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Krupp Industries India - Detlev L. Schroeder - Krupp Foedertechnik, Germany

ABSTRACT

The opencast method used for mining hard coal and rocks requires drilling and blasting of strata which causes considerable investments and also creates an adverse impact on the environment & safety. These disadvantages demand the introduction of improved technology for blasting free, safe, eco-friendly and economic mining. By continuous research and also experience gained from the rock cutting technology with the application of road header etc. it has become possible to do mining without blasting by a continuous surface miner for hard coal and rocks. Krupp Födertechnik, Germany has developed Krupp Surface Miner (KSM 2000) which can work in medium-hard and hard coal and also in overburden very efficiently up to 40 MPa and in special cases like small lenses and/or thin layers up to 120 MPa of compressive strength. The article has been written with a special focus to Krupp Surface Miner (KSM 2000).

PRESENT MINING SCENARIO IN INDIA

India ranks third in terms of coal production in the World today coming after China & USA. While coal production is declining in western countries, in India, it is on an increasing trend. From a level of around 30 million tonnes per annum at the time of independence of the country, the all India coal production has already reached a level of 290 million tonnes in 1998. The trend is likely to continue in the future also. By 2001-02 annual coal demand has been estimated as 400 million tonnes in India. Such a flamboyant growth in coal production can only be met through large-sized opencast mines in the future. Out of the two broad modes of mining i.e. opencast and underground, the emphasis is given mainly on opencast due to its favorable economics, safety, large coal recovery, better output per man shift (O.M.S) and also lower gestation period.

Till now modernization of opencast mines are done mainly by upgradation of sizes for conventional equipment like shovels, dumpers, drills etc. The conventional mining shall continue with drilling and blasting, which is causing serious threats to environment and safety. Blasting is the cause of vibration, dust, noise and noxious Nitrous fumes. Besides, it also requires shifting and rehabilitation of villages situated in and around the mine site. Many of the opencast mines in India have come in close proximity of human habitats and forestland and as such, DGMS has already imposed restrictions against heavy blasting operation. Some of these locations in Mahanadi Coalfields Ltd. (MCL) are indicated below:

i) Lakhanpur OCP – On the West Side, workings have come to a standstill as Ghanmal village has come within 150-m. of the opencast workings. About 1.5 million te of exposed coal is awaiting extraction. Total coal reserves calculated upto 45-m. of the village boundary (which can be conveniently extracted by surface miners) works out to be 2.2 million te.

ii) Lingaraj OCP - The eastern flank of the overburden face has come within 120-m. of village Balugaon and further progress of the mine has been stopped. As estimated, around 1.0 million te of coal can be further extracted within 45-m. of the village boundary.

iii) Belpahar OCP - Daripali village on the north and Chharia village on the south have come within 200-m. of opencast workings. Workings have been severely restricted with about 0.3 million te of exposed coal awaiting extraction.

iv) Jagannath OCP - Balanda village on the north has come within 150-m. and Purnia village within 170-m. of the working face posing serious restrictions on further progress of the mine.

The above are few examples out of many such present and future situations in opencast mines in India. Shifting of villages in India is a big task. This directly increases cost and gestation period of the projects. Sometimes, even after having settlements & accordingly making huge investments for shifting & rehabilitation of villages and also procurement of costly equipment, situation ultimately compels reduction of the size of the mine for not really able to shift the villages from the mining boundary. Mining operations are also interrupted frequently by local villagers for the adverse effect in their houses due to blasting operation in the mine. These factors affect the production heavily. On the otherhand, cost of drilling and blasting are also on the continuous upward trend, whereas quality of coal produced is on the downward trend due to the presence of dirt bands in the coal. Over and above productivity of shovel - dumper is also not upto the expectation due to human factors and also constrained mining condition. It is also difficult to keep proper administrative control over huge no. of operators and equipment also becomes extremely difficult. There may be many more practical problems, which are inherent in today’s method of opencast mining. The above scenario and also the future need to produce quality coal (upto 34% ash) and with competitive price is compelling mining technologists to think for continuous surface mining technology.

Overview of surface miner technology

Till now three types of surface miners have been developed as follows:

1. Milling type - Cutter picks are fitted on drums and having a depth of cut up to 500-600 mm (max). Production capacity is very much less and can be used mainly for selective mining.

2. Boom type - Cutting drum fitted with picks is mounted on a boom, like roadheaders. Due to longer boom the cutting force of the machine is limited.

3. Bucket wheel type - Cutter picks are fitted on various buckets on the cutting drum, which is situated in the front of the machine. The machine can exert huge force in cutting both hard coal and rock. This type of surface miner is basically a mass-production machine.

Comparisons of technical parameters for various surface miners are enclosed with this article (sheet 1 & 2) for ready reference of the readers.

Continuous mining by Bucket Wheel Excavators without drilling and blasting has already been applied successfully in opencast for lignite and marl, which are softer payminerals with compressive strength upto 15 MPa. For decades the rock cutting technology has been applied in underground mining for rocks with a compressive strength in the range of 20 to 120 MPa. However, the attained capacities are considerably lower and the energy requirements are markedly higher compared with opencast mines. Continuous efforts, trial, laboratory tests and also experience gained from underground rock cutting technology have made it possible to develop new type of excavation machine for opencast mines which is able to attain its nominal capacity for compressive strength of 30 to 40 MPa and also can be operated upto 80 MPa with reduced capacity. It is possible for the surface miner to meet the higher compressive strength for the application of many cutting tools placed on it. By its cutting action the product size is normally below 100 mm. The output and power changes in relation to the compressive strength, brittleness, jointing, and abrasiveness of the pay minerals. Due to design and technical features of these machines, the benches are mined in layers from top to bottom and each layer in strips. Surface miner can also do selective mining to remove interband/dirt bands layers for improving the quality of pay minerals.

Krupp Fördertechnik, Germany has successfully developed its surface miner known as Krupp Surface Miner (model KSM 2000R) which is presently in operation at Taldinskij mine in Siberia. The result of the performance test in the mine (June 1996) showed that continuous production during mining of the test block amounted to 1800 bm³/h or 4482 t/h, which was almost 30% more than guaranteed. The mined block essentially consisted of Aleurolithes (siltstone) with a compressive strength of 20 to 30 MPa. The most remarkable event during the performance test was that at the end of the mining block, a Siderite layer with an approx. the thickness of 0.75m with a compressive strength of 60 - 70 MPa was passed through without any problem, whilst maintaining the nominal production rate. The above-mentioned results were confirmed by an inspection committee appointed by the President of the company

The various features of KSM 2000, its method of operation and its advantages in opencast mining have been explained later in this article. In case of operation of surface miner in combination with dumper trucks, the output of the machine is reduced due to frequent stopping of machine for truck change over. The percentage reduction depends on the payload of the truck and time for truck change over. Better productivity of the machine can be achieved in combination with conveyor transport. For higher production, longer haul length and greater depth, conveyor transport can be far superior to dumper transport in all respects. The additional savings for the application of surface miner are also achieved due to elimination of crushing complex in the mining system and also for more recovery of coal.

MECHANISM OF ROCK EXCAVATION

The KSM 2000 operates according to the rock cutting technology. For ready reference of the readers, the mechanism of rock excavation is briefly explained, as below:

The mechanism of primary rock excavation with continuous surface miner is basically penetration of a wedge of some shape into the material to be cut and this action is performed by a heavy duty drum equipped with large number of tungsten carbide tipped cutting tools. The process of digging is commonly specified by the resistance to digging: KF = Pt/b * td (kgf/cm2).

Where,

KF = Digging resistance, kgf/cm2

Pt = Tangential resistance force of rock to digging, kgf.

b = Width of excavated block, cm

td = Depth of cut, cm

‘KF’ and ‘Pt’ depend on the compressive (sc), shearing (ssh), tensile (st) strength of rock, its density (g) and also on jointing property of the massif that is characterized by the co-efficient of structural weakening (l) of rocks in the direction of digging. The value of ‘l‘ depends upon average size of elementary joints and number of joints.

‘KF’ is reduced by multi- bucket excavators fitted with sharp cutting edge and also by increasing the number of simultaneously cutting elements and decreasing the spacing of cutting elements. ‘KF’ is also reduced for semi-free /free digging than blocked digging.

