCL
As on January 2006 in Million Tonnes
DEPTH
(m) 
PROVED  INDICATED  INFERRED  TOTAL 
0-300  5505.49 2239.12 102.25 7846.86
300
-
600 
2897.69
2900.71
553.05
6351.45
300
-
600 
2897.69
2900.71
553.05
6351.45
600-1200  0.00 1018.34 1928.95 2947.29
0-1200 
8403.18 6158.17 2584.25 17145.60

11. LONGWALL 
–
LONGWALL 
–
World & India

12. L
First mechanized powered support longwall
caving face was introduced in August 1978
at Moonidih, CIL.
Longwall in India
L
First Longwall face introduced in GDK.7
Incline in September 1983 in SCCL. L
There is no much improvement taken place
in India in respect of Longwall technology
due to various reasons.

13. “
Serious efforts not made perhaps due to
availability of alternate technologies. “
Upgrading
not
made
when
most
of
the
world
improved
in
90
s
.
Longwall in India
Reasons for less concentration on Longwalls in India
Upgrading
not
made
when
most
of
the
world
improved
in
90
s
.
“
Spares management was poor.
“
Coal India do not need due to opencast and
flat gradients. “
Use of indigenous spares of low quality is
increased, which deteriorated the condition of
faces.

14. Australian Coal Industry
L
World’s largest exporter of coal
L
230 mt worth Au$ 16 b (Rs. 53,000 crs)
in 2004.
L
Most
of
the
74
bt
reserves
in
NSW
and
QLD
L
Most
of
the
74
bt
reserves
in
NSW
and
QLD
L
378 mt in 2004, 82 mt from underground.
L
24 longwalls produced 73 mt in 2004 and
plans to produce 96 mt in 2006. L
148 wagons per rake 2 km length, 8,500 t.

15. Australian Coal Industry
L
Less than 25,000 employees.
L
Each mine has 120 to 200 permanent 
and 100 contractors’ men.
Productivity:
L
Productivity:
O
OMY is 15,000 t.
O
OMH 5t for UG, 10t for OC

16. Longwall Geometry -World
Time
Width 
(m)
Length (m)
1970’s
150
1200
1970’s
150
1200
1980’s 225 1800
Today 330 3000

17. LONGWALL 
-
LONGWALL 
-
METHOD

18. FACE
TOP Gate
LONGWALL GENERAL LAYOUT
Bottom
Gate
Dip direction
-
Longwall mining method includes drivage of two long
roadways in coal and joining them at the end by a
perpendicular drivage forming a face.

19. Different Longwall Methods
1. Longwall Advancing 
Method
2. Longwall Retreating 
Method

20. Modern Longwall Plans in Australia

21. Modern 
Longwall Plans 
in Australia in Australia

22. Gateroad Plans in Australia

23. Advantages of Longwall Method
L
High Recovery.
L
Lower Operating Costs.
L
Easier to Supervise. Easier to Train Miners.
L
Easier to Train Miners.
L
Works Under Weak Roof.
L
Clean Coarse Product.
L
Simple Ventilation.

24. Disadvantages of Longwall Method
L
Small Problems = Big Production 
Losses.
L
Dust Control Difficult.
L
Overloading Conveyor System.

25. Retreat Longwall Mining 
Advantages Over Advance Longwall Mining
“
Reserves are “Proven” on Development
“
Gateroads in the “Solid”
“
Gateroad Development is Separate
“
Water Easier to Control
“
Recovering Equipment Easier
“
Easier Ventilation

26. Retreat Longwall Mining
Disadvantages Over Advance Longwall Mining
“
Delay in getting production for the 
preparation of first panel.
“

27. MAIN GATE WITH SWITCH TRAIN
CHHO
C
K
S

28. LONGWALL METHOD
Retreat per day  –5 meters/day
Production –3000 Tonnes/day 
Thickness of 2.0 m to 3.5 m

29. POWERED ROOF SUPPORT AT LONGWALL FACE

30. LONGWALL 
-
LONGWALL 
-
EQUIPMENT

31. Equipment for Longwall Mining
L
Powered Face Supports
L
Shearer
L
Armored Face Conveyor Conveyor System
L
Conveyor System
L
Electricals & Communication

32. CHOCK SHIELD SUPPORT CHOCK SHIELD SUPPORT

33. Powered Roof Supports (Two legged)

34. POWERED ROOF SUPPORT AT 
LONGWALL FACE Capacity             -4x450 T to 4x800 T
Thickness of  -2.0 m to 3.5 m
Weight  -12 T to 20T
Weight -1.5m 

