COAL BED METHANE

RECOVERY AND UTILIZATION

AT
MOONIDIH, DHANBAD

Submitted by:-
Amit Kumar
Ashish Pandey
Amit Kumar Sinha

B.Tech. 2
nd
Year Training Period
Petroleum Engg 21 Dec 2011- 04 Jan 2012
ISM Dhanbad


ACKNOWLEDGEMENT

I would like to thank Bharat Coking Coal Ltd. Dhanbad for
allowing training program at their premises and for providing all the
needful facilities for completion of the entire program.
I would like to express my sincere gratitude towards my mentor
Mr P. Kumar for his continuous guidance and for enlightening me by
providing vital knowledge throughout the program. Working under
his guidance has been a privilege and a fruitful learning experience.
I also express my deep gratitude to those who have helped and
encouraged me in various ways in carrying out this project work. I
would like to extend my thanks and want to acknowledge the BCCL
(CBM Plant) personnels for sharing their valuable knowledge.


Amit Kumar
Ashish Pandey
Amit Kumar Sinha


INTRODUCTION

Methane and coal are formed together during coalification, a process
in which plant biomass is converted by biological and geological
forces into coal. Methane is adsorbed in coal seams and the
surrounding strata and released during coal mining. Deeper coal
seams contain much larger amounts of methane then shallow seams.
Small amounts of methane are also released during the processing,
transport, and storage of coal.
Coal mining is estimated to account for about 10 percent of all
human-induced emission of methane, a greenhouse gas which is
considered to be 21 times more harmful than carbon dioxide.
Methane is absorbed in coal seams and the surrounding strata and
released during coal mining. Small amounts of methane are also
released during the processing, transportation and storage of coal.
Methane can cause explosions in underground mines when it is
trapped in coal beds and then suddenly released during mining.
Recovery of methane not only reduces the amount of methane that
escapes into the atmosphere but also reduces the danger of mining-
related hazards. When recovered from these coal beds, however,
methane can be used as a source of energy and fuel as it is a
remarkably clean fuel.

For the first time in India, coal bed methane (CBM) is being
recovered and utilised through an innovative project supported by the
Global Environment Facility (GEF) and the United Nations
Development Programme (UNDP) and implemented by the Ministry
of Coal, Government of India. The project has demonstrated the
commercial feasibility of capturing methane from coal bed and
utilising it as transport fuel and for electricity generation. This
recovery of hazardous methane prior to coal mining also ensures
greater safety for miners.












SERIES OF EVENTS LEADING TO CBM
PLANT DEVELOPMENT
As per Govt. of India CBM policy, consortium of CIL and
ONGC has been allotted 2 blocks one each in Raniganj and
Jharia coalfields and have entered into a contract with Govt. of
India for development of coal bed methane. The Govt. of
Jharkhand on 28.08.03 has granted the Petroleum Exploration
License (PEL) for Jharia CBM block. Consequent upon the
geological exercise jointly carried out by CMPDI & ONGC,
location of slim holes has been finalized and drilling of first
slim hole has since commenced. The Govt. of West Bengal on
09.06.04 has granted the Petroleum Exploration License (PEL)
for Raniganj CBM block and geological exercise for locating
slim holes/ wells to be drilled in Raniganj CBM block has been
taken up jointly by CIL & ONGC.
The Directorate General Hydrocarbons (DGH) has awarded the
work of delineation of 7 prospective CBM blocks and
preparation of their data packages/information dockets for 3rd
round of bidding of CBM Blocks by the Govt. of India.
Accordingly, geological exercise for preparation of data
package/ information docket has been taken up.
CMPDI has taken up studies related to "Assessment of Coal bed
Methane Gas-in-Place Resource of Indian Coalfields" through
boreholes being drilled under promotional exploration (Xth Plan
period) being funded by Govt. of India with a total plan
expenditure of Rs 8.83 crores. The prioritization of the blocks
for CBM related studies during 2004-05 have already been
completed and agency has been identified for taking up
desorption studies till such time in-house facilities for the study
is developed at CMPDI. The desorption studies will be taken up
in selected boreholes and are schedule to be taken up from
January' 2005.
CMPDI has been commissioned by M/s Wardell Armstrong for
taking up studies related to gas emissions characteristics of
gassy mines with the objective to develop an understanding for
the methane emission in Indian coal mines and for appraisal of
one or two abandoned mines for assessment of Abandoned
Mine Methane (AMM)/Coal Mine Methane (CMM) prospects.
This project is sponsored by Deptt. of Trade & Industry(DTI),
Govt. of UK and is being managed by M/s Wardell Armstrong.
CMPDI has been commissioned to take up the job with due
approval of Ministry of Coal. The work has since been taken up.
UNDP/Global Environment Facility (GEF)- GOI Project- Coal
bed Methane
Recovery and Commercial Utilisation:
The demonstration project Coal bed Methane Recovery &
Commercial Utilisation was approved by the Government on
15.09.99, under the S&T plan of Ministry of Coal. The project, with
an estimated cost of Rs 76.85 crores, is being funded jointly by the
Global Environment Facility(GEF)/ United Nations Development
Programme (UNDP) and Govt. of India (GOI). The project is under
implementation w.e.f 15.9.99 jointly by Central Mine Planning &
Design Institute Ltd. (CMPDI) as main implementing agency and
Bharat Coking Coal Ltd (BCCL) as co-implementing agency, on
behalf of the Ministry of Coal. Project sites are Moonidih and
Sudamdih mines of BCCL in Jharia Coalfields.