Depth of cut is determined from the diameter of the cutting drum. Overall cross-section of the cut depends upon size of cutting drum, power of the machine, weight of the machine and also on the configuration, design and material of cutting elements.

DESIGN FEATURES OF KRUPP SURFACE MINER

(KSM 2000):

The KSM 2000 is a continuously operating mobile opencast mining machine, which cuts consolidated soils and semi-solid rocks having compressive strength up to 80 MPa, without drilling and blasting, in special cases like small lenses and/or thin layers up to 120 MPa. The KSM 2000 attains its nominal capacity in rock up to a compressive strength of 40 MPa. While cutting, the material is pre-crushed to the size (-100 mm) which is very much suitable for belt conveying. The excavated material is transferred to downstream means of transportation either by dumpers or by conveyors.

The specialty of KSM 2000 is provision of parallel bucket wheels in front of the machine that is attached to main frame without a boom. The cutters of bucket wheels are equipped with point attack picks, which cut the mining face during the continuous advance of two-crawler track assembly.

For design reasons there is a space for the bucket wheel suspension between the inner and outer bucket wheels. During mining, short ribs may be left over in these gaps. Two ripper teeth operate in the gaps in order to break up and remove the remaining rock ribs between the outer and inner bucket wheels. A dozer blade is arranged behind the bucket wheels, which is constantly pressed to the ground during the cutting operation. Thus the remaining rock ribs are removed and the spillage of the bucket wheel discharge is returned to the bucket wheel loading area. This ensures a smooth & level track for easy movement of dumper trucks. The machine is built for high capacity digging upto 2.9-m cutting depth and a block width of 7.1-m. KSM 2000 is primarily a production machine, which can be compared with the present conventional mining system. The design of KSM 2000 also permits the selective mining of changing coal/rock layers of multi-layer deposits with small percentage of fines. In case of selective mining the machine is able to maintain its nominal capacity upto a depth of cut of 800 mm by suitably increasing its advancing speed. However, the depth of cut can be further reduced to a height of 500 mm for selective mining with somewhat reduced capacity of the machine, beyond which selective mining may be un-economic, since, production will be very much reduced. The output of KSM 2000 amounts to 1400 bm3/h in continuous cuttingoperation under normal conditions upto a compressive strength of 40 MPa (400 kg/cm2). The output changes in relation to the compressive strength, brittleness, jointing and abrasiveness of the rocks. KSM 2000 is able to mine at a maximum production rate of 125% of nominal output in easily mineable materials. KSM 2000 is able to excavate pay mineral of compressive strength upto 80 MPa (800 kg/cm2) with reduced output and even small lenses with compressive strength upto 120 MPa (1200 kg/cm2) with very much reduced capacity.

Fig 1: KSM 2000 is cutting overburden at Taldinskij mine, Siberia

FUNCTION AND METHOD OF OPERATION:

By turning the bucket wheels in front of the machine and continuously advancing the crawlers, the face in front of the bucket wheels is mined by the picks. The buckets pick up the cut material directly from the mining face and discharge it at the rear side of the bucket wheels by gravity on to chain conveyors. The conveying system of KSM 2000 consists of two short lead-in chain conveyors, the main belt conveyor and the belt conveyor of the discharge boom. The discharge conveyor is provided with slewing (± 90°), luffing (high 12.6m at +25° & low 3.9m at -8°) arrangements for facilitating discharge either onto dumpers or on conveyor systems.

In order to perform the necessary operating movements, the superstructure is flexibly mounted onto the undercarriage. The undercarriage is having a two-crawler assembly. Each crawler is driven by individual DC motors with infinitely variable speed. The position of the superstructure in relation to the undercarriage is adjusted by means of two hydraulic cylinders moving around in pivot point for ramping in and out of the cut and for the correction of cutting depth. The arrangement also allows the superstructure to be transversely inclined and to cut a transverse track level by the bucket wheels. Longitudinal inclination in normal operation can be up to 6° and up to 8.5° when cutting ramps. The transverse inclination in operation and also traveling can be up to 5°.

The benches are mined in layers from top to bottom and each layer in strips. Depending on the initial state in the opencast, each layer is mined by terrace cut or the KSM 2000 initially cuts a channel and subsequently removes the rest of the layer with terrace cuts. The width of the cut is 7.1m. The depth of cut may be varied from 0.5m to 2.9m. The normal cut dimension is 7.1m by 2.4m. Cut height and advance speed of KSM 2000 can be continuously adjusted. The machine operator selects the preset values in accordance with mine condition. Travel speed during cutting can be adjusted between 0.37 to 3.0m/min. Relocating speed in level terrain may be varied between 1.36 to 31.9m/min. In normal operation, KSM 2000 advances with 1.36m/min. The speed of the bucket wheel is fixed at 6 r.p.m. During scheduled operation, KSM 2000 moves straight ahead. For correcting the advance direction, the machine can be steered in the cut. Steering movements are carried out by controlling the speed and direction of each crawler.

In channel cut operation, the machine is automatically guided along a plane by means of its ‘cut control’ system. Deviations from the ideal line are only a few centimeters. In terrace cut operation, the track level of channel cut is followed and copied by means of the control unit. The control system can also be used for selective mining.

Fig 2: Method of operation of KSM 2000

FIELDS OF APPLICATION

KSM 2000 is suitable for mining of compacted soils and rocks upto a compressive strength of approx. 70 - 80 MPa without drilling and blasting and loading of the mine masses on downstream transport systems. The application of the KSM 2000 offers advantages whenever the following conditions are met:

Mining of huge masses.

1. Selective mining of changing rock layers with thickness exceeding 0.5 m.

2. Selective mining with a high separation accuracy.

3. Production of lump sizes suitable for belt conveying with less fines.

4. Use of cost-beneficial belt conveyors.

The spectrum of mineable materials ranges from soils with semi-solid consistency such as compacted clay and loam to claystone, marl, siltstone, and medium-solid sandstone. Pay minerals such as lignite and hard coal or limestone can also be mined. In view of the applied mining technology, the KSM is not suitable for the mining of soils with plastic consistency such as clay or loam, whose natural water content exceeds the plastic limit. Material characteristics to be investigated in order to determine the diggability and application of a continuous mining machine are :

Uniaxial / unconfined compressive strength UCS (MPa or psi).

Tensile strength (MPa or psi).

Ratio between compressive and tensile strength (ductility).

Point load strength (MPa or psi).

Fracture spacing (m or in).

Rock quality designation RQD (%).

PRODUCTIVITY OF KSM 2000

A sample calculation has been given below showing the production estimates in coal with various dumpers. Annual production hours can be more, however, this has been kept matching the norms usually followed in India. The calculation shows that it is possible to achieve an annual production of 7.0 to 8.0 million tonnes of coal by one KSM 2000.

WORKING TIME
Shifts per day			3	(shifts/day)
Hours per shift			8	(hrs/shift)
Total available time per day			24	(hrs/day)
Working days per week			7	(days/week)
Working weeks per year			52	(weeks/a)
Holidays per Year			15	(days/a)
Total available days / year			350	(days/a)
Total available working time			8,400	(hrs/a)
Total available calendar time			8,760	(hrs/a)
EXPECTED LOSS TIME (during available working time)
Scheduled maintenance	weeks/annum	4.0	672	(hrs/a)
Weekly maintenance	shifts/week	1.0	384	(hrs/a)
Daily maintenance	hrs/shift	0.5	480	(hrs/a)
Shiftchange + teabreak	hrs/shift	0.5	480	(hrs/a)
Bad weather	days/a	12.0	288	(hrs/a)
	Total		2,304	(hrs/a)
AVAILABLE WORKING TIME			6,096	(hrs/a)
Truck changing time/lack of trucks	min/h	10.0	1,016	(hrs/a)
(also maneuver of machine in new block)
Unexpected loss time	%	10.0	610	(hrs/a)
(machine failures, geological problems etc.)
EFFECTIVE LOADING TIME			4,470	(hrs/a)
Possible coal production/hour			1,670	tonne
with 85 Te dumper (considering
30 sec. for truck change over)
ANNUAL PROD. WITH 85 TE DUMPER			7.465568	million tonne
Possible coal production/hour			1760	tonne
with 110 Te dumper (considering
30 sec. for truck change over)
ANNUAL PROD.WITH 110 TE DUMPER			7.867904	million tonne

NOTE:

Possible coal production /hour has been calculated considering truck changing time as indicated, job efficiency & operator efficiency. Variations are possible & shall depend upon application data. Productivity shall increase with conveyor as out by transport.