35. Powered  Face  Face  Supports

36. Armored Face  Armored Face  Conveyor

37. Armored Face Conveyor

38. Armored Face Conveyor

39. Armoured Face Conveyor 
(1 pan set)

40. Shearer working at Longwall Face

41. SHEARER WORKING AT LONGWALL FACE
Capacity             -2x375 Kw
Thickness of 2.0 m to 4.5 m
Web  -0.63/0.85
Drum Dia -1.6 to 1.83m
Length -10m 

42. Shearer

43. Shearer -
Front Half

44. Shearer -
Rear Half

45. Shearer Drum

46. Cutter Bits with Spray

47. Conveyor Belts

48. LONGWALL 
–
LONGWALL 
–
STRATA CONTROL

49. Top Gate 50 L
C L XX
Barrier Pillar
120 m
1000 m
S
C L
STRATA CONTROL PLAN OF 
A LONGWALL PANEL
Not to scale
Bottom Gate 53 L
Longwall Panel dimensions
1000 m x 115 m
INDEX: C Convergence Station
L Load Cell
X Extensometers
S Stress cell
C L X X
G O A F
FACE RETREAT
Barrier Pillar
S
120 m
1000 m
200 m
S
C L

50. Strata monitoring of in 
a Longwall Panel
•
Gate Road ways studies.
•
Face monitoring.
•
Goaf monitoring.
•
Goaf monitoring.

51. Gate Road ways studies –
•
Convergence indicators
•
Load cells
•
Tell tales
Strata monitoring
•
Tell tales
•
Stress capsules
Cum.CONVERGENCE in Tail gate
of a Longwall Panel
0
5
10
15
20
25
30
35
10.0m
30.0m
50.0m
70.0m
90.0m
110.0m
130.0m
150.0m
170.0m
190.0m
210.0m
230.0m
250.0m
270.0m
290.0m
310.0m
330.0m
350.0m
370.0m
390.0m
410.0m
430.0m
LOCATION in mts
Cum.Convergence in mm

52. The maximum convergence depends on 
the following factors
N
Caving properties of the strong bed
causing weightings, indicated by the
Caving Index Number ‘I’ of the strong
bed.
NN
Thickness of cavable beds forming the
immediate roof in between strong bed
and the coal seam in terms of height of
extraction.
N
Resistance offered by the support
system.

53. Convergence and Roof Degradation at 
Longwall Weightings                 (GDK.10A)
Maximum Convergence
Expected Roof Condition
Upto 60 mm/m
Convergence within permissible limit
Above 60 upto 100 mm/m
Minor roof fracturing increasing
Above 60 upto 100 mm/m
Minor roof fracturing increasing with the value of convergence
Above 100 upto 160 mm/m
Significant roof fracturing and roof degradation. Seriousness increasing with increase in convergence
Above 160 mm/m
Rock fall zone.

54. Face monitoring–
•
Leg Pressures
•
Leg Closures
•
Face Convergence
Strata monitoring
•
Face Convergence
PRESSURE SURVEY
Continuous Pressure Recorder in Mid Face
of a Longwall Panel
15
20
25
30
35
40
33.6
39.3
56.2
74.1
95.4
111
119
141
163
180
198
220
237
259
279
305
324
345
369
386
412
FACE RETREAT in mts
PRESSURE (M pa)
Setting Pressure
Yield Pressure

55. Rated Support Resistance The Rated Support Resistance should
take into account the following
deficienciesduringtheactualoperation.
1.
Leakage
in
leg
circuit
1.
Leakage
in
leg
circuit
2. Setting load deficiencies
3. Miscellaneous (deviation from normal
span, premature bleeding of leg
circuits, etc.)

56. Goaf monitoring –
•
Remote convergence indicator
•
Multi Point Borehole Extensometer 
(MPBEx)
Strata monitoring
CAVING OF THE STRATA WITH RESPECT TO FACE PROGRESS
sensors
SURFACE
SOIL-2.7m
36m
25m
13.5m
6m
68.0m
80.0m
141m
Face progress
Anchor1
Anchor2
Anchor3
Anchor4
RemarksAnc 1- 45m Anc2 -37.5mAnc3 -26mAnc4 - 15m
SOIL-2.7m
YellowSST 8m
Light Brown SST-7m
Shaly Coal3m
Grey & Brown
SST-12m
Hard Brown
SST-17m

57. Main Overburden Main Overburden
Longwall Caving Diagram
HcHc
FF
DcDc
ClCl
RoRo
Immediate Roof Immediate Roof
TT
Hs = Seam Height
Hc = Caving Height
Cl = Canopy Length
Dc = Depth of Cut
A = Caving Angle
F = Forward Zone
Ro = Rear Overhang
T = Canopy Tip to Face
Sw = Shield Width (not shown)
HcHc HsHs
FF
DcDc
ClCl
RoRo
AA
GobGob
Coal Coal
Floor Floor
Shield Shield
Support Support

58. Cut after cut, shear after shear the AFC & subsequently
Chock shield supports will be advanced and the
immediate roof rock above caves in.
Longwall Caving

59. -
As the retreat further proceeds substantial area of main
roof rock forms a plate & caves in by imposing load on
supports,known as main weighting.
Main Fall

60. Periodic Fall

61. LONGWALL 
–
LONGWALL 
–
ORGANISATION

62. Organisation Chart

63. MANPOWER
Pre shift
1. EE/AE 1
2. Mech. Charge Hand 1
3. Overman 1
4. Mining Sirdar 1
5.
Shearer 
F+3 
General Shift
1. Overman 1
2. Mining Sirdar 1
3. Gate Road Support 6
4. Face Supporting
(Bamboo bolting & 
5.
Shearer 
F+3 
6. AFC & BSL F+5
7. Power pack & Chocks F+3
8. Switch train & 
U/Frame Shifting F+7
9. GBC F+4
10. Miscellaneous 9
-------------
40
(Bamboo bolting &  Fore polling etc.) 8
5. Face Cleaning 10
6. Slush Tanks cleaning 
along M.G. 6
7. Material transport 6
--------
38

64. MANPOWER
Production Shift
1.   Under Manager 1 2.   
Engineer 1 3.   
Overman 1
4.   Mining Sirdar 1
5.   Shearer Operator
2
5.   Shearer Operator
2
6.   Multi Job Workmen 9
7.   Face fitters 3
8.   Face Electricians 1
9.   Outbye belt Fitters 1
10. Outbye Electricians 1
11. Helpers 6
12. Conveyor Operators 6
13. Misc/cleaning 4
-------------
37

65. LONGWALL 
–
LONGWALL 
–
FACE TRANSFER

66. MESHING
L
Wire meshing is laid in roof from 12 to 15m
behind the face stop line with individual roof
bolts for 5 to 8m and later on along with W-
straps/Channel for balance portion at 1m
interval
.
interval
.
L
Maximum height will be extracted for the last
8m from face stop line, sothat enough
clearance is there for PRS passing underneath
the line supports.
L
After stoppage of the face, meshing and
bolting is done to the face also.

67. DISMANTLING
L
All the equipment in the face are dismantled
except chocks and loaded on to the GMT (Gyro
Machine Trolley) and transported to surface of
new face.
L
Shearer
is
dismantled
into
two
parts
for
easy
L
Shearer
is
dismantled
into
two
parts
for
easy
transport.
L
AFC pansets were dismantled in such a way
that 5 pansets together forms a unit for
loading onto GMT.
L
Similarly BSL, Belt sections are dismantled and
loaded on GMT.

68. CHOCKS TRANSPORT
L
PRS turning is done generally from dip to
raise and 2 buttress supports are used as
goaf edge supports at dip most point of the
face.
L
PRS are being marched with self hydraulic
power upto loading station and shifted on
to GMT for further transport to surface or
to new face.

69. SCCL –A Review SCCL –A Review

70. Strut Pit, Yellandu

71. Singareni
•
Presently operating 47 Underground
and11Opencastmines.
•
Godavari
Valley
Coalfields
spread
out
•
Godavari
Valley
Coalfields
spread
out
over350Kms.

72. L
O
C
ATL
O
C
ATATI
O
N
ATI
O
N

73. The Godavari Valley Coalfield The Godavari Valley Coalfield
L
O
C
ATL
O
C
ATATI
O
N
ATI
O
N

74. 1975: Opencast mining
1979: Side Discharge Loaders
1981: Load Haul Dumpers and Road 
Headers
1983:
Longwall mining
Mile stones -Technology
1983:
Longwall mining
1986: Walking Dragline
1989: French Blasting Gallery method
1994: In-pit crushing and conveying
2004: Phasing out manual Coal filler 
launched.