MAJOR DEVELOPMENTS IN THE
IMPLEMENTATION OF THE PROJECT
DURING 2004-05 are as follows:-
i) International CBM recovery Equipment procurement under
UNIDO:
a) The Package 11: Vertical Drilling Rig (of USD 2.24 million CIF
Kolkata) has reached Moonidih during 26.7.04-11.8.04. Joint
inspection with the suppliers representative has been completed.
Short supply of small items have been brought out in the joint
inspection report and the party is making arrangements for the supply
of the short listed items. The party, as per its contractual obligation is
making arrangements for getting necessary approvals from Director
General of Mines Safety(DGMS).
b) The Package 7: HDPE Pipe collection System (of USD 0.16
million CIF Kolkata) was ordered by UNIDO on 30.4.04 and have
started arriving at Project site-Moonidih.
c) The Package 8: Fusion Machine for UG and Surface (of USD
0.047 million CIF Kolkata) was ordered by UNIDO on 14.5.04 and
has arrived at Project site-Moonidih.
d) The RFP was sent out by UNIDO on 3.12.04 with closing date of
12.1.05 for the following :
Package 9: Production Equipment (Underground)
Package 10: Safety System
Package 24: Gas Gathering Collection System
e) The Package 1: Beam Based Long Hole Drill (Underground) (of
USD 0.90 million) was finalised for purchase and UNIDO has signed
the contract with the supplier.
f) For the Package 3: Downhole Motor (Underground) (of USD
0.10 million CIF Kolkata) the finalisation of purchase order took
some time owing to a demand of 10% increase in component cost due
to metal price rise in the global market. UNIDOs Committee on
Contracts has processed the contract.
g) The Package 4: Steering Tool with NQ- Drill string
(Underground), which did not get any independent response in the
earlier tender (response was received along with underground rig
tender which could not get technically qualified), has been re-
tendered by UNIDO in November.
h) The Package 12:
a) Drill Collars, Stabilizers & Elevators etc. (of USD 0.139 million
CIF Kolkata) were ordered by UNIDO on 18.5.04 and have started
arriving at the Project site-Moonidih.
b) Drill Pipes was re-tendered by UNIDO on 26.8.04 with bid closing
on 17.9.04. The package was re-tendered on account of decline by the
selected bidder to supply the drill pipes at the quoted price because of
substantial steel price increases, and instead offered to supply at
36.6% increased price over the quoted price.
The re-tendered bid was evaluated and the order (of USD 0.278
million CIF Kolkata) has been placed on an Indian Supplier on
20.12.04. The delivery time on site has been negotiated at 6 months in
place of 8 months offered by the supplier. This critical item, to start
surface drilling, will be on site in June05 and the Surface drilling will
start by end June05, thus delaying the Surface drilling activity by
about six months.
i) The Package 13: Drill bits (Surface) (of USD 0.126 million CIF
Kolkata) was ordered by UNIDO on 30.4.04 and have started arriving
at Project site-Moonidih.
j) For the Package 19: Geophysical Logger (Surface) (of USD 0.65
million) services, the modalities of signing of the contract by UNIDO
are under process.
k) The Package 21: Pumping Equipments (Surface) (of USD 0.524
million CIF Kolkata) was ordered on 18.5.04 and have started
arriving at Project site- Moonidih.