COST ECONOMICS:

KSM 2000 executes several operating steps in opencast mining e.g. cutting, shoveling & primary crushing. Therefore all the operating steps must be considered while comparing with shovel/dumper and in-pit crushing/conveyor systems. It has been found that in case of a block height of 15m; KSM 2000 system attains a result, which is better than shovel/dumper system and very close to in-pit crushing/conveyor system. But for lower block height of 2m, KSM 2000 is far superior to all other systems. Besides, due to quality improvement by selective mining and also due to better exploitation of the deposits in comparison with conventional mining by drilling/blasting, KSM 2000 system shall offer further cost advantages. The estimated quantum of coal, which can further be recovered as described in the previous chapter of this article, gives an indication of such additional cost advantage for application of surface miners.

A comparative statement (sheet -3) is provided with this article, in respect of the estimated operating & owning cost of the machine (in Rs/te for coal or Rs/bm3 for overburden) and the cost for drilling/blasting, shoveling and primary crushing of coal needed in case of conventional mining. Operating & owning cost as shown in sheet-3 is tentative but it will give an idea of cost for application of KSM 2000.

ADVANTAGES OF KSM 2000 IN OPENCAST MINING:

The KSM 2000 offers the following advantages over conventional mining and also other milling type of smaller surface miners.

1.Higher productivity and lower mining cost.

2. Elimination of drilling and blasting. It avoids the chance of dilution of pay minerals and also offers more safety. It will also create the possibility of mining the areas where administrative regulations are imposed against blasting.

3. Saving of cost due to elimination of crushing system.

4. Higher yield of pay minerals.

5. Flexibility of its operation with both dumpers and conveyors. For higher production, longer haul distance & higher depth, conveyor transport shall be more economic than dumper transport, which can be easily catered by surface miner. In case of conventional mining, due to bigger output size (more than 800-1000 mm) dumper transport is essential. Conventional mining shall need additional in-pit crushing system to cope up with conveyor transport. In dumper transport the ratio of service weight to payload is much higher than conveyor transport, since, empty dumpers on return movement do not carry any payload. Moreover, annual wear & spareparts cost on account of tires etc. for dumper transport are also higher than conveyor transport. Cost for setting up of workshop for maintenance of Heavy Earth Moving Equipment is also huge and can be saved in case of surface miner/conveyor system. Hence, combination of surface miner and conveyor shall be more economic. Besides, it will be also easier to increase the production of mine in future, if needed, with such combination.

6. Large-scale cutting area and low advancing speed of KSM 2000 makes it possible to load dumpers more conveniently. Dumpers shall remain static at the time of loading by KSM 2000. Smaller surface miner moves at a faster speed and hence dumpers shall also have to be moved suitably at the time of loading. This is a special advantage of KSM 2000 over other surface miners.

7. Since, discharge conveyor of surface miner load the dumpers evenly from a suitable height, dumpers are subjected to better filling, which ensures greater capacity utilization and also it reduces wear of dumpers compared with loading by shovels.

8. The cutting drum of KSM 2000 is in the front. Its diameter is large (4.8m) and speed is low (6 r.p.m). Hence the cutting elements of the drum run at a slower speed and get more time to cool. This phenomenon increases the life of the cutting tools. This is an advantage over other surface miners, since, other surface miners are having smaller cutting drum diameter and rotates with higher speed and hence, cutting tools get much less time to cool. It is also easier to change the cutter picks, since the cutting drum is located in the front.

9. Due to bigger drum diameter the KSM 2000 can go for bigger depth of cut (2.9 m) and more production in comparison with other surface miners. KSM 2000 has more no. of cutting elements (540), much more power (total 3200 kW) and more weight (540 tonne). As a result it can offer much more cutting force and is able to operate in much tougher condition in comparison with other surface miners.

10. KSM 2000 permits block operation. The KSM 2000 can cut whole block on its own. Cutting can be carried out in any direction. Its operation also offers better slope stability.

11. Milling type of surface miners produce more fines (70% of output is around minus 35 mm), whereas, output size from KSM 2000 remains within 75 to 100 mm. This ensures better price realization of coal produced by KSM 2000.

12. KSM 2000 shall offer better economy in respect of cost/tonne or cost/m3 for coal & overburden. The reason is the machine is having longer life (20 years) and one machine is able to produce around 7.5 million tonne/year of coal even in combination with dumpers (please see the paragraph “Productivity of KSM 2000).

CONCLUSIONS:

Surface miner being a new technology is yet to be adopted by mining technologists for medium hard/hard coal and overburden. Due to various disadvantages and hazards of the present conventional mining method, as explained in this article, more & more interests are growing towards this new technology. Many coal mines in India are suitable for applying this technology due to higher production demand, favorable seam gradient, long strike length, multi-seam mining and also presence of villages in close vicinity of the mines. It may not be prudent to use surface miners only for the purpose of selective mining due to the following reasons:

Use of surface miners only for the purpose of selective mining of thinner bands within coal seams shall reduce overall production of mine due to low output for such selective mining. The extent of such reduction shall depend upon the nature and thickness of the interbands and the production capacity of the surface miners. Hence, it should be necessary to assess, whether there will be grade improvement of coal (not only improvement in kcal/kg of output) for such selective mining. Grade improvement of output may prove economic viability to compensate the investment for such surface miners and also for the loss of overall production.

Due to smaller output size (< 100 mm), conveyor can be adopted with surface miner. The various advantages of conveyor system have been explained above. Dumper transport, on the other hand, essential for conventional mining for carrying bigger lumps. Mixing of two mining system, i.e. selective mining by surface miner and main production by conventional method in the same mining block, shall compel using dumper transport for surface miner also. This will obviously reduce the productivity of surface miner.

Surface miner needs different kind of planning for mining coal seams in layers from top to bottom & each layer in various strips. The slope of negotiating ramps shall be different for surface miner. Conventional mining, on the otherhand, follows benches of more height. Height and width of benches depend upon size of shovels & dumpers. Hence, it may be difficult to make proper mining layout for adopting two different kinds of mining methods in the same mining block.

Though milling type (smaller capacity) surface miners are in use in limestone and also in lignite coal for quite sometime, but bigger surface miner for mass production has been recently launched by Krupp Fördertechnik, Germany and yet to become popular. But it shall prove its worth in near future. Adopting this new technology in Indian coalmines shall open a new era in coal mining. It shall be proven as a boon in mining technology in the next millennium.

REFERENCES:

Opencast Mining (Unit Operations) - V.V. Rzhevsky.

Article (Non-Explosive Mining) - Mr. M.P. Mishra, published in MINE SAFE’97.

Article (New Technology in Opencast Mining) - Mr. S.K.Bag, published in Opencast’98 of MGMI.

Article (New Technology in Opencast Mining) - Mr. S.K.Bag, published in Scuim’99 of MGMI.

VIDEO LINK OF WORKING OF KRUPP SURFACE MINER AT TALDINSKIJ, SIBERIA

Special remark:

The above article had been written by the undersigned in 1998 along with his colleague Mr. Detlev Schroeder as his co-author, during his tenure in Krupp Foedertechnik, Germany. Incidentally, after the merger of Krupp with Thyssen in 2000 and also undersigned left Krupp Foedertechnik, further work on Krupp Surface Miner had been discontinued by Krupp Foedertechnik. Subsequently, Krupp had abandoned this product and the reasons are yet not known to the undersigned. This surface miner could have been ideal for working in the overburden had technological up-gradation could have continued by Thyssen-Krupp. The Krupp Surface Miner being the most strong machine could have been very demanding in the present scenario.

S.K.Bag

Managing Partner

Merchentus India Exim International LLP

Dated, 17th Sept, 2020

noreply@blogger.com (Merchentusindia) — Fri, 05 Feb 2021 16:00:00 +0000

INTRODUCTION OF DSI SNAKE HIGH ANGLE CONVEYOR TECHNOLOGY:

Cost of truck haulage from mine pits are high and spiraling with inflation, diesel price, increasing haul distances and depths. Trucks, traditionally, have long been a favorite tool in surface mines for hauling material from the pits. The increasing strain of an inflationary economy has caused mine operators to look at alternatives to the longstanding workhorses (trucks) in material haulage.

