Collieries Division-Jharia, TATA Steel

Jharia Collieries Division

TATA Steel
Unit Profile
Jharia Collieries division is a captive unit of TATA Steel. It is located in Jharia
Coalfields.(location plan JH / ECA-02 enclosed). It has +100 years old 5 underground mines-
operating at maximum depth(600m) in Jharia Coal Fields, 2 Coal Preparation Plants(CPP) /
Washeries with a combined 1.6 mtpa throughput capacity, 1x10MW captive FBC Power
Plant(PP) and Services departments to support the operations.
Its main product is Prime Coking Coal ( Washed / Clean Coal). In FY 03-04, it produced 1.28
million ton(mt) washed coal at <17% ash by beneficiating 1.51 mt ROM Coal . After meeting
the captive requirements of Jamshedpur Steel Works, the balance are sold to Public Sector
Steel Plants. Plant effluents and by-products are very effectively utilized.
It is EMS ISO 14001 certified unit.

ENERGY CONSUMPTION
Its plant (collieries, washeries & PP) combine consumes about ¾th of the total power, out of
which , essential underground mine safety loads like Pumping, Ventilation, Fire Control, Roof
supporting , Stowing etc. alone consume 80%.

Specific Energy Consumption Plant Energy Cost

Total Energy Cost as %of Production Cost
2721
90 . 44 2712
14.01
K W H /T o n e

13.06 85 . 85

R s. L a k h
% 84 . 97
12.48 2575

'01-02 '02-03 '03-04

'01-02 '02-03 '03-04 '01-02 '02-03 '03-04

The ORGANISATIONAL SET UP, COMMITMENT AND POLICY

It has consistently maintained its competitiveness through energy & resource conservation,
cost effectiveness, consistency in product quality & delivery in otherwise; arduous, manpower
& energy intensive Underground coal mining industry in an era when globally, the
underground mining is becoming economically unviable for many of the established players in
this field.
Its commitment to conservation of scarce energy resources is driven by its “Energy Policy”
(enclosed).It has dedicated organizational set up for Conservation, Safety & Environment.
(Organisational set up enclosed) The Improvement Group drives the energy conservation
activities through various improvement initiatives , small group activities, innovations & mass
awareness (Display of EVA meters on Power conservation- enclosed) on energy efficiency.
During 2001-03 period , its employees contributed 464 major ideas on energy conservation
through organizational initiative of TOP:Total Operational Performance- a McKinsey’s
programme implemented first time in the world in underground coal mining application, Black /
Green Belts Projects, Six Sigma, Suggestion Box , etc . It has structured review & monitoring
mechanism of these initiatives through embedded systems like QMS( all units are certified to
internal TISCO 13001- equivalent to ISO 9001 standard), EMS , OHSAS and internal Tata
Business Excellence Model- replica of Malcom Baldrige US National Quality award .

Energy Conservation Achievements

1
 Collieries Division-Jharia, TATA Steel
Maximum coal extraction with utmost care on safety & environment and Optimum recovery of
useful heat / carbon value from this scarce national resource have been its guiding principles
on conservation; accomplished by huge investments on energy & resource conservation and
effectively taking care of the challenges arising out of the increasing mine depth, associated
arduous working conditions and stringent operational & safety requirements stipulated by the
DGMS for Ventilation, Dewatering, Gassiness, Fire and Strata Control by installing High
capacity axial flow fans @ 4 lakh cfm, higher head Pumps, Pneumatic/ Hydraulic roof Bolting
m/cs etc. In the recent years, despite 20% increase in the connected load on these mandatory
energy intensive additional operational requirements and due to extensive mechanization at
greater depths/ scattered mining districts, its has been able to consistently reduce power
consumption.
Sustainable Efforts on conservation of scarce resources
Prime coking coal & Power

14.84 15.5 14%

14.5 2.29%

13.6
12.62 22%

10.35

8
1993-2001 2001-2004

Power(MKwh) Raw Coal(LT) Washed Coal(LT)

In the areas of Conservation, it has played leading role in national underground coal mining
industry by its many pioneering efforts; some of which are:
• First Underground Coal Mine in India ( perhaps in the World ) to be certified with EMS
ISO 14001 in April’ 2003
• Before enactment of law for the conservation of limited energy reserves of good
metallurgical coal, it was First to introduce “ Sand Stowing “(filling the void created from
extraction of coal in underground mine) through large capital investments to improve the
extraction of coal & protection from subsidence - otherwise 50 to 60% of the national
reserves would have been lost
• Injection of Nitrogen to Fire affected areas in u/g mine through newly installed Plant for
protection of scarce coal from Fire & its Conservation
• First to install Coal Washery way back in 1950 for use of uniform sized, blended &
lowered ash coal in steel making , resulting into improved coke rate at Steel Plant;
• First to install way back in 1988, AFBC(Atmospheric Fluidised Bed Combustion)
Technology based 10 MW Power Plant, using residual carbon/energy content of
washery rejects- a by product of coal beneficiation process, for generating power;
otherwise an environmental problem of disposing huge reject stock
• Conservation of surface soil ,degraded due to underground mining by filing Fly ash and
its reclamation through plantation & vegetation- an unique successful experimentation in
the mining industry.
• First to install close circuit effluents re-circulation system in its Washeries & Power Plant
even before the enactment of law thus conserving water and energy as well with
reduced fresh water requirement & associated pumping
• First to launch TPM( Total Productive maintenance) and OHSAS 18001 in
Underground Coal Mine, enhancing its operational capabilities in resource conservation
and environment, health & safety protections
• An Industry breakthrough Trial of using FRP Blades in Main Mine Ventilator is in
progress at its Bhelatand Colliery which has 20% potential on energy saving .
• For conservation of scarce prime coking coal & optimum recovery of its useful heat
2
 Collieries Division-Jharia, TATA Steel
content/ carbon value ,It has invested about Rs. 100 crores during last few years in
enhancing its coal beneficiation technology by installing new state of art Benificiation
Plant at Bhelatand and upgradaing the existing processes by energy efficient
technology like replacement of Primary Cyclones by Scrolled Evolute Cyclones/ MULTO
TECH having higher separation efficiency & higher t’put rate in the Coarser side and
introduction of Richard Mozely Hydro Cyclones in the fines circuit. It resulted into 20%
reduction in the specific power consumption of these plants and 12 % increase in
carbon recovery at 1% lower ash which has breakthrough effect in reduction of coke
rate in the steel plants.

17.17 16.99
80
17
15 78.19 75
13
68.17
11 12 70

9
9.478 65
7
5 60
Avg (1993-1998) Avg( 1998-2004)

Washed Coal Ash% Washed Coal Production(LT) Washed Coal Yield %

In its pursuit for energy conservation, the division has reduced & contained its energy bill in an
energy intensive industry by optimizing operational efficiency & maintaining stringent safety
standards through various conservation projects/ initiatives; some of which are:
• Reorganisation of Belt Conveyor network and optimizing Trunk Belt speed
• Reorganising Pumping & elimination of stage pumping
• Amalgamation of its adjoining mines & Rationalisation of working districts in
underground significantly helped in conservation of energy, manpower & other
resources.
• Optimising plant through put rate by installing higher capacity screens and reducing
down/ idle time at Washeries
• Rightsizing the Motor capacities of Pumps, Compressors, Belts etc.
• Shutting down uneconomical power generating units PH # 1&2- oil supported stoker
fired boilers using HV Coal with avg. generation cost @ Rs.3 per unit. It immensely
facilitated the conservation of HV Coal and contained the ever escalating power bill
• Invested huge money in strengthening & reorganization of power distribution network to
mininmise T&D losses and in installation of Capacitors Bank to operate at cost
economic optimum power mix. Twin objectives of energy conservation & containment of
power bill have been achieved with the above actions
3.32
3.18
3.5 3.01
2.85 2.91
2.64 2.65
3 2.43
1.92
2.5
2.29 2.4
2 2.37 2.48 2.47
2.29 2.36
2.09 2.13 2.18 2.16
1.5

1 1.45 1.54 1.44

1.37 1.42 1.32 1.42

0.5

0
1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02 2002-03 2003-04

Purchase Power Captive Power Combined Rate

3
 Collieries Division-Jharia, TATA Steel

Energy Conservation Plans and Targets

The division has definite plans on energy conservation & reduction in power consumption in
spite of ever increasing energy intensive operational & safety demands associated with
underground coal mining . The major ones are:
Energy Conservation Activities/ Plans Potential Estimated Schedule
saving Expenditure
(Rs.Lakhs) (Rs. Lakhs)
1 Recovery of prime coking coal from locked 125.00 75.00 March’05
up Fire area
2 Optimising Carbon recovery from prime 400.00 210.00 Jan’06
coking coal & Conserving electrical energy
by improving plant throughput at washeries
3 Installation of capacitors for improvement of 24.00 12.00 March’06
power factor at collieries sub station
4 Replacing overhead lines by u/g cabling to 14.00 34.00 Oct.’06
eliminate power theft
5 Identification & right sizing of Motors, Cables 24.00 64.00 March’05
etc.
6 Upgrading & Strengthening of transmission 28.00 38.00 July’05
network to minimize line losses
7 Reorganisation of Pumping 16.00 2.00 March’05
8 Phasing out ageing Motors, Electrical 55.00 68.00 Oct’05
equipments etc.
9 Fire Protection activities to contain its National 120.00 Continuous
propagation to virgin areas in u/g mines Duty
Some of the improvement projects/ initiatives identified through employees’ small group
activities/ cross functional teams have been listed out in the Annexure-
In addition, the initiatives like attending to water/ compressed air/ steam pipe line leakages
/replacement of damaged pipes, replacement of energy saver bulbs in phases, extensive
recovery of blocked coal in underground through stowing etc are part of our Annual Business
Plan .

Environment & Safety:

The mined coal is transported from the underground face at a depth of 600m through a series
of Coneveyor network to the Washery at the surface. After benificiation at Washeries, the fines
rejects (Tailings) are sold to Briquette & Clin and the coarser one is utilized for generating
power .Bed ash & Fly ash from Power Plant are utilized respectively for stowing in
underground voids and filling of low lying areas / degraded land on the surface- a unique eco-
friendly system of taking out coal from mother Earth and filling it back with its by
products- nothing left unutilized.
It is guided by its EHS Policy( enclosed). EMS 14001 certification has been effectively
sustained. Its mines have been selected as model mines for conducting joint risk assessment
with Indian & USA Directorate General of Mines Safety. It has implemented Green Cross
movement on safety and OHSAS 19001 implementation is in progress
The Division has dedicated departments to monitor and improve safety, occupational health,
and environment.
Its Pioneer effort in the areas of environmental protection and conservation of energy by
generating -“ Power from Waste” has been duly acknowledged & recognized by PCBs.
It has won major awards in the areas of Safety & Pollution Control and Some are listed in the
Annexure

