Mining Strategy for Excavating Steep Coal Seams

Sanjay Singh*

ABSTRACT
Coal reserves are available worldwide with recoverable reserves in 70 countries around the world. With the
current rate of consumption of coal in the world, the proven recoverable reserves of coal may only last for
another 147 Years. In contrast, proven oil reserves stand to last for 41 years and gas reserves stand to last for
63 year at the current usage rate respectively. Around 90% of the proven coal reserves are available in six
countries i.e. USA, Russia, China, India, Australia and South Africa. As per World Energy Council (WEC),
total world reserves of coal at the end of 2002 were around 909 billion metric tons (By rank world coal
reserves on tonnage basis are as - 53% Anthracite & Bituminous Coal, 30% Sub bituminous Coal and 17%
Lignite). If that is true then high grade Coal is only available for 78 years if the data published is correct.
The data on coal reserves is not accurately analyzed as the reserves were calculated on the basis that the
mining will be done with feasible mining areas, as per what is currently being mined. What has not been
taken into consideration is that cost of production of coal that is increasing all over the world because of the
development of new mining areas, difficult geological and local conditions, and additional infrastructure
costs and high fuel costs. Therefore the availability of recoverable reserves of coal is in fact decreasing.
Because of all this data, coal reserves that have been calculated by all the world bodies and organizations
concerned with such figures are looked at being overestimated amounts and the same is supported by the
fact that the world ‘in situ reserve’ has decreased from 10 trillion metric tons of hard coal in 1980 to 4.2 trillion
metric tons in 2005 (60% revision in 25 years as per Energy Watch Group, even though many new mining
fields have been explored during that period.).Looking at these facts on reserves of coal around the world,
this maybe depleted in less then 78 years because of the increase in consumption of coal as well as the
increasing costs of production.
The savior to this crisis in the future may well be the coal from Indonesia, as long as changes are made into
the thinking of how coal mines should work and new mining methods are adapted.
In this paper the author will focus exactly on that, describing to the reader the development of new mining
methods for steep and high grade coal seams in Indonesia and all around the world and for the recommendation
towards some change in mining strategy for the recovery of high grade coal, so as to maintain if not increase
the world’s proven coal reserves in a time of increasing mining costs and increased coal consumption.

INTRODUCTION coal and also provides better efficiency. Therefore 77% of

Indonesia has 6.97 billion metric tons of proven coal reserves
(Around 0.5% of the world’s total proven reserves of coal).
Around 83% of reserves are in the category of Lignite and
Sub bituminous coal and the remaining 17 % are in the
categories of Bituminous and Anthracite i.e. high grade
Coal. Indonesia is the second largest exporter of Coal and
7 th largest producer in the world. With the current
consumption rate of Indonesian coal, proven reserves of
coal in the country may deplete in 37 years, if new mining
fields are not developed.
Indonesian coal generally has a low ash and Sulphar
percentage with a high Gross Calorific Value (GCV) and is
best used as steam coal in power generation due to the
fact that it causes less pollution than using other types of
* Production Manager, Luwe Coal Mines, PT.
Victor Dua Tiga Mega, Central Kalimantan,
Indonesia
Indonesian coal is exported all around the world, to countries
like Japan, Korea, India, Philippines, Vietnam, Taiwan and
China, to meet their energy requirements every year.
53% of the world’s total reserves of coal is high grade coal
and is mainly located in countries (China, USA, Australia)
that are themselves thinking of reducing the export of their
coal, so that they can meet their own domestic requirement.
(China has already stopped their export). In fact the total
reserve of high grade coal is predominantly located in 2 or
3 countries and its fast depletion may threaten future energy
generation in a manner that is both economic and eco
friendly.
In today’s context, developed countries (USA, Japan,
Korea, etc) are trying to maintain the best environmental
norms when trying to produce energy for their domestic
use, pressured mainly by the Kyoto Protocol that was setup
to reduce the pollution produced by the developed countries,
as they were the biggest environment polluters based on

The Indian Mineral Industry Journal i ENTMS 2008

their advanced stages of their industrialization. Due to the
external pressures to industrialize in environmental friendly
ways and having the strong financial position, the developed
countries are able to utilize high grade coal, while the
developing countries are left to use low grade coal.
As reserves of high grade coal is limited, it has therefore
led to new innovations for power generation, so as to reduce
the pollution as well as the use of high grade coal with
methods such as, optimum blending of low and high grade
coal, cleaning of low grade coal, etc. What has been missed
out, which can make a big impact on this future problem is
the planned mining method & utilization of high grade coal.
Most of the coal deposits of Indonesia are having steep
seam structures with having high quality but with difficult
topographical, geological and environmental conditions.
Therefore long term mine plans are very much necessary,
with emphasis on how to mine such steep seam structures.