The intent of any major modification of the time-honored material handling by trucks is to achieve the goal of a marked reduction in haulage costs; sufficient not only to recoup the capital investment, but to make the final product more competitive in today's world market. Due to increasing cost of truck haulage, now In-pit crushing and belt conveyor systems are one prominent alternative that has gained popularity.

The favorable economics of conveyor based haulage, especially in moving large volumes, has long been acknowledged. This has given impetus to significant developments over the last two decades in conveying systems and equipment. Such developments have resulted in improved equipment and system reliability, versatility and mobility. This may not be out of place to mention here the success story of fully mobile in-pit crushing & conveying system working in Piparwar project of CCL handling production @ 7.0 MTPA for around two decades & achieved highest OMS amongst CIL opencast projects.

Conventional belt conveyors offer a most economical method for transporting bulk materials at recommended inclination angles up to 12° to 18° for most common materials. Internal friction development and the induced dynamics of the moving conveyor belt limit the conveying angle. Higher angles approaching the internal friction angle could be achieved by reducing the dynamic effects. The inclination angle cannot, however, exceed the angle of internal friction of the material at the free surface.

Conveying angles beyond the angle of internal friction can be achieved by adding a cover belt which, when pressed against the material, will create a hugging action to prevent sliding at the contact surface.

The trend of reducing haulage costs with belt conveyors prompted the US Bureau of Mines to take it to the next level. The Bureau recognized the incline angle limitations for open troughed belt conveyors and the cost of accommodating the limitations. At the end of 1979 the US Bureau of Mines funded a major study entitled High Angle Conveyor Study. The Study ran from August of 1979 to December of 1981. In 1979 the Bureau of Mines, United States Department of the Interior, funded a major study entitled “High Angle Conveyor Study”.

The purpose:

(1) To advance the state-of-the-art in high angle conveying.

(2) To develop high angle conveying systems that would reduce the haulage costs in open pit mines.

The study was awarded to a prominent U.S. engineering company.

Joseph A. Dos Santos - Project Engineer was assigned to the Study.

The two volumes “High Angle Conveyor Study” report, published in 1981, included the Dos Santos theory and various sandwich belt conveying methods. Drawing from the success of the Loop Belt, Dos Santos Sandwich Belt systems included its best features and offered versatile profiles that could follow any high-angle path.

The Snake-Sandwich High-Angle Conveyor was cited as the preferred method and it was submitted for patent in 1981.

The Sandwich Belt High-Angle conveyor research and development was published more concisely in the 1982 landmark article “Evolution of Sandwich Belt High-Angle Conveyors” by Dos Santos and Frizzell.

Sandwich belt high-angle conveying systems use two smooth surfaced rubber belts that hug the conveyed bulk material, in a sandwich between them, along the carrying path. The hugging pressure develops the material's natural internal friction, successfully conveying it along any steep incline up to vertical.

A high angle conveying system is an economic and energy saving alternative, with the capability of achieving very high, steep angle lifts and capacities up to 10 000 TPH. High Angle Conveyor system deploys Standard locally available components and conventional belts.

RELEVANCE OF DSI SNAKE HIGH ANGLE CONVEYOR AT KATHARA OPENCAST MINE

Katharaopencast mine of Central Coalfields Limited lies in the South-Western part of the East Bokaro Coalfields in Bokaro District of Jharkhand. Mining in Kathara block was started in the year 1944 by M/s Anderson Wright and Company on behalf of M/s Kathara CoalCompany. It is very difficult mine with lot of faults & steep gradiant of coal seam.Ultimate depth of the mine shall be more than 150 m. The mine is producing washery GR IV coal @ 1.0 MTPA. Kargali seam is the bottom seam, where presently mining is in progress. The Kathara mine has been divided in three sections. The western section is being operated by MDO. The eastern section is not in operation at present & the pit floor is submerged in water. Presently ROM coal is being transported by 16 Te truck to Kathara Washery, where coal is being crushed to suitable size for washing. Excess ROM coal is transported by truck to railway siding.

PHOTOGRAPHS OF KATHARA MINE (EASTERN SECTOR)

NECESSITY OF SETTING UP DSI SNAKE HIGH ANGLE CONVEYOR AT KATHARA OPENCAST MINE (IN THE EASTERN SECION OF THE MINE)

Currently, there has been not sufficient exposure on this state of art High Angle Conveyor (HAC) technology in India. Indian Mine Planners & Consultants (IMPCON), Kolkata has been working on this technology for quite some time to apply this technology for the most economic solution of coal transport from deep mines.

IMPCON recently made a presentation at CCL (Hq), Ranchi on DSI Snake High Angle Conveyor technology. It had been agreed that a suitable mine in CCL shall be identified to explore the possibility of application of this technology to solve the transport problem in the mine.

Presently, at Kathara trucks are carrying coal from pit bottom from a depth of more than 100 m. It may be difficult to continue coal transport by trucks with further progress of mine, when the mine shall be deeper. Space at pit-bottom is limited and it will not be possible to install conventional conveyor for transport of coal from pit-bottom. The mine has 15 years of life & shall further go deeper by more than 50 m.

As such, CCL wanted S.K.Bag to visit KATHARA opencast mine to explore the possibility of application of High Angle Conveyor Technology for the best economic solution for coal transport . Accordingly, S.K.Bag had visited the mine on 8th Sept, 2016. After visit & studying the working mine plan, it is strongly feels that High Angle Conveyor shall be the only solution for this mine, since, DSI Snake High Angle Conveyor can be installed along the existing steep inclination of sidewall/highwall for carrying coal from pit-bottom to surface. Such steep gradient is beyond the limit of conveying angle of conventional conveyor. DSI Snake high angle conveyor shall be capable to transport coal along any slope (up to vertical) exceeding the dynamic stability angle of the transported material. S.K.Bag has made detailed study & economic evolution. The report is submitted as below.

STUDY REPORT BY S.K.BAG FOR APPLICATION OF DSI SNAKE HIGH ANGLE CONVEYOR AT KATHARA OPENCAST MINE IN THE EASTERN SECTION

Based on site visit, discussions & study of mine plan, S.K.Bag observed by combining the flexibility of truck transport in-pit with movable (skid mounted) crushing plant followed by DSI Snake High Angle conveyor along the side slope of existing in-pit overburden dumps coal can be transported at surface, wherefrom coal can be directly transported to washery by an overland conveyor. With such system it is very much possible to transport entire coal production for the main haul out of the pit completely avoiding a long path of trucks.

Truck haulage shall be restricted to travel between the working face and the in-pit crusher. The cost savings in transport by high angle conveyor over the present truck system shall be sufficient to achieve the pay back for investment in less than 5 years with target production 1.0 MTPA . It will be also possible to increase the production by 50% without any additional capital investment. This will achieve better IRR & PAY BACK.

Initially, two alternatives e.g, Alt 1 & 2, as shown below, have been thought for possible location of DSI Snake High Angle Conveyor system to transport coal from Kargali seam.

TWO ALTERNATIVES FOR DSI SNAKE HIGH ANGLE CONVEYOR FROM KARGALI SEAM AT KATHARA

ALTERNATIVE 1:

In this alternative HAC (DSI Snake High Angle Conveyor) shall be located towards internal dump. HAC shall be installed over the settled internal dump. Skid mounted in-pit crusher shall be installed in a suitable location at pit-bottom at RL 100.00 m level. An truck unloading platform shall be made by levelling the existing dump, so that trucks from coal benches can approach the unloading platform without any difficulties & un-load coal in the hopper of the in-pit crusher.

The crusher unit shall be provided with one internal grizzly within hopper to by-pass fine coals. (-) 600 mm size coal shall be discharged to roll crusher through apron feeder. The oversize lumps (+) 600 mm shall remain over another grizzly at top for breaking manually. The output from crusher shall be (-) 100mm & shall discharge on to DSI Snake High Angle Conveyor (HAC) by an integrated take-away conveyor fitted below crusher & one short bench conveyor. The entire crushing unit shall be skid mounted for easy installation at site & also shifting within pit, if required.