4
TATA Steel-Jharia Collieries Division

KEY BUSINESS PROCESS

Underground Coal
Beneficiation of Coal
Mining
JH / ECA-02
 Jharia Collieries Division : Production Process schematic Diagram (JH/ECA-01)
DSS : De- sliming Screen
SS : Sizing & Screening DSS
DMC : Dense Media Cyclone Re circulated
FFC : Froth Flotation Cell Fines decanted
Coarse (R.C.D) Water
WLS : Wagon Loading System
CPP : Captive( FBC) Power Plant
SDL : Side Discharge Loader DMC FFC Settling Ponds
B & P: Bord & Pillar Clean
Tailings
WTP : Water Treatment Plant Rejects Coal
P : Pumping Washery (CC)
Tailings for
WLS Briquette etc.
ROM Coal
CC
R.C.D Water CPP Bunker TISCO
Crushing
WAGON CC to SAIL
Fly Ash
Sizing / IISCO
WTP
Screening Settling Ponds Bed Ash
Sand from River TM /
Others
Winder To CPP
ROM Fly Ash Water To Stowing
Silo Bricks Stowing
Chamber

Land filling & degraded Shale

land reclamation,
Plantation/ Vegitation
Sand Stone

Caving Stowing
Drifts

Development B&P
ROM Coal
Conveyor Belt
network from u/g De-Pillaring Stowing
to surface Supporting
Drifts
u/g Loading on
Bunker Blasting Drilling Coal Pillar
Belt by SDL
Transport Track Pumping Station
P

TATA Steel P P P
 MATERIAL & PROCESS FLOW (tons per day- tpd) CHART : JHARIA DIVISION ( JH / ECA-03)

JAMADOBA GROUP SIJUA GROUP

JAMADOBA DIGWADIH 6&7 PITS BHELATAND SIJUA

RC RC Q=1030 RC Q= 1100
RC Q= 1000 RC Q=1050 Q=1000 A= 25.50%
A= 24% A= 22% A=22% A= 26.75%
Q=2130
Q= 3050
A= 26.25% BHELATAND COAL PREPARATION PLANT
A = 22.96% RC Q= 2050
JAMADOBA COAL PREPARATION PLANT M= 4.57% A= 26.00% LARC
RC
Q= 3050 , A = 22.92%, M=4.57% Impactor
Q = 91 LEGEND
Rotary Breaker / Crushers Q= Quantity in tpd, A= Ash % ,M= Moisture% Coal Handling Plant Q= 250
Q= 2959 , A = 22.92%, M=4.57% S= Size(mm), RC= Raw Coal , CC=Clean Coal S= 25 X 0 mm A= 16 %
Rotary Discard Y= Yield % A= 26 % M= 7 %
Coal Handling Plant Radial Blender
S =(-)15 mm To +0.5 mm S= (-)0.5 mm , Q =533
S= 25 mm x 0.5 MM , Q =1640 S= 0.5 x 0 mm , Q =410
Q = 2426

Dense Media Cyclone Froth Flotation Cell

Dense Media Cyclone Froth Flotation Cell
Froth
Tailing
Rejects A- 42%
A- 46 % Screen Bowl Q-85 Rejects Middling
Q- 461 Centrifuge A- 64 % A- 38% Tailing
M- 8% A- 42%
Q- 242 Q- 250 Centrifuge Screen
Clean Coal M- 6 % M- 6 % Q- 98
A- 14.5% M- 25% Bowl
Clean Coal
Q- 447 A- 17 % Centrifuge
Coarse Coal M- 20% PONDS Q- 1148
M-6.5% Clean Coal
Centrifuge A- 13.5%

SALE Clean Coal SALE SALE Q- 312

10MW 10MW M- 21%
A- 17.5%
FBPP Q- 1965 FBPP
Q= 2412 M- 6%
A= 17%
M=10% Sale Clean Coal Stock Pile
Y=81% DESPATCHES
Q- 1460, A- 17%
Q= 128 M- 9.5%
A= 17% Q- 1710
M=10% Jamshedpur Sale Q=2284
A- 17%,
A= 16.94%
SD= 0.19 Cokeries M=10.19%
JAMSHEDPUR M-9.5%
 Depth wise production in %
Arduous Geo-Mining conditions of TISCO u/g Mines; + 50%
production from depth+ 300m against 6% of BCCL who is only
other player in Jharia Coal Fields
60 54
50
41.46
40 37.29

30 25.72
20.28
20 15.54

10 5.66

0
Meters <100 M 100-200 200-300 >300 M

BCCL TISCO

Jharia Division
TATA Steel
DISCOMFORT INCREASES WITH DEPTH
1960 1975 1990 2000 2002

850’
950’

1250’

2000’
2400’
960F
970F

880F
TEMP.0F

830F

800F

850’ 950’ 1250’ 2000’ 2400’

WORKIG DEPTH IN FEET
Collieries Division-Jharia,
TATA Steel
Coal Preparation Activity – Manpower intensive
manual Drilling Operations in u/g Face

Jharia Division
TATA Steel
Productive & Safe Mechanized Drilling Operation in u/g Fcae

Jharia Division
TATA Steel
After Blasting Coal Face Dressing Activity in u/g Face

Jharia Division
TATA Steel
Manual shoveling and loading of blasted Coal in u/g Face

Jharia Division
TATA Steel
Manual Loading of coal by miner in u/g

Jharia Division
TATA Steel
Mechanized loading of coal by SDL- Side Discharge Loader