75. Technology-Wise production-2005-06
L
Opencast :
23.42mt
(64.8%)
L
Underground :
12.71 mt
(35.2%) (35.2%) L
Manual mining :7.12 mt
L
Longwall :0.85 mt
L
Intermediate mech.  :4.74 mt
(LHD, SDL, BG & RH)

76. PROJECTIONS TECH 2006-07 2011-12 2016-17 2021-22
PROD
(M.T)
%  PROD
(M.T)
%  PROD
(M.T)
%  PROD
(M.T)
% 
HS
6.005
16
5.225
13
3.780
8
3.620
8
SDLS
3.30
9
2.865
7
1.610
4
1.280
3
LHD
1.655
4
1.110
3
1.12
2
0.680
1
LHD
1.655
4
1.110
3
1.12
2
0.680
1
LW
1.205 3 3.900 10 5.600 12 8.500 18
CM
0.400
1
1.800
4
1.770
4
2.000
4
BG
1.210
3
1.150
3
0.920
2
0.920
2
TOTAL UG
14.251
37
16.050
39
14.800
33
17.000
36
OC
21.749
63
24.750
61
30.200
67
30.500
64
TOTAL 37.500
100
40.800
100
45.000
100
47.500
100

77. C&MD
Dir/ Fin.
Dir/ P&P
Dir/ Oprs.
Dir/ E&M
Dir/ PAW
Finance Int. Audit
Areas
Areas
Civil
Forestry
SO
Personnel
Medical
E&M, UGM
E&M, OC
Marketing
General Organisation of SCCL
Co. Secy.
SO
Safety CP&P
Corp. Plg Proj. Plg.
SurveyExplrn.
Environ.
Estates
IE
Vigilance Security
IT
LawHRD
Stores
PH&WS
Edn.
Central WS
Cap. budget
Purchase
R&D
Qual. Mgt

78. GM
Mines
IE
Finance
SO
Safety
Civil
IT
General Organisation of Areas
Personnel
HRD
Qual.Mgt.
Survey
Medical
Township
E&M
Workshop
Stores
Purchase
WM Comn.
Coal handling

79. Mine Manager
Safety
Ventilation
E&M Mntnce
Min. Mntnce.
Pit Office
General Organisation in the Mines
E&M Mntnce
Min. Mntnce.
Survey
Welfare
Production
Shifts Drilling, Blasting
Loading, Transport,
Mine support,
Coal handling etc.

80. Organisation of statutory personnel
Owner Directors
on the Board
General Manager (deemed Agents)
Corporate HoDs
(Deemed Agents)
(deemed Agents)
Named Agent
(group of mines)
Mine Manager
Officers
For various
disciplines
Supervisors
Competent
persons

81. STATUS OF 
LONGWALLS AT SCCL

82. INTRODUCTION
L
The first Longwall was commissioned in SCCL
at GDK.7 Incline, RG-II in September, 1983. L
Till now 10 sets of Longwall were purchased by
SCCL
.
Mainly
the
equipment
was
by
SCCL
.
Mainly
the
equipment
was
purchased from UK and China.
L
Till now 70 Longwall panels have been
completed in SCCL and presently 4 Longwall
units are in operation in 4 Underground
mines.

83. EXISTING LONGWALL MINES OF SCCL
S 
No
Name of the mine No of 
Units
1 PVK-5 Incline,KGM Area 1 unit 
2006-07
2 GDK-9 Incline,RG-II Area  1 unit 
3 GDK-10A Incline,RG-II Area 1 unit 
4 JK-5 Incline, YLD Area 1 unit 

84. LONGWALL PRODUCTION TREND-SCCL
1520
25
0
5
10
15
PROD (LT)
LW PROD1.33 2.47 5.75 6.18 6.12 6.12 4.62 6.32 12.17 13.2 16.1 10.4 20.19 22.9 19.3 16.42 15.79 13.66 11.27 10.1 11.17 11.19 8.5
1983-
84
1984-
85
1985-
86
1986-
87
1987-
88
1988-
89
1989-
90
1990-
91
1991-
92
1992-
93
1993-
94
1994-
95
1995-
96
1996-
97
1997-
98
1998-
99
1999-
2000
2000-
01
2001-
02
2002-
03
2003-
04
2004-
05
2005-
06

85. INTRODUCTION OF LW SETS
S 
No
Mine where LW sets 
introduced
No.of sets 
& Yr.
Support 
capcities
1 GDK.7/9 Incline, RG-II 1, 1983 4 x 360T
2 VK-7 Incline, KGM 1, 1984 4 x 360T
3 GDK.11A Incline, RG-I 3, 1990-92 4x450T(2),  
4x430T(1)
4 JK-5 Incline, YLD 1, 1990 4x450T
5 GDK.9Extention, RG-II 1, 1996 4x800T
6 GDK.10A Incline, RG-II 1, 1994 4x800T
7 Padmavathikhani, KGM 2, 1995-96 4x760T

86. GDK.7 INCLINE
L
Longwall equipment introduced in no.3 seam
bottom section in September 1983. L
After
completion
of
two
panels,
due
to
non
L
After
completion
of
two
panels,
due
to
non
availability of the property the equipment
was shifted to adjacent GDK.9 Incline. L
Main Problem - Strength of coal is high for
Shearer cutting & sand stone bands running
across the panel.