The HAC shall elevate (-) 100 mm size coal from RL +100.00 m level to a transfer hopper which shall be located in the dumble area by the side of existing road. The level at this point is around RL +238.00 m. The discharge drum of HAC shall be raised by another 8 to 10 m to discharge on to transfer hopper. The level may be RL + 248.00 m. That means the HAC shall negotiate a height of around 150 m. An overland conveyor shall collect coal below transfer hopper & shall carry directly from the transfer hopper to the washery. The overland conveyor (OLC) shall be installed onr structures with gantry keeping 8.0 m clearance from surface, so that there will be no interference with truck movements on the existing road.

ALTERNATIVE 2:

In this alternative, the HAC shall be located just in the opposite side of Alt 1 & shall be installed over the existing sidewall of the mine, where mine has come to an end. In-pit crusher shall be located at pit- bottom in a suitable location in relation with the HAC. In this alternative, coal shall be disharged by HAC on to existing coal stock heap at surface. Washery shall be far from this location. Coal shall have to be transported by trucks from stock yard to either washery or to railway siding, as per existing system.

The alternative 2 shall be cheaper than alternative 1, since, this alternative shall not have any additional overland conveyor system. However, we have selected alternative 1& calculated economics, since, this is a complete solution & shall totally eliminate truck transport.

PROPOSED SKID MOUNTED IN-PIT CRUSHING SYSTEM

GENERAL ARRANGEMENT OF IN-PIT CRUSHER & DSI SNAKE HIGH ANGLE CONVEYOR

The detailed layout of integrated system with in-pit crushing system, DSI Snake HAC & overland conveyor are enclosed with this proposal vide drg. No.

ECONOMIC EVOLUTION OF DSI SNAKE HIGH ANGLE CONVEYOR SYSTEM (SYSTEM II) & COMPARISON WITH PRESENT TRUCK TRANSPORT

SUMMARISED INPUT DATA FOR SYSTEM I & II

SYSTEM I:	Dumper transport from coal face to washery & crushing of coal at washery (Existing system)
SYSTEM II:	Dumper transport from coal face to in-pit crusher, HAC, OLC to washery

IN-PUT DATA TABLE:

1. Annual production (MTPA)	1.00
2. Capacity of the system (TPH)	250.00
3. Annual operating hours (Hrs)	4,000.00
4. Lead distance of dumper (one way) from coal face to coal washery (SYSTEM I) (kM)	3.0
5. Lead distance (estimated) of dumper (one way) from coal face to in-pit crushing station for SYSTEM II (kM)	1.0
6. Estimated truck transport cost (Rs/Te) from face to in-pit crusher (SYSTEM II)	10.00
7. Dumper capacity (Te) 16 16. Existing contract rate for transport of coal from coal face to washery (SYSTEM I) (Rs/Te)	85.00
8. No. of skid mounted in-pit crusher	1
9. Length of HAC (meter)	200.00
10. Width of HAC & overland conveyor (millimeter)	1000
11. Annual discount rate (%) (for NPV calculation)	10.00
12. Annual escalation rate (%) (for DCF calculation)	4.00
13. Bank interest (%)	10.00
14. Life of project (Years)	15
15. Crushing cost for SYSTEM I (assumed) (Rs/Te)	5.00
16. Total manpower including operation & maintenance for SYSTEM II (for 3 shifts)	24
17. Annual salary & wage per person (Rs)	300000
18. Increase in contract price every fourth year (assumed)	10.00%
19. Electric unit price (Rs)	6.00

Detailed economic analysis have been made for both SYSTEM I & SYSTEM II & relevant output charts/graphs are enclosed. The analysis has been done with our special MINE OPTIMISATION PROGRAM.

The following economic evolutions have been made:

SPECIFIC COST/TE (CAPEX & OPEX) FOR BOTH SYSTEMS WITH BREAK-UP OF ALL THE COSTS
COMPARISON OF DISCOUNTED CASH FLOW FOR THE LIFE OF PROJECT (15 YEARS) FOR BOTH THE SYSTEMS
NPV FOR SYSTEM II
IRR FOR SYSTEM II
PAY BACK PERIOD FOR SYSTEM II
DCF FOR SYSTEM I & II
TABLE & GRAPH SHOWING NET PROFIT (MINR), NPV & DISCOUNTED PROFIT (NPV & ESCALATION) FOR SYSTEM II

The output results of analysis establish very attractive results in favor of SYSTEM II. The economic analysis has been made for annual production of 1.0 MTPA, considering 250 TPH system capacity with annual working hours of 4000 hrs. Since, the HAC system, in-pit crusher & overland conveyor, selected, are capable to handle 300 TPH without any additional investment, hence, economic analysis have been carried out with three options as follows:

Option 1 - 1.0 MTPA annual production with 250 TPH capacity & 4000 annual working hours.
Option 2 - 1.25 MTPA annual production with 250 TPH capacity & 5000 annual working hours.
Option 3 – 1.50 MTPA annual production with 300 TPH capacity & 5000 annual working hours.

From the analysis it may be observed that the opex shall be reduced for SYSTEM II with the increase of production, and there shall be no increase in capex. Hence, increase in production shall lead to better NPV, DCF, IRR & PAY BACK for SYSTEM II. All the comparisons relating to OPEX, NPV, DCF, IRR & PAY BACK for Options 1, 2 & 3 are included in this report. The relevant calculations, tables, charts & graphs are enclosed with this report as Annexures 1 to 8.

BRIEF TECHNICAL SPECIFICATIONS OF THE EQUIPMENT UNDER SYSTEM II :

Skid mounted crusher :

Feed hopper – 30 cu.m, suitable for 25 Te truck
Capacity – 300 TPH
Total power – 150 kW
Weight – 75 Te
In-put limp size – (-) 600 mm, with the provision of breaking oversize lump over integrated fixed grizzly
Integrated with Apron feeder, crusher & discharge conveyor

DSI Snake High Angle Conveyor :

Belt width – 1000 mm
Belt speed – 3.25 m/sec
Length – 200 m
Capacity – 300 TPH
Troughing angle – 35 degree
Drive power for top & bottom belt – 200 kW

Overland conveyor :

Belt width – 1000 mm
Capacity – 300 TPH
Belt speed – 3.25 m/sec
Trough angle – 35 degree
Length – 500 m
Drive power – 100 kW

TOTAL POWER REQUIREMENT FOR SYSTEM II shall be 450 kW

ESTIMATED CAPITAL INVESTMENT FOR SYSTEM II :

For skid mounted crushing system – 18.0 MINR
For DSI Snake Conveyor & feeding arrangement – 200.80 MINR
Overland conveyor – 30.0 MINR

FINANCIAL ANALYSIS :

I) TABLE SHOWING NET PROFIT (NOT DISCOUNTED), NPV, IRR, PAY BACK & DCF

TABLE SHOWING NET PROFIT (NOT DISCOUNTED), NPV, IRR, PAY BACK & DCF

		SYSTEM - I	SYSTEM - II	SAVINGS IN COST FOR SYSTEM II	ANNUAL NET SAVINGS	ANNUAL PRODUCTION (MTPA)	DISCOUNT RATE FOR NPV
YEAR	CAPITAL INVESTMENT (MINR) FOR SYSTEM - II	OPERATING COST (Rs/Te)	OPERATING COST (Rs/Te)	COST/TE (INR)	MINR	1.00	10%
0 year	55.68
2nd	55.68	90.00	34.32	55.68	55.68
3rd	55.68	90.00	34.32	55.68	55.68
4th	64.18	98.50	34.32	64.18	64.18
5th	64.18	98.50	34.32	64.18	64.18
6th	64.18	98.50	34.32	64.18	64.18
7th	64.18	98.50	34.32	64.18	64.18
8th	73.53	107.85	34.32	73.53	73.53
9th	73.53	107.85	34.32	73.53	73.53
10th	73.53	107.85	34.32	73.53	73.53
11th	73.53	107.85	34.32	73.53	73.53
12th	83.82	118.14	34.32	83.82	83.82
13th	83.82	118.14	34.32	83.82	83.82
14th	83.82	118.14	34.32	83.82	83.82
15th	83.82	118.14	34.32	83.82	83.82
INVESTMENT	248.80
NET PROFIT (MINR)	804.38
NPV (MINR) @ 10%	504.06
IRR	24%
PAY BACK PERIOD (YRS)	4.47
DCF	475.13	DCF HAS BEEN CALCULATED CONSIDERING BOTH NPV & ESCALATION PER YEAR