Jharia Division
TATA Steel
Mechanized Coal getting( cutting & loading from one m/c) operation
by ROAD HEADER m/c

Jharia Division
TATA Steel
Coal Evacuation in mine TUBS in u/g

Jharia Division
TATA Steel
Coal Evacuation by BELT CONVEYOR in u/g

Jharia Division
TATA Steel
Roof Support by Timber in u/g

Jharia Division
TATA Steel
Inspection of Cog stool support by Mining Sirdar &
Overman

Jharia Division
TATA Steel
 Economic Viability , Productivity & Safety of u/g caol mine is dependent on Energy intensive
Mechanisation
Total Production Vs Mechanized Production

18 120.0

16.13
16 15.61
14.72 100.0
14 13.46 13.62
12.96

12 80.0

10

60.0
8
6.59

6 5.55 40.9 40.0

35.6
3.87
4 26.3
2.76 2.9 21.3
20.5 20.0

2
1.11
8.6

0 0.0
1998-99 1999-00 2000-01 2001-02 2002-03 03-04

Mech Production Total Production % of Mech Prod. Jharia Division

TATA Steel
 Industry Comparisons on Underground Mine
Productivity : Output per man shift
0.92

0.8
OMS in tonnes

0.6

0.4

BCCL
0.2 TISCO
ECL
CCL

0
1981-82 1986-87 92-93 97-98 2K-01 2002-03 2004-05

Jharia Division
TATA Steel
Coal Preparation Plant / Washery: Raw Coal Distributor .
Blending for optimum Yield
Coal Preparation Plant / Washery:Thickner
Optimum Recovery of Carbon
Coal Preparation Plant / Washery: Screen Bowl Centrifuge.
Dewatering for water recovery & environmental protection
from effluents
Coal Preparation Plant / Washery: Sized, Screened &
beneficiated Washed Coal for Wagon Loading
 Beneficiation Process :Tata Steel
capability to beneficiate Indian coals
24 Ash% of coalr eceived St eelPlan t s Vs. T at a St eel
22.5

22 18 . 9

20
19 . 4

18

16
16
14

12
CI L T at a St eel
10
19 7 3 19 7 6 19 7 9 19 8 2 19 8 5 19 8 8 19 9 1 19 9 4 19 9 7 2000 2003

Source: Report of Working group on coal & lignite for 10th 5 Yr. Plan (2002-07)Jharia Division
Govt. of India Ministry of Coal , Nov. 2001 TATA Steel
Capacitor installed at 33 KV RS-Bhelatand

Jharia Division
Jharia Division
TATA Steel
TATA Steel
Capacitor installed at 33 KV RS-Jamadoba

Jharia Division
TATA Steel
 Improved Plant Load Factor & Availability of Captive Plant

120

95.17 96
100 94
91.71
89.42
84

80
80.7
77.06 78.5
74.76 76
70.85
60

40

20

0
1998-99 1999-00 2000-01 2001-02 2002-03 03-04

Availability Load Factor

Jharia Division
TATA Steel
 Eco-friendly Processes
• Closed Circuit Washeries
• Zero Effluent Discharge
• Reducing water and air pollutants
• Reducing Timber Consumption
• Waste discharge elimination
• Water conservation
• ISO –14001 Certification
• 10MW Washery Rejects based Power
Plant. Jharia Division
TATA Steel
Environment friendly Coal Preparation / washery Plant

Jharia Division
TATA Steel
Settling pond filled with washery effluent before
decanting/ removal

Jharia Division
TATA Steel
Clean water collected at the end of Settling Pond

Jharia Division
TATA Steel
Bed Ash of Power plant used for STOWING-
mother Earth gives Coal & takes back its product

Jharia Division
TATA Steel
Subsided land surface

Jharia Division
TATA Steel
Reclamation with Fly ash for Park development

Jharia Division
TATA Steel
Overview of Sir Dorabji Park-TISCO, Jamadoba.
Developed by Environment Cell on Fly Ash

Jharia Division
TATA Steel
Awareness on Conservation through Displays of
EVA( Economic Value addition) Meters

Jharia Division
TATA Steel
Awareness Displays on Conservation at
Jamadoba Washery

Jharia Division
TATA Steel
 Collieries Division-Jharia, TATA Steel

List of Power Saving Projects completed during FY03-04

Jharia, TATA STEEL

Sl. No. Project Title/ Summary Savings (Rs.L)

1. REDUCTION IN POWER CONSUMPTION ON PUMPING 59.59

& IMPROVING THE AVAILABILITY OF RAW WATER
TO CAPTIVE WATER TREATMENT PLANT IN JAMADOBA

The 1408RL in 16 seam of Jamadoba colliery there are 9 pumping units installed. Out of 9
units, 5 are type-III x 9 CHR, M&P pumps with 350 KW motors and 4 units are type-III x 6
CHR, M&P pumps with 300 KW motors. The type-III x 9 CHR pumping units are discharging
at 3 pit surface reservoir and type-III x 6 CHR units are discharging at 2 Pit dam in
underground. At 2 pit dam there are 5 unit of type-III x 6 CHR pumping units which are
delivering at 2 pit surface reservoir. The surface reservoir at 2 pit caters raw water to 2 pit sand
stowing plant and 2 pit water treatment plant.
At 3 pit surface reservoir a 90 KW, split casing centrifugal pump a installed which supplies
water to 10MW power plant, 2 pit water treatment plant, colonies, 2 incline etc. Since water
supply to 10 MW power plant and the stowing plant always remains on top priority, scarcity of
raw water has been faced by the water treatment plant, particularly during monsoon period