87. GDK.7 INCLINE
Borehole Section 
showing  showing 
3 seam Top & Bot 
Section.

88. GDK.7 INCLINE
L
Two panels have worked with 4x360T
supports in No.3 seam bottom section
withafacelengthsof110mand96m.
L
The production achieved is 0.8LT with
anaverageproductionof1900T/day.

89. VK.7 INCLINE
L
Longwall equipment with 4x360T Conventional
supports was introduced in Top seam in 1985. L
With 4x360T supports, 8 panels of 120m face length
and 7 panels of 60m face length have been worked
successfully
.
successfully
.
L
Second set (4x450T IFS) shifted from GDK.11A Inc in
1994 & is presently in operation. L
Experience in – varied face lengths, up hill transport,
crossing the developed gallery, working in between
goaves, fault running across the panel.
L
Main Problems – Underrated capacity of supports,
Cavity formation.

90. Borehole Section 
showing Top seam 
(Middle Section)
VK.7 INCLINE
Depth  Thickness  Strata     Description

91. VK.7 INCLINE
L
8 panels of 120m face length have completed
With 4x360T supports by producing around
3.6MT and daily production varied from 400
to 1800T.
L
7 panels of 60m face length have completed
With 4x450T supports by producing around
1.6MT and daily production varied from 1000
to 1300T.

92. GDK.11A INCLINE
L
Two longwall sets were introduced with
4x450T/4x430T supports during 1991, followed by 3
rd
Longwall unit with 4x450T supports during 1992.
L
First
time
longwall
was
introduced
in
No
.
1
Seam
of
L
First
time
longwall
was
introduced
in
No
.
1
Seam
of
Ramagundam.
L
Main Problems – Underrated capacity of supports,
Oblique fault running across the panel, high water
seepage, improper geo-technical investigations.

93. Borehole Section 
showing No.1 seam 
GDK.11A INCLINE
showing No.1 seam 
(Bottom Section)

94. GDK.11A INCLINE
L
Longwall unit –I : 2 panels worked producing around
0.5MT of coal.
L
Longwall unit – II : 4 panels worked producing around
1.3MT of coal.
L
Longwall unit – III : 3 panels worked producing
around 0.96MT of coal.
L
While working with Longwall unit-II & III, experienced
more strata problems and cavity formations, due to
underrated capacity of supports.

95. PADMAVATHIKHANI
L
First time Chinese longwall was introduced in
PVK in 1995 in Queen Seam (Top seam). L
2 sets were introduced, One in 1995 and the
other in 1996 with 4x760T supports. L
11 panels have been completed by producing
around 5 MT. L
Experience in – varied face lengths,
negotiation of fault, deviation of gate
roadways.
L
Main Problems – Non-availability of Spares.

96. Borehole Section 
showing Top seam 
PADMAVATHIKHANI
showing Top seam 
(Middle Section)

97. JK-5 INCLINE
L
Longwall with 4x450T supports (IFS) was
commissioned in June 1990. L
Longwall panels were extracted in both, Top and
bottom sections of Queen (Top) seam after
allowing
for
goaf
settlement
.
allowing
for
goaf
settlement
.
L
2 panels in Queen seam bottom section and 8
panels in Queen seam Top section have been
completed by producing around 2.7MT of coal.
L
Experience in – varied face lengths, negotiation
of fault, in between goaves, steep gradient (1 in
3.6).
L
Main Problems – Geological disturbances, Cavity
formation, underrated capacity of supports.

98. Borehole Section 
showing Top seam
Top & Bottom section
JK-5 INCLINE

99. GDK.9/9E INCLINE
L
Longwall equipment (4x360T) introduced in
no.3 seam bottom section in 1986 which was
shifted from GDK.7 Incline.
L
New Longwall set with 4x800T capacity was introduced
in
No
.
1
seam
in
1996
.
introduced
in
No
.
1
seam
in
1996
.
L
Main Problem – underrated capacity of
supports for 3 seam, Cavity formation,
Insufficient geological data, slow progress in
development of panels, more water seepage,
spares mgmt.