Mining Planning: Luwe Coal Mines, PT. Victor Dua Tiga
Mega, Central Kalimantan, Indonesia
In order to participate in the development of non-oil gas
energy sources, particularly coal, PT.VICTOR DUA TIGA
MEGA – an Indonesian private company has been allotted
an area of 3,464 HA for exploration and exploitation
purposes in the Central Kalimantan region of Indonesia.
The following factors were broadly considered during the
planning and designing of the opencast coal mines:
· Dip of Coal seam
· Depth of Coal seam
· Quality of Coal
· Selection of Mining Method
· Selection of Mining Equipments & others
· Pit limits for mining operation.
· Cut-off stripping ratios based on the cost of
production & the expected sale price based on
the market conditions for high grade coal.
· Availability of the land from land owners for mining.
The mining operation was planned for full recovery of
coal up to the optimum depth, which is the point (pit limit)
where the cost of production equals the revenue from sales)
so that natural resources may be utilized fully and hence
the reserves of coal as well as the life of the mine will be
increased for long term planning.
· Dip of Coal seam: Dip of the seam varies from 24°
degree to 47° in the Luwe coal deposit as per current
detailed report of exploration and mining operation. Dip
in between 24 - 45° are termed as steeply dipping
deposits and that restricts the operation of mining in
dip direction because of the cut off limit of stripping
ratios decided on the basis of topography contour
The Indian Mineral Industry Journal
survey, thickness of coal seam, dip of coal seam as
well as the cost to mine such seams and the potential
revenue from the sales of such coal.
· Depth of Coal seam: Luwe mines has a number of
outcrops at different locations with different thicknesses
of 0.2m to 1.2m, note that almost all the deposits of
coal start from a very shallow depth. Thus the
maximum depth of the recoverable coal is 35 - 45m
from the surface level but that also depends on the
topography and dip of the coal seam.
· Thickness of Coal Seam: The actual thickness of
the coal seam varies from 0.3 m to 2.7 m. The same is
required for the calculation of the cut-off stripping ratio
before starting the mining operation. Generally four
seams has been found in the concession area and
they are usually having the thickness of 0.8m, 0.9m,
0.3m and 2.7m as the 1st, 2 nd, 3rd and 4th seam
respectively.
· Cut-off Stripping Ratio: Stripping ratio is generally
expressed as a ratio in the proportion of overburden to
coal (Cum/MT). As the depth of overburden increases,
the more amount of money is spent for removal of the
overburden to expose and extract the coal. As this
ratio increases there comes a point beyond which the
coal can not be economically extracted out and this is
called the break even stripping ratio or cut-off stripping
ratio. Cut-off stripping ratio is decided on the basis of
the total cost of production versus the expected sale
price of that coal. This cut-off stripping ratio can be
increased if the price of coal increases based on the
market conditions or the costs of production decrease
due to improvements in the mining method and wastage
reductions.
· Pit limits for mining operation: Based on the contour
survey, dip of seam, thickness of coal, depth of
overburden, length of block in strike direction, & the
cut-off stripping ratio, the limit of pit/mine is calculated
in dip direction so that operation can be well planned,
maintained within the economical mining point (cut-off
point) and the smallest virgin area is disturbed for the
mining operation.
· Nature of Overburden: Overburden above the coal
seam mainly included top soil, hard silica sand & grey
clay stone. Generally the top soil is soft in nature and
may be excavated directly by excavators but the silica
sand and grey clay stone are hard in nature as such
rippers along with dozers are used for loosening of the
hard strata instead of using other methods such as
blasting because of the local constraints. These local
ii ENTMS 2008
 constraints usually relate to the local community in
these areas, hence making blasting a non usable
method, due to the dangers it may bring about in terms
of injury, noise and destruction.
· Quality of Coal: Sample of the outcrop coal has been
analyzed for proximate analysis as received /dry basis
before starting the mining operation. The same is
required to predict the limit of stripping ratio as well as
the future selling price. The quality of coal in this area
varies from 5300Kcal /Kg to 6300 Kcal/Kg (Prime High
Grade Coal).
· Land availability for mining: Before starting the
exploration and drilling activity as well as mining
operation, the management has to get permission from
the respective land owners as well as negotiate a
compensation rate for using their land to extract the
coal. Note it is not compulsory for any land owner to
give his land to the concession owner to mine in
Indonesia and it is up to the management’s negotiating
ability. Also due to the unmarked lands, it results in
disputes between two land owners, thus involving the
village head as well as the local land department. This
may at times delay the operation as it takes time to
find the right papers and records in the department’s
data base, as well as come to a conclusion as to whose
land it may actually be. This may at times, even lead
to change in planning of the mines, as certain lands
may not be used due to conflicts or the reluctance of
the land owner to provide the land for mining.