DRILLING OPERATION AT MOONIDIH
CBM PLANT
In the first phase of CBM drilling in Moonidih 5 (five) wells were
decided to be drilled using mud system. The locations viz. CBM #04,
CBM #10, CBM #03, CBM #11, CBM #12 were selected judiciously
to get the best of the virgin parts of the coal seams from XVIII to XIV
where most of the seams were known to be highly gassy. The depth of
seams in the borehole could be from 500 meters (XVIII Seam) to 960
meters (XIV Seam) or more. All the 5 boreholes were placed in the
dip side of the property within the leasehold of Moonidih where
extraction of coal in parts of different seams had already been
performed or is in the process of being performed and hence it is
known as active mining area.
CBM drilling and utilization at Moonidih is a Pilot Project under the
financial and administrative control of UNDP/GEF-GOI, New Delhi.
The Central Mining Planning & Designing Institute Limited
(CMPDIL) is the implementing agency for GOI and beneficiary of the
gas output will be Bharat Coking Coal Limited (BCCL). Oil &
Natural Gas Corporation (ONGC) is also participating in the project
mainly in cementation and hydro fracturing of the wells.
Drilling at 1
st
well site #04 started in September 2005 and first part of
drilling (12 hole dia.) up to 207 meters depth was completed with
good return from the well by 30
th
November 2005. Here the formation
pressure, as predicted, was found hydrostatically and drilling could be
done with mud specific gravity of 1.02 to 1.06 and viscosity of 30 to
35 seconds. The planning was to drill up to 1000 meters with two size
casing policy.
The jobs those followed the 1
st
part of drilling were Geological
logging, lowering of 9 5/8 casing, cementation, wait on cement
setting, well head fitting & welding followed by the ball nipple
fabrication and fitting. Imported motors of the mud pumps and tanks
were replaced by indigenous FLP motors which were falling within
the hazardous zone.

The 2
nd
part of drilling was resumed on 9
th
January 2006 and drilling
rate was normal but at the depth of 375 meters the bit & bit subs were
detached from drill collar and left at the bottom of well during
drilling. The same was fished out using 6 grapple. At 410 meters
the first mud loss was observed on 27-01-2006. This was temporarily
controlled by using high viscous LCM (Loss Control Material) plugs
against loss zone, but thereafter the real problem started. Twenty-
seven loss zones were encountered one after another during further
drilling and coring from 410 to 594 meters.
All the above loss zones were tackled, though temporarily, by putting
LCM plugs with limited chemicals for improvement of viscosity.
From 410 to 594 meters the consumption of bentonite was 72.60
tonnes as compared to only 7.40 tonnes consumed for drilling up to
410 meters. It may be mentioned here that from 485 meters to 497
meters, Blind Drilling was also tried using water only, but it was
found that drilling with water invited some serious down hole
problems such as tight pull, bad torque etc. At the same time other
plugging methods such as Cement + Bentonite and Diesel + Bentonite
were also experimented without any satisfactory results. However,
drilling up to 594 meters, the Geo Technical Order (GTO) was
followed with the presumption that the formation pressure would be
hydrostatic and could be drilled with improved specific gravity and
viscosity to get a good return. But all assumptions failed and mud loss
continued.
At that point of time it was thought of going Under Balanced Drilling
(UBD) because of the following observations:
1) The symptoms such as continuous static & dynamic losses were
possible in a sub-hydrostatic pressure due to existence of faults and
weak zones in the formation.
2) Existence of large cavities in goaves above long wall panels in
the seams. These helped migration of water from the well site
formations to the depressurized zone in fractured rock causing
reduction of formation pressure around the well.
3) Weak formation due to existence of several coal seams of high
porosity.
4) Specific gravity of return mud was higher due to re-circulation of
cutting during drilling & coring.
5) CBM could be blowout free drilling operation.