100. GDK.9/9E INCLINE
Borehole Section 
showing 1 seam

101. GDK.10A INCLINE
L
Longwall equipment (4x800T IFS) was introduced in
no.1 seam in 1994.
L
GDK.10A longwall produced daily, weekly and
monthly record output in India. In the year 1997-98,
the
mine
produced
8
.
67
LT
.
the
mine
produced
8
.
67
LT
.
L
GDK 10A produced 5.40 LT of coal against
the target of 5.38 LT in the year 2005-06. L
Main Problem –more water seepage, non-availability
of good quality spares, Cavity formation.

102. Borehole Section 
showing 1 seam
GDK.10A INCLINE

103. FUTURE 
LONGWALLS AT SCCL

104. FUTURE LONGWALL PROJECTS
• Adriyala Shaft Project 
– Extension of GDK.10A dip side
• Jallaram Shaft Project 
–
Extension of GDK.9 Inc Dip side
–
Extension of GDK.9 Inc Dip side
• Peddampet Shaft Project
- Extension of GDK.11A Inc Dip side
• Kakatiya Longwall Project, Bhupalpally
- Steeply inclined, New mine.
• Shanthikhani Longwall Project, Bellampalli
- Extenstion of existing mine

105. STATUS OF APPROVAL OF LW PROJECTS
S.
No
Project FR 
approved 
by SCCL 
Board
Status of EMP Status of GOI approval 1 Adriyala July’ 2003 EC obtained
11.10.2004
Sanctioned from GoI in Sept 06 2 Shanthikhani Dec’ 2003 EC obtained
24.01.2006
Submitted to GOI on 26.02.04.        In principle approval received. 
PIB note submitted on 01.01.05
3 KTK LW June’ 2005 EMP to be prepared Submitted to GOI 5.08.2005
4 Jallaram Oct’ 2004 Public hearing completed.
Application for EC under 
preparation.
Submitted to GOI 11.11.04
5 Peddampeta Dec’ 2003 Public hearing completed.
Application for EC under 
preparation
Submitted to GOI 26.02.04

106. ADRIYALA SHAFT PROJECT 
1. Location : Ramagundam coal belt
Ramagundam Area
2. Geological Block : RG SB-II & RG SB-III
3. Geological Reserves : 109.59 Mt
4.
Extractable Reserves (Apr.)
: 43.38 Mt
4.
Extractable Reserves (Apr.)
: 43.38 Mt
5. Area (in Sq.Km) : 3.40
6. Capacity (MTPA) : 2.14
7. Life of the Mine : 31 years
8. Face length : 150m
9. Panel length : 700 - 1300 m
10. Depth range : 294 – 644m
11. Gradient : 1 in 6.0 to 1 in 7.8
:

107. Details of seams:
SeamAvg. 
Thickness 
Height of 
Extraction 
(m)
Geological 
Reserves 
Extractable
Reserves 
Grade
ADRIYALA SHAFT PROJECT
Thickness 
(m)
(m)
Reserves 
(Mt)
Reserves 
(MT)
I 5.64
3.5
27.99 10.98 E
II 3.27
2.0
15.24 6.07 D
III 9.40
3.5(Top)/
3.5(Bot)
43.09 23.31 D
IV 3.66
3.5
15.56 11.28 C

108. SHANTIKHANI LONGWALL PROJECT 
1. Location : Dorli - Bellampalli coal belt
Bellampalli Area
2. Geological Block : Shantikhani Extn Block
3. Geological Reserves : 8.87 Mt
4.
Extractable Reserves (Apr.)
: 17.78 Mt
4.
Extractable Reserves (Apr.)
: 17.78 Mt
5. Area (in Sq. Km) : 6.81
6. Capacity (MTPA) : 1.17
7. Life of the Mine : 23 Years
8. Face length : 150m
9. Panel length : 450 - 2000 m
10. Depth range : 309 – 596m
11. Gradient : 1 in 3.5 to 1 in 5

109. Details of seams (Phase-I)
SeamAvg. 
Thickness 
(m)
Height of 
Extraction 
(m)
Geological 
Reserves (Mt)
Extractable
Reserves 
(Mt)
Grade
SHANTIKHANI LONGWALL PROJECT
(m)
(Mt)
SJ Top 1.88
1.5
18.96 3.91 F
SJ Bot 3.18
2.5, 3.5
29.91 13.87 D

110. 1. Location : Mulug coal belt
Bhoopalpalli Area
2. Geological Block : Gollapalli block & Peddapur block
3. Geological Reserves : 67.45 Mt (Phase-I)+ 60.06 Mt (Phase-II)
4.
Extractable Reserves (Apr.)
: 40.02 Mt (Phase
-
I)+ 35.99 Mt (Phase
-
II)
KAKATIYA LONGWALL PROJECT
4.
Extractable Reserves (Apr.)
: 40.02 Mt (Phase
-
I)+ 35.99 Mt (Phase
-
II)
5. Area (in Sq. Km) : 9.71
6. Capacity (MTPA) : 2.16
7. Life of the Mine : 24 + 22 Years
8. Face length : 250m
9. Panel length : 1200 - 2900 m
10. Depth range : 35 – 412m
11. Gradient : 1 in 2.8 to 1 in 3.3

111. Details of seams (Phase-I)
SeamAvg. 
Thickness 
Height of 
Extraction 
(m)
Geological 
Reserves 
Extractable
Reserves (Mt)
Grade
KAKATIYA LONGWALL PROJECT
Thickness 
(m)
(m)
Reserves 
(Mt)
Reserves (Mt)
IA 2.02
2.0
12.16 7.62 E
I 2.66
2.5
17.18 9.45 F
II 2.72
2.5
17.55 9.71 F
III 3.05
3.0
20.53 13.24 B

112. JALLARAM SHAFT PROJECT 
1. Location : Ramagundam coal belt
Ramagundam Area
2. Geological Block : RG SB-II
3. Geological Reserves : 206 Mt
4.
Extractable Reserves (Apr.)
: 79 Mt
4.
Extractable Reserves (Apr.)
: 79 Mt
5. Area (in Sq.Km) : 7.29
6. Capacity (MTPA) : 2.28
7. Life of the Mine : 53 years
8. Face length : 200m
9. Panel length : 500 - 1800 m
10. Depth range : 123 – 579m
11. Gradient : 1 in 5 to 1 in 8

113. Details of seams
SeamAvg. 
Thickness 
(m)
Height of 
Extraction 
(m)
Geological 
Reserves 
(Mt)
Extractable
Reserves 
(Mt)
Grade
JALLARAM SHAFT PROJECT
(m)
(m)
(Mt)
(Mt)
I 5.09
3.0
53.99 14.13 E
II 2.99
2.0
27.43 12.17 E
III 8.79
3.0 (Top)/ 
3.5 (Bot)
85.04 36.91 D
IV 3.00
3.0
29.19 16.21 B

114. 1. Location : Ramagundam coal belt
Ramagundam Area
2. Geological Block : GDK-6B Integrated Mine Block
3. Geological Reserves : 112.62 Mt
4. Extractable Reserves (Apr.) : 41.40 Mt
5.
Area (in Sq.Km)
: 7.25
PEDDAMPETA SHAFT PROJECT
5.
Area (in Sq.Km)
: 7.25
6. Capacity (MTPA) : 1.46
7. Life of the Mine : 32 Years
8. Face length : 150m
9. Panel length : 470 - 1200 m
10. Depth range : 118 – 443m
11. Gradient : 1 in 6 to 1 in 10

115. Details of seams
SeamAvg. 
Thickness 
Height of 
Extraction 
(m)
Geological 
Reserves (Mt)
Extractable
Reserves 
Grade
PEDDAMPETA SHAFT PROJECT
Thickness 
(m)
(m)
Reserves (Mt)
Reserves 
(Mt)
II 2.64
2.0
24.27 7.06 E
III 8.69
2.0 (Top)/ 
3.5 (Bot)
65.69 21.39 D
IV 2.50
2.5
22.66 12.95 B

116. Variants of Longwall Mining Variants of Longwall Mining
(NEW CONCEPTS)

117. Punch Longwall
- Developing longwall panels directly off high walls  of OC

118. Field site operations
Punch Longwall

119. Advantages   CStep change in cost and productivity
CMore production capacity
CHigh productivity & low cost 
C
Longer term and higher % of reserves extraction
Punch Longwall
C
Longer term and higher % of reserves extraction
CEasy logistics – near surface
CHigh gate road development rates feasible
CHigher and faster returns on investment
CTotal investment ~ $100 million – compared with > 
$300 millions UG

120. 1st pressure
peak
Rock stress Low stress Stress
abrupt drop
2nd pressure
peak
Compact
stress
Pressure curve of top coalseam
Technical Principle Of Top Caving
Longwall Top Coal Caving (LTCC)
goaf
Virgin
coal
Fracture
Coal
Broken Coal
caving
Working
Height
Front AFC
Rear AFC
28005600
backback back

121. Longwall Top Coal Caving (LTCC) Supports used

122. Advantages of LTCC
Longwall Top Coal Caving (LTCC) •Increased resource recovery in thick seams (> 75%)
•Lower face working height (better face control)
•Improved spontaneous combustion control
•
More efficient capital utilisation/ financial 
•
More efficient capital utilisation/ financial  performance
•Reduced operating costs
•Improved production consistency
•Less gate road development requirements
•Some dust and gas issues

123. LONGWALL –
INDIAN  INDIAN 
PERFORMANCE 

124. INDIAN LONGWALL
-PAST EXPERIENCE:
- Introduction of advanced technology system in Indian
coal mining industry marked a major step with the
installation of first mechanized Longwall Powered support
face at Moonidih in August 1978.
- In between 1978 to 1985, a major number of first
generation Longwall faces started through out India in
various mines of CIL such as Moonidih, Jhanjra, Seetalpur,
Dhemomain and Pathakhera Colliery and in SCCL at GDK-
7 & VK-7 Incline.

125. -PASTEXPERIENCE:
- Churcha Longwall face failed due to dynamic
loading.
-
Jhanjra
with
shallow
depth
Longwall
working
face
INDIAN LONGWALL
-
Jhanjra
with
shallow
depth
Longwall
working
face
ran into acute spares problem.
- Kottadih face failed after successful completion of
two Longwall panels due to dynamic loading and
underratedcapacity of supports.
- GDK.11A failed due to underrated capacity of
supports.

126. -PAST EXPERIENCE:
Longwall technology was introduced in
Seven mines of SCCL. Their performance
hasbeen:
LONGWALL-SCCL
• GDK-10A, JK-5 and VK-7 Incline gave
consistently good results, and
• The other four mines GDK-7, GDK-9, GDK-
11A and PVK suffered mainly due to non
availability of sufficient geological data.

127. MAIN REASON :
Insufficient geo-technical investigations
resulted in surprises by encountering major
geological
disturbances
while
working
the
INDIAN LONGWALL
geological
disturbances
while
working
the
longwalls. Thus effecting the performance of
Longwalls to the maximum extent.

128. -PRESENT & FUTURE :
- With the likely reduction of contribution from Open
cast and the more or less stagnant production from
Underground by Conventional methods, it is time
that an impetus is given to boost Long wall
Technology
to
able
to
meet
the
future
energy
needs
INDIAN LONGWALL
Technology
to
able
to
meet
the
future
energy
needs
of the country.
- On the positive side, coal companies have now
gained sufficient experiences right from senior
executive level to front line workforce to be able to
plan, execute and work longwall faces.What are
required are proper geo-technical
investigations for effective layout of longwall
panels.

129. REASONS FOR POOR PERFORMANCE 
OF LONGWALL
>Large expansion in opencast mining in the past
two decades provided cheaper and safe method
for bulk coal production and as a result long wall
had to take back seat.
>Clear strategies were not pursued for its
sustenance as there was mixed results from long
wall in the early years of its introduction.

130. >Long walls were introduced mostly in the blocks
left over by working Bord and pillar method.
Clean and extensive blocks have not been
identified. Even the smaller blocks, which were
identified,were of inferiorgrade coal.
REASONS FOR POOR PERFORMANCE 
OF LONGWALL
>Long wall had to co exist with the conventional
mining in most of the mines, which caused
management problems.
>There were some deficiencies in the imported
spares management and the supplies were not
reaching in time.

131. >Coal companies were sensitive to the failures of
a few long wall faces and were not prepared to
risk huge investments.
REASONS FOR POOR PERFORMANCE 
OF LONGWALL
>Development could not keep pace with the
extraction of Long wall panels, slow progress in
dip has delayed the formation of Long wall
panels and affected the performance.

132. -
Longwall should be promoted as a
technology mission.
-
A
high
level
thrust
group
could
be
constitute
FUTURE REQUIREMENTS  -
A
high
level
thrust
group
could
be
constitute
at national level to promote, coordinate and
interact different aspects related to Longwall
technology.

133. -
Huge investments incurred on different
operations for extraction of coal from greater
depths in future can be attained by imposing
a special cess on present OC production or
from other sources.
FUTURE REQUIREMENTS  -
R&D efforts are to be doubled.
-
Efforts are required by the policy makers to
transform ideas into actions.

134. FUTURE REQUIREMENTS 
-
Foreign participation is required for
extraction of thin seams and steeply
inclined seams.
-
The manufacturing companies of India such
as
MAMC
and
Jessop
are
to
be
such
as
MAMC
and
Jessop
are
to
be
reconstructed/ re-organized.
-
More number of longwall blocks are to be
identified to assure the market for
manufacturers.

135. THANK YOU