Ø Mines Working:
· As coal deposits are outcropped and the gradient
is steep, therefore the opencast mining method is
the best and most economic method that should
be used.
· As 90% of the strata is hard clay stone, the height
of the overburden bench may be kept up to 8m
without problems of any slope failure.
· Height of benches is restricted by a maximum 8m
and if the height of the overburden is greater then
its negotiated by making a number of benches,
each time leaving a bench width of 1.5 - 2m to
maintain an optimum ultimate pit slope of 85°.
· The ultimate pit slope as well as the bench slope,
considered up to 85° as at the end of the limit,
allows the reclamation process to start early.
· Steep ultimate pit slopes are considered because
of the hard clay stone in overburden, the hardness
of the strata facilitates the full recovery of coal
reserves from the benches.
· Height of benches, slope angle and width of
benches are kept as follows:
§ Bench Height - 8 m Max
§ Bench Width - 1 . 5 – 2 m
Min.(For Ultimate Slope)- 4 m
(During working)
The Indian Mineral Industry Journal
§ Bench slope - 70°
§ Ultimate pit slope - 85°
§ Number of benches
- Depends on depth of working.
· Normally the mines are developed in a strike
direction and then progress is made in the dip
direction for optimum production and productivity.
Ø Haul road Design: As the deposit is of a steep
gradient and as such the development in each mine
becomes deeper and deeper, therefore the gradient of
the haul road and its location also becomes critical,
hence the following precautions are taken during the
design of the haul road:
· Design of permanent haul road at end of pit i.e. pit
limit.
· Gradient of haul road kept to a maximum of 1:10
at some places to recover the coal at greater
depths.
· Initial road gradient is maintained up to a ratio of
1:16 to 1:20.
· Proper drainage system has to be made so that
the roads are not under water when it rains, based
on the topographical data which is taken during
the exploration stage.
Ø Overburden Disposal area: Overburden is dumped
in the disposal area outside the excavation area of the
mine. All the overburden material is dumped in the
designated area with the help of Dozers and Loaders.
· Disposal area is selected near the mine pit and
not having any coal deposits.
· The angle of inclination of disposal area is
maintained at a maximum of up to 37 ° or up to the
natural slope to avoid slope failure.
· Height of the bench is restricted by a maximum of
8m and the heightening of the disposal area is done
by leaving a 4 - 5m width, for the proper stability of
the disposal area.
· Height of the disposal area may be maintained up
to 30 - 35m, based on the size of the disposal
area and by making 4 benches by spiral dump
process, with the gradient of the haul road at a
ratio of 1: 10.
· In the case of there being a shortage of external
disposal area, the mining method maybe changed,
so that the mine is developed in the dip direction
and then progress is made in the strike direction.
Thus the reclamation of the mined out area is done
sequentially using the most optimum area for
disposal.
iii ENTMS 2008
 · The top soil is preserved at a specified location for
its spreading on the top of the mined out area for
rehabilitation of the area.
Ø Mine Drainage & Pumping: The area of the Luwe
mines has a number of small rivers that disturb the
overall mine working and layout. In most of the cases
it is very difficult to divert the rivers because of the
topography as well as getting the permission of the
local land owners (who may use the river for various
things). Therefore suitable precaution has to be taken
to protect the mine from such rivers. Normally the water
accumulates only in the monsoon period, because of
the continuation and intensity of the constant rain. This
monsoon period, in the central Kalimantan region
ranges from September to April (8 months). Average
rain fall in this area is 446 mm per month and average
rainfall per month is around 9 days (estimates).Therefore
the following controlling measures are adopted to control
the surface and rain water during this period:
· Most of the rain water should be diverted to
other places by following the natural drainage
contours. In any case the pit floor of the mines
and other areas are well sloped (2°) and graded
to divert the rain water from the mine pit.
· In the case of an area having hillock
topography, the mine is developed in a strike
direction to divert the rain water by making a
suitable drain that is lower down the elevation,
hence draining the rain water away with the
help of gravity and without using any pumps.
· As the size of the mine working area increases,
the catchments area will also increase and
thus making it difficult to avoid to a certain
amount of rain water based on the high rainfall
in the monsoon period. Therefore suitable
sumps are made at the lowest point of the
pits, to collect all the water in one area rather
than have it spread all over the pit area.
· Pump of suitable capacity is selected and
installed in the sump for dewatering of the pit.
· Normally centrifugal diesel pumps are installed
in the pits, because of the ease in operating
procedure and frequent shifting.
· Mine areas that are near active rivers are
planned to be excavated out in the dry period,
so as to not take a risk in terms of having the
river break the banks and flood the mine area,
affecting the equipment and personnel.