2 REDUCING POWER CONSUMPTION OF MAIN 8.5

MECHANICAL VENTILATOR AT JAMADOBA

For mine ventilation at Jamadoba Colliery, Voltas make, VF3000 type fan with 337 KW,
Synchronous Induction Motor is installed at 3 pit. There is SIROCCO make Axial Flow fan
with 200 HP synchronous motor, installed at 3 pit and the same is used as stand by main
mechanical ventilator Reduced power consumption of main mechanical ventilator has resulted
in a saving of Rs.8.5L

3 INCREASING UTILISATION OF STOWING PLANTS 5.43

IN TERMS OF TPH OF SAND STOWED, 6&7 PITS

With the increase in stowing demand, rate of stowing had to be increased to improve the
efficiency of plant Amount of sand stowed increased from 1,45,012 tones to 1,90,090 tones in 7
months. With increased stowing less water was required to be pumped out saving the power
consumption.

1
 Collieries Division-Jharia, TATA Steel

Sl. No. Project Title/ Summary Savings (Rs.L)

4 REARRANGING OF PUMPING LAYOUT IN 45.2

6&7 PITS COLLIERY

Pumping out capacity from dip most area to surface was in sufficient and unnecessary pumping
station was used, the layout of pumping in 14 seam & 11 seam was not proper. Elimination of
two pumping stations and increase in pump out capacity from dip most area to the surface.
Also concentrating on dip pumping by avoiding stage pumping has resulted in saving of power
consumption at 6&7 pits colliery

5. REORGANISATION OF PUMPING CIRCUIT 2.26

IN 2 PIT 10 SEAM (WEST SECTION), SIJUA

In 2 pit 10 seam of Sijua colliery one 6L3 pump was installed at 15 th level/1st dip to handle
stowing water as well as make of water of east section & thus resulting more pumping cost.
Reorganization of was done and 6L3 pump was eliminated. A saving of Rs.2.26 L has been
achieved.

6 IMPROVEMENT IN RATE OF STOWING 5.2

IN 2 PIT SIJUA COLLIERY

In Sijua 2pit the ratio of coal output to sand stowed is 1:2.97. Therefore, for 500 TPD of
production from 2 pit total stowing requirement is 1485 TPD. This requires 23 hrs. of stowing
per day at the present rate of 63 TPH.At 700 GPM of water requirement for stowing , total
consumption of water for 23 hrs. of stowing is 9.6 lakh gallons of water per day which needs to
be pumped out. Improving the rate of stowing to 90 TPH will reduce the water requirement to
6.93 lakh gallons therefore a saving of Rs.10 Lakhs per annum on pumping cost alone
At present the rate of stowing is 63 TPH in 2 Pit, requiring 23 hours of stowing per day. leaving
little time for plant or range maintenance or. Therefore in case of breakdown total stowing
requirement cannot be met. As a result required coal to sand ratio is not maintained. Therefore,
improving the rate of stowing will reduce cost of pumping and improve face availability
Actions Taken: Surface screen was constructed in north side of sand bunker to sort +5” size
pebbles. Size of the screen was increased to +4", Ergonomics’ of the chamber was improved by
bringing all controls nearer to the operator, improving lighting, steps ,regular housekeeping,
and proper seating arrangement, damaged pipes are being changed @ of 20 pipes per month
and daily inspection of the main range introduced, Daily inspection of range is being done as a
preventive measure to avoid breakdowns.

7 IMPROVING STOWING RATE AT BHELATAND COLLIERY 2.24

At Bhelatand colly the stowing rate was increased from 61.27 tph to 81.26 by Construction of
grizzly in north side of the sand bunker, increasing the Size of the screen to +2" & specially
designed nozzles for increasing the pressure of water, Reduction in no. of bends and
replacement of 4'' pipe by 6'' pipe at face

2
 Collieries Division-Jharia, TATA Steel

Sl. No. Project Title/ Summary Savings (Rs.L)

8 REDUCTION IN SPECIFIC POWER CONSUMPTION 3.29

BY USE OF SMALLER COMPRESSOR AT JCPP
Power consumption by compressor is high though requirement of compressed air has reduced
power consumption has been reduced from 11.73 Kwh/T of Rc to 11.51 Kwh/T of RC at
Jamadoba Coal Preparation plant achieving a saving of Rs.3.29L

9 REPLACEMENT OF DESLIMING SCREEN 0.8

HIGHER CAPACITY AT JCPP
At Jamadoba Coal Beneficiation Plant an improvement initiative was taken to enhance the
efficiency of desliming screen. The investment made in replacing the desliming screen was Rs.
16.00 Lakhs. It has resulted in a recurring saving of 0.8 Lakhs per annum.

10 ELIMINATING CONVEYOR 111 OF PRETREATMENT 0.5

PLANT AT BCPP

At Bhelatand coal preparation plant, conveyor 111 was causing frequent breakdown, a
modification ion in the layout was done eliminating the conveyor 111. It has resulted in saving
of Rs.0.5 L

11 REDUCTION IN AUXILIARY POWER 5.94

CONSUMPTION AT POWER PLANT

Power Requirement to the collieries are fulfilled by captive generation at Power Plant and
purchased Power from DVC. Customer needs Power Supply at Lower cost. The captive
generation cost is Rs. 1.31 whereas the purchase power cost is Rs. 3.10. Thus it is necessary to
reduce the combined Power Cost (Purchase + Generation).
The average auxiliary Power Consumption for the Power Plant during the period Sept ’03 to
Dec.’03 was 29452 Kwh / Day. This effects net Generation of the Power Plant and increases
combined Power Cost.
Actions Taken are: Replacement of motor at TRF TE-13 Screen by 37 KW motor- November
2003, Replacement of raw water pump motor for slurry system by 45 KW motor – December
2003, Installation of Belt weigher monitor at control room of CHP to monitor CHP feed rate.-
November 2003

12 IMPROVEMENT IN PLANT LOAD FACTOR 8.03

Power consumption in this division has increased with new installation of underground
equipment. In last year, there was power interruption in every shift during peak load period
which affected the production of collieries.
Remedial action was taken by staggering timing of Pumping and production load after
discussion with Head, Collieries. The transmission line was modified to connect additional
lighting load of Digwadih during low load period CT fan blade angle was increased To 350 ,
(b) all leakage was arrested and (c) Strainers were cleaned. These were completed on 10.6.03
and inlet- outlet temperature Difference was increased up to 12 0 C .Condenser vacuum has
also Increased from 660 mm to 675mm at a load of 9 MW
3
 Collieries Division-Jharia, TATA Steel

Sl. No. Project Title/ Summary Savings (Rs.L)

13 REDUCTION IN ELECTRICAL POWER CONSUMPTION 0.94

AT DIGWADIH NO.12 OFFICERS' CLUB AND GT HOSTEL
AMD IMPROVEMENT IN OVERALL AESTHETIC LOOK

Previously high power consuming luminaries were in use at both the places and illumination
was also not adequate . Moreover there used to frequent replacement of luminaries. High power
consuming luminaries have been replaced by energy saving luminaries improving illumination
as well as saving Rs.0.94 L

14 REDUCTION IN ELECTRICAL POWER CONSUMPTION 2.33

BY RE-ORGANISING POWER DISTRIBUTION NETWORK
IN DURGA MANDIR AREA OF 6&7 PITS COLLIERY

There were lot of unauthorized power connections taken by persons living in private houses of
the adjacent village thus increasing the power consumption. It was decided to divert the
existing LT overhead transmission line through another route so that the accessibility to the
same by villagers is eliminated. It has resulted in a saving of Rs.2.33 lakhs.

15 REDUCTION IN ELECTRIC POWER CONSUMPTION 3.07

OF JAMADOBA PROJECT OFFICE COMPLEX

The power distribution network of Project Office Complex was from cable laid over the roof
top of Project Office, where from huge unauthorized connection where taken by the outsiders
residing in the village adjacent to Project Office. This was causing more power consumption
and frequent breakdown of power distribution in the complex. Reduction in power
consumption has been achieved by reorganization the power distribution in the complex.

16 REDUCTION IN DOMESTIC POWER CONSUMPTION 4.42

OF STREET LIGHTS OF JAMADOBA GROUP

There were 422 numbers, 250 watts sodium vapor lamps in Jharia Division for street lighting
purposes in addition to 150 watts and 70 watts SV lamps. The power consumption of 250 watts
SV lamps are more than 150 watts SV lamps with nominal difference in illumination.
Replacement of all 250 watts SV lamps with 150 watts SV lamps in Jharia Division has
resulted in power saving of Rs.4.42 lakhs

4
 Collieries Division-Jharia, TATA Steel

Sl. No. Project Title/ Summary Savings (Rs.L)

17 REDUCTION IN DOMESIC POWER CONSUMPTION 9.04

BY UNDERGROUND CABLING ETC. IN NO.1 COLONY,
JAMADOBA

The actual power consumption of 105 nos. of quarters at No.1 Colony, Jamadoba was much
more then what should be because of power pilferage by the outsiders residing near the colony.
By modifying the power supply networks through underground cabling a power saving of Rs.
9.04 lakhs has been achieved

18 REDUCING DOMESTIC POWER CONSUMPTION 11.05

AT SIJUA GROUP

In Sijua group of collieries the domestic power consumption was high. The transmission
network has been modified to reduce the power consumption. It has been resulted in a saving of
Rs. 11.05 lakhs

19 PHASED REPLACEMENT OF GENERATING 1.65

TUBES AT F.B.C PLANT
In Captive Power Plant of Jharia division the generating tubes were having poor efficiency. The
tubes have been replaced in a phased manner incurring an investment of Rs.38.00 Lkhs. It has
resulted in a saving of Rs.1.65 Lakhs.

20 PHASED REPLACEMENT OF DAMAGED 2.65

WATER & COMPRESSED AIR PIPELINE IN COLLIERIES
In all the collieries of Jharia division compressed air is used for roof bolting operation and
water is used for quenching the dust after blasting the coal as well as for drinking purpose.
Replacement of theses damaged pipes has incurred Rs.28.00 Lakhs of investment and resulted
in a saving of Rs.2.65 Lakhs.

21 PHASED REPLACEMENT OF AGING MOTORS, 1.65

COMPRESSORS, TRANSWITCH UNITS
The equipments like Motors, Compressors, Transwitch units etc. are used in various
underground mining operations like transportation, Supporting, Pumping, stowing etc. The
replacement of these equipments in a phased manner has given a saving of Rs. 1.65 Lakhs. The
investment made for these replacements has been Rs.38.00 lakhs.