II) FINANCIAL ANALYSIS FOR OPTION 1, 2 & 3 (SYSTEM II)

COMPARATIVE FINANCIAL ANALYSIS FOR VARIOUS OPTIONS FOR SYSTEM II

	Opt 1	Opt 2	Opt 3
CAPITAL INVESTMENT (MINR) (SYSTEM II)	248.80	248.80	248.80
PRODUCTION (MTPA)	1.00	1.25	1.5
NET PROFIT (MINR)	NET PROFIT (MINR)	1540.48	2515.31
NPV (MINR)	504.06	860.46	1334.16
NPV (MINR)	504.06	860.46	1334.16
DCF (MINR)	475.13	736.03	1019.93
IRR (%)	24	41	63
PAY BACK PERIOD (YRS)	4.47	3.22	2.46

III) COMPARISON OF OPEX FOR OPTION 1, 2 & 3 (SYSTEM I & SYSTEM II)

COMPARATIVE STATEMENT OF OPEX FOR SYSTEM I & II (RS/TE)

	PRODUCTION (MTPA)	SYSTEM I (Rs/Te)	SYSTEM II (Rs/Te)
OPTION 1	1.00	90.00	34.32
OPTION 2	1.25	112.50	35.23
OPTION 3	1.5	135.00	33.9

IV) SPECIFIC COSTS (RS/TE) WITH BREAK-UP FOR SYSTEM I & II

V) TABLE FOR DISCOUNTED CASH FLOW FOR SYSTEM I & II

VI) DISCOUNTED CASH FLOW (DCF) GRAPHS FOR SYSTEM I & II (ANNUAL PRODUCTION 1.0 MTPA)

VII) GRAPH SHOWING PAY BACK PERIODS FOR OPTION 1, 2 & 3 (SYSTEM II)

CONCLUSIONS :

1. From the economic analysis it is evident that coal transport by proposed System II with in-pit crushing & DSI Snake High Angle from Kargali seam pit-bottom to washery shall be quite profitable and shall save present dumper transport cost to a great extent. The capital investment for SYSTEM II shall be paid back in less than 5 years, whereas mine life is 15 years.

2. There shall be provision to increase production from 1.0 MTPA to 1.5 MTPA without any further capital investment. For increasing production present dumper system (SYSTEM I) shall be costlier, whereas SYSTEM II shall be cheaper. This shall further improve IRR of the project & shall bring down the pay back period to less than 3 years. Over & above, increase production shall lead to more revenue.

3. The DSI High Angle Conveyor shall be pollution free out of dust and exhaust fumes from trucks. The system shall satisfy the present norms of environment & pollution in mine.

4. The system shall be very safe & free from safety hazards of trucks, especially due to steep gradient in the mine.

PROVENNESS OF DSI SNAKE HIGH ANGLE CONVEYOR TECHNOLOGY :

DSI Snake High Angle Conveyor had been introduced in USA in 80’s & few hundreds of installations had been installed in several countries & have been running very successfully.

A reference list of High Angle Conveyor indicating locations & brief specification is enclosed. Currently DSI Snake High Angle Conveyor has attained capacity of more than 10,000 tph with 3000 mm Belt Width.

Enclosures :

Annexure -1: Summarized statement
Annexure – 2: Break down of cost for SYSTEM I
Annexure – 3: Total system cost calculation for SYSTEM II
Annexure – 3/2: Break-down of costs for SYSTEM II
Annexure – 4: Specific cost for SYSTEM I & II (Graphs)
Annexure – 5: Discounted cash flow curves for SYSTEM I & II (Graph)
Annexure – 6: Discounted cash flow table for SYSTEM I & II
Annexure – 7: Calculation of NPV, IRR & Pay back for SYSTEM II (Option 1)
Annexure – 8: IRR, PAY BACK, OPEX for SYSTEM II (OPTION 1, 2 & 3)
Drawing of SYSTEM II – Drg no:
Reference list of High Angle Conveyor installations (8 sheets)

Gobindbhog rice - the most scented rice of India

noreply@blogger.com (Merchentusindia) — Tue, 23 Jun 2020 18:35:00 +0000

GOBINDOBHOG RICE

BLOG PRESENTED BY S.K.BAG

Gobindobhog is a non-Basmati type indigenous aromatic, rice highly scented, white and sticky having a sweet buttery flavor from West Bengal. The paddy variety, which got the GI (Geographical Indication) status in August 2017, is primarily cultivated in East Burdwan district in the Raina 1, Raina 2, and Khandaghosh blocks.

Gobindabhog has been categorized as a khaas dhan (special grain) and is the chosen offering for Lord Krishna on Janmashtami, thus its unique name. It tastes absolutely delectable when prepared as payesh (the Bengali version of rice kheer), and is widely used for auspicious offerings, pujas, and festivals.

It derives its name from its usage as the principal ingredient in the preparation of the offerings to Govindaji, the family deity of the Seths of Kolkata.

Gobindobhog was traditionally cultivated in the districts of Bardhaman, Hooghly, Nadia, and Birbhum. Later, it began to be cultivated in Bankura and Purulia. In Bihar, it is cultivated in Kaimur, Naugachia, and other rice bowl areas. In August 2017, the Gobinobhog rice was allotted the geographical indication (GI) tag of West Bengal by the Government of India.

It has many traditional Bengali recipes intended for it specifically.

Excellent all-purpose all cuisine rice.

Spurt in demand

There was a sudden demand for around 10,000 tonnes of Gobindobhog rice from Bangladesh this year, market sources said. Tirupati Agri, which markets the rice under the ‘Rice Villa’ brand, has exported close to 550 tonnes of Gobindobhog so far during this season. It had exported around 1,000 tonnes the whole of last year. The company exports to Bangladesh and West Asia.

Apart from Bangladesh, there has been a steady rise in demand from Kerala and other markets in South India, said Tamal Mal, Director of Greenstarline Udyog, manufacturer, trader and exporter of different varieties of rice from Bengal.

Better prospects

The increase in prices is despite the fact that the State witnessed a 17 percent rise in the production of Gobindobhog paddy this year. West Bengal produced close to 2.8 lakh tonnes of Gobindobhog paddy in 2018-19, as compared to 2.4 lakh tonnes produced in 2017-18. Nearly 55-56 percent of this is converted to rice.

Driven by the prospect of earning more, farmers in Bengal have taken to cultivating Gobindobhog. The area under cultivation, which was close to 35 hectares in 2016-17, has increased to 51 hectares in 2018-2019.

SPECIFICATIONS OF GOBINDOBHOG RICE

Model Name	· Gobindobhog Aromatic Rice
Rice Type	· Gobindobhog Rice
Texture	· Raw
Color	· White
Grain Size	· Small Grain
Maximum Shelf Life	· 12 Months
Cuisine	· Indian
Origin	· West Bengal
Dietary Preference	· No MSG, No Cholesterol, No Trans Fat, Dairy Free
Nutrient Content	· Carbohydrate 28-30 grams, Vitamin B6: 5%, Protein: 5%
Caloric Value	· 130 cal

Black rice is the best healthy rice

noreply@blogger.com (Merchentusindia) — Tue, 23 Jun 2020 17:41:00 +0000

Black rice (Oryza Sativa L.)

by

Saptarshi Mondal

History

Black rice, also known as “Black Pearl” or “Medicine Rice” or “Longevity Rice.” ^[¹^], is a pigmented rice variety of Oryza Sativa L. species. Despite a long history, the origin of black or purple rice is in a gray zone and is assumed to have originated from different parts of Asia. The grain contains a high concentration of anthocyanin pigment which gives the rice its identity/color. The concentration of anthocyanin increases the amount of antioxidants ^[²^,³^] and that’s the reason black rice is well-regarded among extremely nutritious and healthy diets. Black rice is also known as “Forbidden Rice” or “Emperor’s rice”. Widely speculated oral history suggests that emperors in ancient times used to consume black rice due to high nutritional values and banned its consumption by ordinary people. Though black rice was reserved only for the emperor’s consumption in history, no such restriction exists nowadays.

China and India are the leading producers of black rice, followed by Indonesia, Bangladesh, Vietnam, and Thailand. About 30 varieties of black rice are found in India. North-eastern states of India have long traditions of growing black rice, apart from West-Bengal, Odisha, and Jharkhand.

Uses in ancient time

Due to its numerous nutritious and meditative qualities, black rice occupied a high acclaimed position in Indian Ayurvedic Medicine and Traditional Chinese Medicine. In Ayurveda, it is called “Krishna shali” resembling the dark-skinned Lord Krishna and considered as Tridoshaghna meaning: healer of vitiated state of the three touches of humor (pacifying all three Doshas: Vata, Pitta, and Kapha) ^[⁴^]. In Traditional Chinese Medicine, black rice is considered to have the capacity to stimulate appetite; increase blood circulation by strengthening blood vessels and heart muscles; regulates blood pressure; improve vision; warm liver ^[¹^].

Recent trend

This natural variety does not tolerate chemical fertilizer and pesticides. So, it is grown pure organically. The nutritional quality in black rice (traditional landraces) has been found higher than in chemically grown white rice mainly due to the effective accumulation of bioactive compounds in black rice ^[⁵^]. In recent times, the consumption and demand for black rice have been increasing as its nutritious and medicative values are realized by the generation “Y” who are way more conscious towards a healthy diet. The market of this precious rice has grown not only in Asian countries but also in Middle-East and the United States. While growing consumer’s interest has created a substantial market, it is simultaneously providing economic benefits to farmers and producers as well.

Benefits of black rice

Black rice is enriched with a high amount of fiber which helps to maintain the digestive system better. It is also a good source of plant-based protein content and concentration of Vitamin B, E, iron, zinc, magnesium, niacin, and calcium is higher compare to white rice. The major nutritional benefits of black rice include:

· Rich source of antioxidant: The Black or purple color of the rice is mainly due to an abundance of anthocyanin pigments. Its anthocyanin pigment provides high antioxidant content which is both fat and water-soluble. The antioxidant has a high capacity to fight against free radical damage, microbial infection, diarrhea, and also prevents cardiovascular diseases.

· Low Glycemic index prevents diabatic risk: Black rice has a low glycemic index and bran is enriched with dietary fiber. Dietary fiber makes sugar absorption slower and helps to provide stable energy. Thus, the consumption of black rice prevents random spikes in blood sugar levels as well as diabatic risk ^[⁶^]. Germinated Black rice is found to be a strong antidiabetic compare to normal Black rice ^[⁷^].

· Source of 18 amino acid: Amino acid deficiency in diet decrease protein production and leads to nutritional imbalance ^[⁶^]. Amino acid helps in protein metabolism and is very essential for the development of our body. Black rice is a good source of 18 amino acids ^[⁸^] (such as alanine, arginine, asparagine, aspartic acid, glutamine, glutamic acid, glycine, histidine, isoleucine, leucine, lysine, methionine, phenylalanine, proline, serine, threonine, tyrosine, and valine).

· Naturally gluten-free: Protein gluten is present in wheat and barley. People who are sensitive or allergic to gluten often suffer from constipation, diarrhea, etc. Fortunately, Black rice is naturally gluten-free. People sensitive to gluten may replace wheat or barley by black rice in their diet to maintain daily protein requirements. ·

Anti-cancer: The anthocyanin pigment of black rice is found to have anti-cancer properties. Research conducted on mice concluded that anthocyanin extract of black rice successfully suppresses tumor growth and reduces the growth of breast cancer cells ^[⁹^,¹⁰^,¹¹^].

· Anti-inflammatory: Studies found that ethanol and aqueous extracts from black rice contains anti-inflammatory activity ^[¹²^]. Consumption of black rice found to be effective to reduce chronic inflammation like edema and skin allergy.

· Improves heart health: Cholesterol is the leading driver for many cardiovascular diseases. The presence of anthocyanin photochemical in black rice helps to reduce low-density lipid-protein (LDL) or bad cholesterol ^[¹³^].

· Improves brain/cognitive health: The study found that anthocyanin-rich food delays mental aging or slow cognitive decline ^[¹⁴^]. Consumption of anthocyanin contained food also helps to increase learning capacity and memory. Black rice is believed to be beneficial to improve brain or cognitive health since it contains a high amount of anthocyanin and antioxidant.

· Improves Eyesight: Anthocyanin found in Black rice is known to be effective for improving eyesight by reducing and preventing retinal damage caused by fluorescent light ^[¹⁵^].

· Reduce high blood pressure: The dietary fiber present in Black rice helps to maintain blood pressure level and reduce the lipid profile level. Thus, the consumption of Black rice is beneficial to protect cardiovascular health.

· Improves liver health: Deposition of excessive fat in liver causes for fatty liver disease. Research conducted on mice found that antioxidants present in Black rice help in reducing triglyceride and total cholesterol in the liver by regulating fat metabolism ^[¹⁶^].

· Helps in weight loss: Black rice contains a high amount of fiber. Fiber takes a longer time to digest and prevent frequent hunger. Thus, the consumption of black rice helps to lower calory intake and contribute to weight loss.

· Improves Kidney health: High blood pressure is considered a big risk for people suffering from chronic kidney diseases. Consumption of Black rice regulates blood pressure levels and thus helps to improve kidney health.

Natural detoxifier: Black rice is considered to be a natural detoxifier. A high amount of antioxidants in black rice helps in eliminating disease-causing toxins from our liver. In addition, phytonutrients present in black rice helps to release toxic substances from our body.

Reference

1. https://www.sciencedirect.com/science/article/pii/B9780128137680000153

2. https://pubmed.ncbi.nlm.nih.gov/27016122/

3. https://www.annualreviews.org/doi/10.1146/annurev.food.080708.100754

4. https://www.ayuruniverse.com/blogs/benefits-of-rice-ayurveda/

5. https://www.frontiersin.org/articles/10.3389/fgene.2020.00229/full

6. https://www.sciencedirect.com/science/article/pii/S2590259819300469#bb0065

7. https://www.mdpi.com/1424-8247/10/1/3

8. https://www.koreascience.or.kr/article/JAKO199903042091036.page

9. https://pubmed.ncbi.nlm.nih.gov/21058201/

10. https://pubmed.ncbi.nlm.nih.gov/25124601/

11. https://www.tandfonline.com/doi/abs/10.1080/01635581.2014.899371

12. https://www.tandfonline.com/doi/full/10.1080/09540105.2017.1332006

13. https://www.sciencedirect.com/science/article/pii/S1756464608000091

14. https://onlinelibrary.wiley.com/doi/abs/10.1002/ana.23594

15. https://pubmed.ncbi.nlm.nih.gov/23820171/

16. https://pubmed.ncbi.nlm.nih.gov/22458550/

VIDEO ON COOKING OF BLACK RICE

ABOUT THE AUTHOR

Mr. Saptaeshi Mandal is a highly experienced scientist, Ph.D. in Remote Sensing Application in Mountain Agriculture. He has been the founder of "Punarutthan AgroFarm" for farming of Black Rice and other kind of rice. Seeing the interest of Merchentus India Exim International LLP to promote this precious crop produced in India, he has taken lots of interest and has been encouraging us for the export of Black Rice.

Shyamal Kumar Bag

Merchentus India Exim LLP

23rd June, 2020

Tulaipanji aromatic rice with cooking tips by Merchentusindia

noreply@blogger.com (Merchentusindia) — Sun, 31 May 2020 19:21:00 +0000

TULAIPANJI RICE

Tulaipanji is known for its aroma, lightness, and jasmine-white appearance when cooked. ‘Tulaipanji’ is a non-basmati indigenous aromatic rice of West Bengal. It has medium-slender, white kernels with desired cooking quality and a pleasant aroma. One of the main features of Tulaipanji rice is that the grains can retain the aroma for around a year or more. Delicacies like Pulao, Payesh, Biryani can be made with this rice. This Bengali Tulai Panji Rice rice is sourced from the Northern province (Uttar Dinajpur) in West Bengal and shipped directly to the customer's place.

Tulaipanji is grown in a small pocket of north Bengal, has gained so much interest among the farmers due to the state government’s encouragement that its area of cultivation has increased by 45 percent in just three years, district officials said. Tulaipanji is cultivated in Raiganj, Kaliaganj, Hemtabad, and Karandighi blocks of Uttar Dinajpur district and Kushmandi block of Dakshin Dinajpur district. Earlier, the farmers were not very keen to cultivate Tulaipanji, but following the encouragement by the state government, more and more peasants are now engaged in farming this variety. “The yield of Tulaipanji was not enough in earlier years.

In Uttar Dinajpur, Tulaipanji was cultivated in 6,700 hectares in 2017-18, compared to 5,400 hectares in 2016-17 and 4,600 hectares in 2015-16, registering a growth of 45 percent in three years. The production of Tulaipanji has also been gradually increasing – 10,120 million tonnes in 2015-16, 11,880 mt in 2016-17 and 14,740 mt in 2017-18 – in the district,

In 2012, the Government of West Bengal sent Tulaipanji rice to the food festival at the London Olympics.

The aroma and quality of this rice variety are strongly associated with its native origin. Tulai Panji rice grown in West Dinajpur of West Bengal, which has got GI, has a very long history and there is mention of this rice even in Mythology. Tulai Panji means it is lighter like cotton and highly scented. Tulaipanji is categorized as 'non-Basmati aromatic rice'. It has a medium-long slender grain with an average length of 5.5 mm, length/breadth ratio of 3.4, and an elongation ratio of 1.6. Cooked rice is tasty, good in texture, bright in appearance, non-sticky, and friable due to high amylose content. Tulaipanji contains amylose – 28.3%, protein – 7.3%. It has comparable quality parameters like 77.1% hulling, 65% milling, 54.2% head rice recovery, and alkali value at 4.0. Traditionally, Tulaipanji is grown without using any fertilizer in mid-land to high-land condition and preferably in jute harvested fields, after a rainy season during the August–December period. Low soil fertility and moisture stress generally prevail in the growing field and believed to be the key factor behind the aroma. Inorganic fertilizers are generally not used due to the reduction in aroma and other qualitative parameters.

Some of the main features of Tulaipanji rice are as follows:

1. Beautiful aroma, which can last up to one year

2. Ideal for making sweet dishes like payesh (see the video)

3. Finest quality grains. It has a medium-long slender grain

Detailed descriptive parameters of Tulaipanji rice are:

VIDEO ON COOKING TIPS ON TULAIPANJI RICE

Blog created by Shyamal Kumar Bag, MD, Merchentus India.

How to cook Basmati rice

noreply@blogger.com (Merchentusindia) — Sun, 17 May 2020 10:24:00 +0000

COOKING TIPS FOR BASMATI RICE

WHAT IS BASMATI RICE

Basmati is a fragrant, nutty-tasting long grain rice grown in the Himalayas and Pakistan. “Bas” in Hindi language means “aroma” and “mati” means “full of,” hence the word Basmati or “full of aroma.”

Basmati rice is a thin, long-grain rice that is commonly used in the cuisines of the Indian subcontinent, Central Asia, and the Middle East. Meaning “fragrant,” basmati rice has a subtle nutty flavour. India generates most of the world’s production of Basmati rice. Most basmati rice that is imported to Iran, Yemen, Dubai, UAE, U.S. has been aged for at least 6 months to intensify its nutty aroma. Besides its flavour, the grains can become incredibly long once they’re cooked, about 3/4-inches in length.

To cook Basmati rice maintaining its shape and fragrance without making the rice sticky, it needs special techniques. Merchentus India has included Basmati rice as one of the product for export under their Aromatic Rice product range and is uploading a beautiful, very well demonstrated video in this blog for the benefit of the viewers.

AFTER COOKING SHAPE AND SIZE OF RICE SHALL BE MAINTAINED AS ABOVE

In order to get this distinct shape, one needs to soak the rice first and use the same water to cook the rice.

The key to making Basmati rice that is light, tender and fluffy is to rinse it first, otherwise, the grains will be gummy and stick together. It only takes a minute or two. Simply place the rice in a bowl with water, and then swish it around to release any excess starch. The water will be cloudy at first but after several rinses, it will be clear.

COOKING TIPS FOR BASMATI RICE AT A GLANCE

For most regular rice and Basmati rice, the ratio of rice: water Is usually 1:2.in a pot. If using Brown rice, Basmati rice or Parboiled Basmati rice (Sella Basmati rice) the ratio changes as both these rice take a longer time to cook. For definition of Sella & Brown Basmati rice please visit the video link in our website www.merchentusindia.com

RICE:WATER RATIO:

For Cooking Pre Soaked Rice In A Pan:

Regular basmati rice – 1:2
Organic basmati rice – 1:2½
Brown basmati rice – 1:3
Parboiled basmati rice or sella basmati rice – 1:2½ to 3

Method 1 - Boiling method – rice is cooked is ample amount of water. Once the rice grains are cooked, the water is discarded.

Rice: water Raito – 1:6

Method 2 - Absorption method – rice is cooked in a precise amount of water.

Rice: water Raito – 1:2

Method 3 – Cooker method – rice is cooked in pressure cooker with exact amount of water.

Rice: water Raito – 1:1.5

THE VIDEO

TO CHECK THE DONENESS:

Press a cooked rice grain with your thumb and forefinger. It should be soft and mash easily.

Or you can bite into a few rice grains. If there is resistance in the bite, this means the grains need to be cooked for some more time.

Blog has been written by Shyamal Kumar Bag, MD, Merchentus India Exim International LLP for export.

www.merchentusindia.com

Best Quality Aromatic Rice

noreply@blogger.com (Merchentusindia) — Sat, 16 May 2020 05:15:00 +0000

Aromatic rice in India for Export by Merchentus India:

Aromatic rice (Oryza sativa L.- Asian Rice) is considered as the best quality premium rice. The varieties are preferred by consumers because of its preference criteria such as shape, colour, distinctive aroma and flavor. The price of aromatic rice is higher than ordinary rice due to its special needed growth condition, for instance, specific climate and soil.

Aromatic rice provides the most benefits of health and nutrition. These are considered healthier as they possess more vitamins and fiber in their outer bran layers.

Aromatic rice constitutes a small but special group of rice and are considered the best in terms of quality and aroma. The aroma is one of the most significant quality traits of rice, and variety with aroma has a higher price in the market.

India is a treasure trove of varieties scented rice from every region and has a tradition of production, since ancient times. For example, Gobinda Bhog rice (West Bengal) has the history since, 500 to 600 years in the past. This rice has got GI. Kalanamak rice is the oldest rice brand that started at 600 years BC. According to the story the seed had been gifted by Gautam Buddha to the villagers of Malta now known as Modila village (UP). Britishers also had preserved this rice and used to send it to England. This rice has got GI in 2012. Similarly, Tulai Panji rice grown in West Dinajpur of West Bengal, which has got GI, has a very long history and there is mention of this rice even in Mythology. Tulai Panji means it is lighter like cotton and highly scented.

Look beyond the Basmati on the shelves of your supermarket and give indigenous aromatic varieties a chance — your taste buds are sure to thank you for bringing something new to the table!.

BASMATI RICE

GOBINDA BHOG RICE

TULAIPANJI RICE

BLACK RICE

Black rice also called forbidden rice or "emperor's rice,"(in China) is gaining popularity for its high levels of antioxidants and superior nutritional value. It is the only rice to contain the antioxidant known as anthocyanin which is known to be cancer-fighting, beneficial for heart health and inflammatory conditions. It also helps fight obesity. Black rice contains more Vitamins B and E, Niacin, Calcium, Magnesium, Iron and Zinc compared to white rice.

Non-basmati aromatic rice is having several varieties, not very popularly known, are more scented and tastier.

VIDEO ON AROMATIC RICES BY MERCHENTUSINDIA

Top Exporting Countries of Rice in the World:

1. India (30.1%)

2. Thailand (22.7%)

3. Vietnam (9%)

4. Pakistan (8.1%)

5. U.S.A (6.9%)

Top Importing Countries of Rice in the World:

1. China (6.5%)

2. Iran (4.9%)

3. Saudi Arabia (4.8%)

4. Indonesia (4.2%)

5. U.S.A (3.9%)

India's Export to countries:

1. Saudi Arabia

2. Iran

3. UAE

4. Iraq

5. Bangladesh

6. Nepal

The blog is written by S.K.Bag, MD, Merchentus India as part of www.merchentusindia.com