· Mine areas are planned, so that they are
protected from the river by making a suitable
embankment. Though sometimes it maybe
restricted because of the flow of water, therefore
it is planned that a minimum 5m area along
the river will be left without mining so that the
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problem of inrushing water in to the pit may be
avoided.
· In the case of a river existing at the centre of
the coal deposit and there being no chances
of diverting the river due to topographical
reasons, then the mine operation needs to
become quick and concentrated so as to
excavate the maximum reserve in the dryer
period, before the start of the monsoon period.
· Submersible pumps as well as centrifugal
pumps of higher capacity may also been
planned for fast dewatering of the pits in the
future as the size of mine area increases.
Ø Method of working:
· Removal of all trees or bushes that are present
over the site of the planned mining pit, either
with the help of a dozer or by excavators.
· A box cut is made over the top soil or hard
clay stone present over the coal outcrop. This
box cut is made along the strike direction from
the outcrop of Coal deposits and to be touched
up to the ends of the boundary of the mine.
· Box cut is made directly by Back hoe
Excavators in case of loose strata or with the
help of Dozer cum Ripper in case of Hard
strata.
· Permanent haul road is made along the pit
limit location.
· Selection of site for disposal area as well as
Top soil storage and its leveling, dozing and
Carpeting by Clay stone before starting of
mining operation.
· Deployment of Backhoe excavators and
Suitable DT at planned location on the basis
of pit limits area, production plan and mine
working plan.
· Normally around 25-30m area allotted for one
excavator with suitable deployment of DT
based on lead from pit to disposal area, and
capacity of excavators in Overburden strata.
· Dozer cum Ripper is mainly used for ripping in
hard clay stone to improve the loading efficiency
of excavators as well as disposal area.
· Selection of disposal area is mainly done
nearby mine pit with maximum lead of 1 km..
· Mines are developed in strike and then
progress in Dip direction.
· Sequence of mining and reclamation are
followed one by one, after recovery of all Coal
from one mine pit, that area used as disposal
area of next pit adjacent to the same pit.
Ø Land Reclamation and Rehabilitation:
After total winning the Coal the mined out area is
iv ENTMS 2008
 planned to be backfilled with the Overburden and
area is well leveled with help of Dozer, Loader,
Grader and Vibro as required and top soil is spread
on the same for normal vegetation.
The mined out area is leveled and dozed, as required
by particular land owner and the same land is
returned to particular land owner after completion
of mining.
Some times the mined out area is converted into
water pond, fish firming or water reservoir as
required by particular land owner. Conversion of
mined out area in to water reservoir facilitate the
charging of water level in nearby area, generate
earning to owner by making fish firming, facilitate
the water requirement for greenery of nearby plants
and tree in dry periods. The conversion of mined
out area into Water reservoir may also be planned
as per land owner requirements.
Following Points may be considered by Mining
Authority for making their strategy of Mines operations:
1. Feasibility of underground mine/Coal gasification
for winning of high grade after certain depth Coal
may be review after completion of mining operation
by opencast mine.
2. Reclamation process of Opencast mine may be
review whether it will affect the operation of
Underground mine/Gasification plant in future or
not.
3. Disposal of Overburden in front of deposit after pit
limit should not be encouraged, as the same Coal
is available at greater depth may be mines depends
on the sale price of Coal.
4. Employment of competent person in Mining
Department to review mining operation and plan in
With Best Compliments From:
Luwe Coal Mines, PT. Victor Dua Tiga Mega,
Central Kalimantan, Indonesia.
The Indian Mineral Industry Journal
totality and complain of NGO, locals etc should
be review by technical person as most of the
complains all around the world is for personal gain
by making pressure on mine management.
5. Schedule Inspection of Mining authority should be
for done solving the field mining problem as
technocrats and not like police –Theft relationships.
Mining authorities should promote and motivate
economic and eco friendly mining operation
technically in long term with field Mining Engineer.
6. More strict rules should be framed and
implemented for Illegal Miners.
7. Land owner in mining lease area are making
difficulties for Exploration and Exploitation
operation and in some cases systematic operation
is not possible because of non availability of the
land, necessary support should be provided to mine
management for systematic mining operation.
CONCLUSION
Indonesia has lot of mineral resources and their economy
is also growing because of improvement in production of
minerals but they are in preliminary stage of making &
implementation in their mining policy,& legislation for
effective and economic mining operation.
They have to increase their exploration activities, Investment
in power plant run on low grade Coal, opening of low grade
Coal mine for domestic use, faming & implementation Mines
draft, Motivate foreign investors by considering the all aspect
of market as well as their domestic requirement may lead
Indonesia to new era in this world.
ACKNOWLEDGEMENTS
The view given in this paper is solely of author and not the
view of company in which he works. Author is thankful to
Mr. Mohit Maheshwari and Mr. David - Directors of the Mines
for their approval to publish this paper.
v ENTMS 2008