22 REDUCING POWER CONSUMPTION IN INDUSTRIAL 0.67

COMPLEX & OUTSIDE AREAS BY RE-ENGINEERING
THE LIGHTING ARRANGEMENT

In the Sijua Group Industrial Complex lighting power consumption was high leading to high
power cost. Rationalization of the lighting arrangement and simplification in the network has
reduced the power consumption in the industrial complex and surrounding areas. The saving
achieved is Rs.0.67 lakhs

5
 Collieries Division-Jharia, TATA Steel
List of Power saving Improvement Projects (2001-2003) Annexure-16
Jharia Collieries Division, TATA STEEL

Sl. PROJECT TITLE Year of Savings Savings Investment

No. Completion (KWH) (Rs.Lakhs) (Rs.Lakhs)
1 REDUCTION IN POWER CONSUMPTION ON PUMPING & IMPROVING THE 2003 2190809 59.59 16.00
AVAILABILITY OF RAW WATER TO CAPTIVE WATER TREATMENT PLANT
IN JAMADOBA
2 REDUCING POWER CONSUMPTION OF MAIN MECHANICAL 2003 312500 8.5 1.45
VENTILATOR
3 INCREASING SAND STOWING RATE(TPH) OF STOWING PLANTS 2003 199632 5.43 2.35
4 REARRANGING OF PUMPING LAYOUT IN 6&7 PITS COLLIERY 2003 1661765 45.2 0.26
5 REORGANISATION OF PUMPING CIRCUIT IN 2 PIT 10 SEAM (WEST 2003 83088 2.26 0.53
SECTION)
6 IMPROVEMENT IN RATE OF STOWING IN 2 PIT SIJUA COLLIERY 2003 191176 5.2 0.00
7 IMPROVING STOWING RATE AT BHELATAND COLLIERY 2003 82353 2.24 0.00
8 REDUCTION IN SPECIFIC POWER CONSUMPTION BY USE OF SMALLER 2003 120956 3.29 1.62
COMPRESSOR
9 REPLACEMENT OF DESLIMING SCREEN WITH HIGHER CAPACITY AT 2003 45000 0.8 16.00
JCPP
10 ELIMINATING CONVEYOR 111 OF PRETREATMENT PLANT 2003 18382 0.5 0.00
11 REDUCTION IN AUXILIARY POWER CONSUMPTION AT POWER 2003 218382 5.94 0.00
PLANT.
12 IMPROVEMENT IN PLANT LOAD FACTOR 2003 295221 8.03 0.00
13 REDUCTION IN ELECTRICAL POWER CONSUMPTION AT DIGWADIH 2003 34559 0.94 0.45
NO.12 COLONY
14 REDUCTION IN ELECTRICAL POWER CONSUMPTION BY RE- 2003 85662 2.33 0.16
ORGANISING POWER DISTRIBUTION NETWORK IN 6&7 PITS COLLIERY

15 REDUCTION IN ELECTRIC POWER CONSUMPTION OF JAMADOBA 2003 112868 3.07 0.25

OFFICES
16 REDUCTION IN DOMESTIC POWER CONSUMPTION OF STREET LIGHTS 2003 162500 4.42 1.27
OF JAMADOBA GROUP
17 REDUCTION IN DOMESIC POWER CONSUMPTION BY UNDERGROUND 2003 332353 9.04 0.27
CABLING ETC. IN NO.1 COLONY, JAMADOBA
18 REDUCING DOMESTIC POWER CONSUMPTION COLONIES 2003 406250 11.05 0.00
19 PHASED REPLACEMENT OF GENERATING TUBES AT F.B.C PLANT 2003 128000 1.65 38.00
20 PHASED REPLACEMENT OF DAMAGED WATER & CMPRESSED AIR 2003 245000 2.65 28.00
PIPELINE IN COLLIERIES
21 PHASED REPLACEMENT OF AGING MOTORS , COMPRESSORS, 2003 125000 1.65 38.00
TRANSWITCH UNITS
22 REDUCING POWER CONSUMPTION IN INDUSTRIAL COMPLEX & 2003 24632 0.67 3.80
STREETS BY RE-ENGINEERING THE LIGHTING ARRANGEMENT
TOTAL 7076088 184.45 148.41

Jharia
12/28/2004 TATA Steel
 List of Power saving Improvement Projects (2001-2003) Annexure-16
Jharia Collieries Division, TATA STEEL
Collieries Division-Jharia, TATA Steel
Sl. PROJECT TITLE Year of Savings Savings Investment
No. Completion (KWH) (Rs.L) (Rs.L)
1 IMPROVING RATE(TPH) OF COAL TRASPORT CIRCUIT JAMADOBA, 2002 129333 2.91 1.75
COLLY.
2 REORGANISING VENTILATION AT 16 SEAM IN D/NORTH SECTION 2002 411556 9.26 2.68
3 REDUCE PROCESS VARIABILITY BY OPTIMISING THE SAND:WATER 2002 449778 10.12 6.80
RATIO IN STOWING DISTRICTS OF 6&7 PITS COLLIERY

4 ELIMINATING STAGE PUMPING FROM B-DIP. 2002 1468889 33.05 18.00

5 BOREHOLE PUMPING IN 6TH INCLINE FROM SURFACE TO 16 SEAM 2002 512889 11.54 9.00
6 INCREASING RATE OF STOWING IN 2 PIT THROUGH BOREHOLE 2002 319111 7.18 9.79
7 REORGANISING SURFACE PUMPING AT BHELATAND 2002 215111 4.84 0.97
8 REORGANISATION OF BELT CONVEYOR SYSTEM IN 17 SEAM OF AT 2002 319111 7.18 4.24
BHELATAND A. COLLY.
9 TO REDUCE POWER CONSUMPTION IN FINE COAL TREATMENT 2002 170667 3.84 1.57
SECTION
10 REDUCTION IN POWER, FLOCULANT CONSUMPTION & IMPROVING SD 2002 397333 8.94 4.50
OF ASH OF FEED TO CYCLONE BY MODIFY RAW COAL DISTRIBUTOR.

11 REDUCTION IN AUXILIARY CONSUMPTION BY RATIONALIZING PRIME 2002 444 0.01 0.08

MOTORS
12 REDUCTION IN POWER CONSUMPTION IN PUMPING 2002 104000 2.34 0.10
13 UTILISATION OF CAPACITOR BANK DURING LOW LOAD PERIOD 2002 48889 1.1 0.00
14 REDUCTION IN CONSUMPTION OF ENERGY AT CENTRAL WORKSHOP 2002 75111 1.69 0.35
AND GARAGE
15 REDUCTION INPOWER CONSUMPTION AND IMPROVEMENT IN 2002 9778 0.22 0.68
ILLUMINATION WITHIN DIGWADIH COLLIERY OFFICE COMPLEX
16 REDUCTION IN DOMESTIC POWER CONSUMPTION BY INSTALLING 2002 1432444 32.23 5.86
ENERGY METER IN OFFICERS RESIDENCES ETC.
17 REDUCTION OF POWER CONSUMPTION IN SIR DORABJI TATA PARK 2002 14667 0.33 0.25

18 REDUCTION IN POWER CONSUMPTION OF TRUNK BELT BY 30% 2002 456000 4.85 1.68
THROUGH EFFECTIVE THRUSTER BRAKE ARRANGEMENT
19 REPLACEMENT BED EVAPORATOR TUBES IN F.B.C PLANT 2002 143000 1.5 35.00
20 REPLACEMENT OF AGING MOTORS, COMPRESSORS 2002 275000 3.85 25.00

6953111 146.98 128.30

Jharia
12/28/2004 TATA Steel
 List of Power saving Improvement Projects (2001-2003) Annexure-16
Jharia Collieries Division, TATA STEEL
Collieries Division-Jharia, TATA Steel
Sl. PROJECT TITLE Year of Savings Savings Investment
No. Completion (KWH) (Rs.L) (Rs.L)
1 REORGANISING BELTNETWORK IN N DIP 2ND BELT 2001 390213 9.17 0.10
2 REORGANISATION OF PUMPING IN 14 SEAM 4-S SECTION OF 883404 20.76 0.00
JAMADOBA COLLIERY 2001
3 INCREASING POWER FACTOR BY INSTALLATION OF CAPACITOR BANKS 923404 21.7 3.50
IN POWER HOUSE NO.3 2001
4 REDUCTION IN SURFACE PUMPING POWER CONSUMPTION. 2001 430213 10.11 0.07
5 REDUCTION IN SPECIFIC POWER CONSUMPTION 2001 530213 12.46 0.00
6 REORGANISATION OF TRANSPORT CKT OF DUNGRI NORTH SECTION. 72766 1.71 0.00
2001
7 OPERATING A1 BELT CONVEYOR OF JAMADOBA TRUNK NETWORK 151489 3.56 0.00
WITH ONE MOTOR 2001
8 REDUCTION IN POWER CONSUMPTION BY ELIMINATING MISMATCHES 84681 1.99 0.00
IN BELT CONVEYOR MOTORS. 2001
9 REDUCTION IN MAINTENANCE COST AND POWER COST BY 94043 2.21 0.00
ELIMINATING 306 SCREEN. 2001
10 REDUCTION IN POWER CONSUMPTION AND SPILLAGES BY 403830 9.49 4.80
MODIFICATION OF RAW COAL FEED BELT CONVEYOR NETWORK. 2001
11 ELIMINATING LEAKAGE RECIRCULATION PUMPS BY PUTTING DIVERT 180000 2 0.25
BALANCE VALVE WATER OF 14-SEAM H.T PUMPS TO ITS OWN SUCTION
LINE AT COLLIERIES 2001
12 IMPROVEMENT IN COMMUNICATION SYSTEM WITH PUMPING STATION 35000 0.4 0.10
AT WASHERIES 2001
13 REDUCTION IN PLANT LIGHTING AT WASHERIES BY USE OF PERPEX 64000 1.5 0.75
SHEETS IN BUILDINGS 2001
14 REPLACEMENT OF DAMAGED STOWING PIPELINES 2001 54000 1.1 6.00
15 REDUCTION IN COMPRESSED AIR PIPELINE LEAKAGES AT 6&7 PITS 24000 0.58 1.00
2001
16 INSATLLATION OF SCADA SYSTEM FOR CONTROLS AT POWER PLANT 134000 1.54 36.00
2001
17 REPLACEMENT OF STEAM TUBES AT POWER PLANT 2001 85000 1.12 25.00
18 REPLACEMENT OF 350 KW MAIN VENTILATOR FAN AT DIGWADIH BY 250 600000 7.75 16.00
KW KIRLOSKAR MOTOR 2001
19 SUBSTITUTION OF FREE DOMESTIC COAL BY COOKING GAS 0 14.5 18.00
CONNECTIONS TO WORKERS 2001
20 REDUCTION IN LIGHTING POWER CONSUMPTION INSIDE THE ADMIN. 49787 1.17 0.60
OFFICES 2001
5190043 124.82 112.17

Jharia
12/28/2004 TATA Steel