Mining and energy are the bedrock of modern society, underpinning our daily lives and economic prosperity. India, with its rich heritage in minerals and mining, has played a significant role in shaping these critical sectors. At the heart of this transformative journey lies the CSIR-Central Institute of Mining and Fuel Research (CSIR-CIMFR), an institution of excellence that has consistently pushed the boundaries of research and development in the fields of mining, energy, and environmental sustainability.
The CSIR-CIMFR Dhanbad, a constituent laboratory under the aegis of Council of Scientific and Industrial Research (CSIR), New Delhi, was formed on 2April 2007 by integrating the core competencies and the great visions of the two erstwhile premiere institutes: Central Fuel Research Institute (CFRI, 1946) and Central Mining Research Institute (CMRI, 1956). The core R&D strengths of the institute lie broadly in the areas of Mining Technology, Infrastructure and Civil Sector, Fuel Sector, Environmental Management, Testing, Analysis and Calibration Services. The present director of CSIR-CIMFR is Prof Arvind Kumar Mishra.
Resource Centres: Dhanbad, Digwadih, Ranchi, Bilaspur, Nagpur, Roorkee, Raniganj.
Objectives
The mission of CSIR-CIMFR encompasses a comprehensive array of objectives aimed at optimising the utilization of natural resources and fostering sustainable industrial practices. These include efficient recovery of fossil fuels, minerals, and ores, development of clean coal technologies, nationwide coal quality monitoring for power generation, R&D support spanning the mining industry, scientific assistance to strategic sectors, innovative underground mining methods, environmental preservation, and the facilitation of industry-society synergy through skill development and knowledge dissemination.
CSIR-CIMFR’s Knowledgebase
Mining Technology
Opencast mining, a predominant practice in India, has witnessed remarkable advancements. The introduction of large-sized draglines, shovels, dumpers, and surface miners has revolutionized opencast mining operations. CSIR-CIMFR has played a pivotal role in this success story by offering critical assistance to large opencast mines. Through its expertise, the institute has optimized blast designs, slope designs, highwall structures, overburden removal, and backfilling, thereby enhancing safety, productivity, and efficiency.
For six decades, CSIR-CIMFR has researched engineering rock mechanics and ground control for designing stable mining operations in India’s diverse geological conditions. The institute has developed indigenous norms and technologies, using extensive field investigations and simulations. CSIR-CIMFR has formulated key methodologies, including Rock Mass Rating for roof support, failure criteria for coal measures, safe vibration limits, pillar strength estimation, stress prediction models, and subsidence forecasts. The institute has also developed guidelines for mechanised depillaring, estimating strata behaviour, and roof support with Roof Bolt Based Breaker Line Support (RBBLS) design norms. The institute has also pioneered many technologies for energy efficient and fire safe ventilation, DOF technique for free silica determination in air borne repairable and coal mine fire dealing methodologies
Fuel Sciences
CSIR-CIMFR collaborates closely with coal exploration agencies, conducting comprehensive studies on coal resources nationwide. The lab and pilot-scale studies of the institute support steel plants, washeries, power stations, and the coal industry. The institute has gained international recognition for its research on coal structure, especially hydro-aromatic properties. It has standardized coal-related standards for the Bureau of Indian Standards, aiding in coal classification and pricing. The work of CSIR-CIMFR on coal washing led to establishment of public sector coking coal washeries. The institute has also developed coal beneficiation techniques for low volatile coking coals, formulated coal blends for steel production, designed innovative coke ovens, and utilized coke by-products.
Technological Innovations
CSIR-CIMFR, is dedicated to reducing India’s reliance on imported coking coal for coke production. The institute has developed groundbreaking non-recovery and drag-type coke ovens with stamp charging and coke quenching methods. Additionally, CIMFR has devised innovative processes for coal and coke briquette production. In safety and security, the institute introduced a biometric-based exploder and dry fog dust suppression system, enhancing operational safety. The innovations extend to mining, with systems like the Mine Transport Surveillance System and Vision Enhancement System for improved visibility in foggy conditions. The institute’s expertise in geo-mining conditions has led to the development of robust ground reinforcement systems, enhancing safety and productivity in Indian underground mines. Formulation of failure criteria for Indian coal, pioneered equivalent material mine modelling techniques, and promoted various mining methods for optimal coal extraction have also been contributed by the institute.
CSIR-CIMFR addresses environmental concerns by repurposing fly ash for stowing in mines and as value-added products like bricks and fertilizers. The guidelines produced by the institute for safe blasting practices and standards are internationally recognized. The institute is advancing mining safety further by transforming physical mines into 3D virtual mines with cutting-edge technologies like IoT devices, AI, and wireless communication.
Beyond mining, CSIR-CIMFR evaluates coal quality, estimates resources, and contributes to coal-based industries’ growth. The institute has tackled challenges posed by hard-to-wash Indian coals, including low-volatile coking coals, fine coal slurry, and high-ash non-coking coals, developing innovative stamp charging methods for improved coke quality. In the pursuit of cleaner energy solutions, the organization plays a pivotal role in the methanol economy mission, converting coal into methanol and dimethyl ether. The institute’s 1.5 TPD pilot plant for oxygen-enriched pressurized fluidized bed gasification aids this mission.
CSIR-CIMFR actively addresses environmental concerns by mitigating fugitive methane emissions during coal mining. The institute is involved in estimating methane emissions and GHG emissions from fossil fuel combustion, aligning with emissions reduction goals. The cutting-edge oxy-fuel combustion pilot plant pioneers CO2 capture research, while microbial routes are explored for CO2 capture in thermal power plants. To promote cleaner energy, the institute is researching biogas from coal washery effluent and biomass, offering alternative energy solutions.
The institute’s involvement in the Minamata Convention on Mercury demonstrates the commitment of CIMFR to environmental responsibility by compiling a national inventory of mercury emissions, particularly in extraction industries. CSIR-CIMFR’s contributions extend to redefining mining methods. The institute’s work on techniques such as the wide stall method, cross-development-based extraction, shortwall methods, and longwall mining technologies has been instrumental in optimizing the extraction of thick seams and locked-up coal reserves. Beyond mining, the institute has played a crucial role in expediting road construction projects, particularly in challenging terrains and border areas, through controlled blasting techniques.
Pilot Plant Services
CSIR-CIMFR aims to achieve excellence in providing basic R&D and industry support in the areas of clean coal and combustion technologies. There are varying concerns about their applicability and commercial viability under Indian context that need to be addressed expeditiously. The institute has developed several pilot plants towards implementation of clean coal technologies in India.
- 30-60 kg/h pilot scale oxy-fuel combustion test facility.
- Co-combustion study of coal and biomass blends using pilot scale combustion facility i.e., drop tube furnace (DTF).
- Pilot scale air blown pressurized fluidized bed gasifier (PFBG) of 1.5 TPD.
- Pilot plant for coal to liquid (CTL) synthesis (process development unit, PDU; catalyst capacity: 10 L) of maximum 5 L per day liquid hydrocarbon production.
Unique Facilities
- National facilities for FLP, Intrinsic Safety, Explosive & Mining safety equipment testing including human breathing simulator for performance evaluation of life saving equipment in mines.
- Testing facilities for coal properties; spectro-radiometric technique for differentiating coal litho-units in the field for selective mining; drop tube furnace; simultaneous thermogravimetric analysis; PFBG.
- High temperature and pressure single tube fixed bed reactor and pilot plants for coal processing.
- High performance computing for large scale geo-mining modelling and simulation.
- Petrographic and geochemical testing facilities: Rock-Eval 6, Field Emission Scanning Electron Microscope (FE-SEM).
- Unique test facility for geo-mechanical properties of rock: MTS 815 Rock Mechanics Test System.
Societal Work of CSIR-CIMFR
CSIR-CIMFR has played a vital role in empowering rural women within the climate change context through sustainable energy initiatives. These efforts involve customized domestic biogas systems, active involvement of rural women in green energy and climate initiatives, and the creation of model villages that promote sustainable development. Additionally, the institute has introduced mine water reclamation technology to provide safe drinking water and offers training to villagers in various socio-economic activities like medicinal plant cultivation, reforestation, carbon sequestration, and value-added product development. These endeavours underscore the institute’s unwavering commitment to positive change.
External Cash Flow
CSIR-CIMFR through its knowledge base and transfer of technology achieved positive cashflow of Rs 1000 crores in the financial year 2019-2020. The institute strives to continue this trend using its privileged position as a premiere organisation in the field of mining and fuel technology.
Figure. Year wise external cash flow of CSIR-CIMFR
Table. Return on Investment by the laboratory/institute
R&D Roadmap of CSIR-CIMFR
Mining Technology: The institute primarily concentrates on mining technology, with a key emphasis on accessing coal resources located beneath surface structures and creating methods for extracting deep-seated coal deposits in an effective and environment-friendly manner. Additionally, the institute places a strong emphasis on advancing safety, productivity, and sustainability in both open-pit and underground mines. Furthermore, it is committed to pioneering new, state-of-the-art technologies for the mining industry, including automation and the utilisation of drones, to enhance overall efficiency and innovation in the field.
Intelligent Mining Systems: CSIR-CIMFR has multifaceted approach to mining technology, which includes the creation of real-time analysis systems for coal and mineral grades and sizes during dispatch. The institute is committed to digitize every operational mine in India, allowing centralized monitoring from control rooms. Additionally, Augmented Reality and Virtual Reality systems with computer vision for mining applications are being developed.
Coal to Methanol: Cutting-edge research is focused on two critical fronts. The first involves the creation of zero-emission, energy-efficient gasification technologies, facilitating the targeted production of hydrogen and valuable chemicals. In parallel, researchers are advancing syngas-based poly-generation methods, shaping a sustainable energy landscape.
Coal to hydrogen: Innovative approaches are being explored across various domains. Hydrogen production methods encompass pulverization, photothermal, and ultrasonic techniques. Meanwhile, Type V composite cylinder development, from design and fabrication to prototyping and rigorous testing, is underway. The institute scientists are investigating hydrogen storage within underground coal seams, focusing on high-pressure solutions.
Carbon Capture Utilization and Storage (CCUS): The institute is actively engaged in pioneering advancements in carbon capture and storage (CCS) and biofuel development. This includes innovative methods to convert CO2 into valuable chemicals, fuels, and polymers. Additionally, efforts are focused on sub-surface CO2 sequestration within geological reservoirs, enhancing hydrocarbon recovery and mitigating carbon emissions.
Coal Carbonization: In the realm of coal and coke innovation, multiple initiatives are underway. These encompass lab-scale development of Hot Stamp Charging Technology, bench-scale processes for needle coke and graphite electrode production, H2-rich coal gas generation, and continued enhancements in By Product Coke ovens technology.
PATH AHEAD
The CSIR-CIMFR is a trailblazing institution at the forefront of India’s mining, energy, and environmental sustainability sectors. Its relentless pursuit of excellence, alignment with national priorities, and commitment to innovation underscore its pivotal role in driving technological advancements and economic growth in India. As CSIR-CIMFR continues to adapt to evolving challenges, it remains a catalyst for transformative change, forging a sustainable and prosperous future for India’s mining and energy industries.
*The writer is Chief Scientist and Head, Mine Fire, Ventilation and Minor Safety Research Group, CSIR-CIMFR, Dhanbad