Keeping in mind all the above points in mind it was decided for
definite to undertake UBD by reducing mud density. Method tried
were:-
1) Supply air in drilling mud get bubbles
2) Use foaming agent in drilling mud to get bubbles.

The first method was tried but it did not give satisfactory result due to
non-availability of requisite compressed air from the rig. The 2nd
method i.e. to create foam in mud was found to be a time taking
process. To overcome this problem, extensive laboratory test were
done at the site by mixing different liquids with detergent powders to
get a decisive dose. Lastly a satisfactory result was obtained and was
tried at 594 metres with the mud specific gravity brought down to
from 1.03 to 0.90. After old mud replaced drilling was done from 594
to 600 metres with the decided mud specific gravity and no mud loss
was observed and thereafter drilling progressed satisfactorily. In this
way UBD method was established.
Drilling continued uninterruptedly thereafter and the drilling of the
first well (No.4) was completed up to 1000 metres, which had cut
across all the seams from XVIII to XIV seam and the core recovered
was about 95%. CMRI was in a position to access the percentage of
methane available from the cores of the coal seams and the results are
encouraging except for XIV seam.
It may be mentioned here that after the mud loss problem was
successfully dealt with from 594 metres, the progress registered was
18 metre per day and on some days it was even 23 metres.
At the end of drilling of this well, following conclusions were
drawn, and noted for the benefit of upcoming drilling wells in the
mining area.
1) The hydrostatic formation pressure of nearby locations may be
depleted to a sub-hydrostatic after 410 metres or so.
2) Before switchover to UBD, one or two loss zones may be
observed for deciding the sub-hydrostatic pressure zone otherwise it
could create well problems.
3) Abruptly low mud weight should not be applied in sub
hydrostatic formation.
4) Wherever possible, formation pressure should be made known to
the drillers before drilling operations at different depths.
5) Quality of bentonite must be maintained. Viscosity of the
bentonite mud should increase to 40 sec after 8 hours of mixing with
5 to 6 % of bentonite.
6) Shale shaker screen to be kept in good condition to avoid re-
circulation of rock particles in the mud.
7) Every loss may have its own requirement of mud parameters.

IMPACT
Under this project, methane was extracted from two wells in the
famous coal mines of Dhanbad, in the eastern Indian state of
Jharkhand, and power generated at a competitive price of Rs.4.50 per
kilowatt hour (kWh). The recovered gas from the two coal mines was
about 11.52 million cubic metre or 7,626 tonnes of gas per year. This
was equivalent to 160,151 tonnes of carbon dioxide, another
greenhouse gas. Mere utilisation of the captured methane reduced
150,500 tonnes of carbon dioxide-equivalent greenhouse gas
emissions annually, assuming that otherwise all this methane would
have escaped to the atmosphere due to the mining operations. Thus,
annual carbon dioxide reduction, solely from the two demonstration
sites, was an estimated 180,000 tonnes.

Besides, the electricity generated is being supplied to 400 households
in the nearby mine workers colony. To ensure replication, the project
has been successful in making CBM recovery a subject in the
curriculum of the Indian School of Mines in Dhanbad.

The capacity of the Central Institute for Mining and Fuel Research,
Dhanbad, a major resource centre for CBM, in recovering methane
from working mines has improved substantially under this project.
To disseminate the data generated to private players and to replicate
these efforts, a Clearing House has been set up with the assistance of
the US Environment Protection Agency at the Central Mine Planning
and Design Institute Ltd., in Ranchi, the capital of Jharkhand.
Importantly, the project has influenced the Ministry of Coal to take
informed decisions on CBM recovery across the country.
The 11
th
Five-Year Plan of the Indian government refers to this
innovation as a potential alternate source of energy and fuel.
Prospective investors are keen to replicate CBM recovery from
gaseous mines, ensuring nationwide and far-reaching impact of this
project.