company is incorporated in the year 1995 for the manufacturing of underground
coal mining equipment, namely Hydraulic props, legs and Valves for Powered Roof
supports and Armoured conveyors. With its vast experience in the manufacture of
mining hydraulic equipment and high tensile steel fabrications, the company in collaboration
with Indian School of Mines (I.S.M) Dhanbad has submitted a joint E.O.I bid to
CMPDI for the development of Self Advancing (Mobile) Goaf Edge Supports (SAGES)
for depillaring operations in underground coal mines . The project for
development of 6 nos of Mobile Roof Supports was sanctioned under S&T
projects of Ministry of coal Government of India in the year 2010. After
development of the Mobile Roof Supports and undertaking required modifications
based on the field observations the project is successfully completed in May-2014. Now it is possible to indigenously
manufacture the Mobile Roof Supports of required capacity and operating range
to suit the mine workings.
Mobile Goaf Edge Roof Supports (Jaya Bharath-
state of the art Mobile Roof Supports (Jaya Bharat-MRS) for use as goaf edge
supports during extraction of coal by depillaring method from room and pillar
workings are developed using a patented design concept of “Base lift
mechanism”. This unique advanced design facilitates reduction in Support weight
and cost up to 70% when compared to the weight and cost of the conventional Mobile
Roof Supports that are available in the international market today. In the
conventional Mobile Roof Supports the Support crawlers have to be designed to
withstand the load equivalent to rated load bearing capacity of the Support
including its own weight i.e for a Support weighing 30.t and rated at 400.t the
Crawler frames have to be designed to withstand a total load of 430.t. In the
“Jaya Bharat-MRS” of the same capacity, the roof load is directly transferred
to the floor via the sliding Base frame, the load on the Crawlers will be zero
in the support mode. After release of the load and lowering of the Canopy, the
Base gets lifted up and the Support weight is transferred on to the Crawlers. In
the transport mode the Crawlers will carry only the support weight of about
12.t. This feature of the “Jaya Bharat-MRS” makes it lighter and cheaper. Further
the Support uses only two Hydraulic cylinders along with Canopy stabilizers
compared to that of four to seven Hydraulic cylinders and elaborate linkages
used in conventional Mobile Roof Supports.
the application of the above mentioned unique features i.e the “Base lift
mechanism” and Canopy stabilization, the “Jaya Bharat-MRS” have become compact,
light weight and cost effective with minimal maintenance.
Hydraulic circuit of the Support is operated by a self contained power pack
through solenoid valves. The solenoid valves are operated by a RF based remote
hand set from a distance of up to 100 m. The Support is covered from all the
sides either with foldable steel plates or chain curtains for preventing the
coal and rock debris entering in side the Support during side spalling and rock
falling from the roof. An electronic data logging and display system having
battery back up unit, facilitates continuous monitoring of the roof load and
convergence. An audio-visual warning system is in-built into the system for
giving warning related to status of strata load on supports.
Almost all mines with Room and Pillar workings with Continuous Miners in U.S and South Africa use Mobile Roof Supports ( MRS) as Breaker line supports. It has been proved in these countries that after switching over to MRS from other means of Breaker line supports such as Roof bolts and Timber Cribs and Props the accidents rate has fallen down and the percentage of extraction and overall production have increased by at least 10%. High cost of imported MRS and low coal prices in India are the reasons for keeping away the MRS from Indian coal mines having Room and Pillar method of extraction. As cost of SAGES will be less than 25% of that of imported MRS even with 10% increase in production that will be achieved without incurring any additional costs towards roof support and infrastructure establishment the payback period of SAGES will be less than one year.
Even without considering the increased production, the owning and operating cost of SAGES will be comparable to the installation cost of Breaker line supports with Roof bolts or Steel/Timber Cogs& Props along with Strata monitoring instrumentation.
Deployment of MRS at goaf edges not only facilitates enhanced safety and production but also builds up confidence among workmen working in hazardous mining environment.
Annual Deployment Cost Of SAGES
A. COST OF FOUR 500.TONNE CAPACITY SAGES FOR DEPLOYMENT WITH CONTINUOUS MINER WORKINGS: