mining methods for aggregate quarries n … methods for aggregate quarries " ... fly rock and...
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“Innovative Blast FreeMining Methods for
Aggregate Quarries "
Ramesh Bhatawdekar,
Edy Tonnizam Mohamad,
Firdaus Azlan
Department of Geoteknik and Transportation,
Faculty of Civil Engineering,
University Teknology Malaysia,
G.K.Pradhan
Department of Mining Engineering
AKS University, Satna, India中国砂石协会
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Introduction
• Concrete – Per capita consumption 1 T
• Consumption of natural aggregates concrete
• Aggregates are commonly mined with blasting worldwide
• Blasting increases various hazards
• Study of geological factors necessary for optimizing blast
design as well as for breaking rock with new technology
• Physio mechanical properties affect selection of technology
• New Innovative Technologies under development for breaking
rock with minimum hazards 中国砂石协会
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Environmental Hazards due to Blasting
• Type of hazard Possible Impact Common Causes
• Fly-rock Property damage, Geological conditions,
Serious injury, Over charge of explosives,
Loss of life Stemming length, back break
• Ground Vibration Annoyance to public, Exceeding max charge/ delay
Cracks in property
• Air Blast Annoyance to public, Use of detonating fuse
Glass pane breakage
• Fumes, dust Local hazard
• TECHNOLOGICAL DEVELOPMENT IN INITIATION SYSTEM
Ordinary detonators – Electric delay detonators- Sequential Blasting
Machine- Cord relays -Non electric detonators- Electronic detonators
中国砂石协会
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Technological Milestones in Mechanical Cutting
• YEAR
• 450 BC
• 1913
• 1920
• 1980s
• 1987
• 1990
• 1994
• 1999
• TECHNOLOGICAL EVENT
• Surface scratching by Paleolithic miners for stone implements
• Development of bucket wheel excavator
• Concept of continuous and mass mining systems
• Surface miners emerge as a clean mining system
• Hofmann, reported use of continuous surface miners as a
technology for opencast.
• Gujrat Ambuja Cement developed Wirgen 1900 Surface Miner
for trial basis
• Introduction of high wall system
• Surface miner introduced in Indian Coal Mines中国砂石协会
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Types of Natural Aggregates
• India• Basalt
• Calcgranulite
• Charcnockite
• Chert
• Granite
• Greywacke
• Limestone
• Magnetite
• Muscovite
• Quartzite/ Quartz wacke / Greywacke
• Quartz/Quartz Mica Schist
• Sandstone
• Trap Rock
• Malaysia• Agglomeratic tuff
• Chert
• Glassy Acidic to Intermediate Volcanic
• Granite
• Geyseites
• Hornfels
• Impact rocks
• Intermediate Volcanics
• Metaquartzite
• Mylonized rocks
• Quartzite
• Rhyolite
• Sandstone
• Siliceous Shale
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Selection of Rock Excavation Process,Machines
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Evaluation of Rock Breaking Methods
for Rock Breaking Systems
• Determining rock strength – compressive and tensile strength
• Determining energy related indices- crushing energy factor
• Measurement of rock breaking parameters – cutting resistance, depth
中国砂石协会
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Rock Properties
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Prediction of specific energy required for cutting (Barendsen, 1970)
Barendsen, (1970)
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Determination of excavation possibilities(Atkinson, 1971)
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Pettifer–Fookes chartDiscontinuity Spacing Index Vs Point Load Index
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Overall Assessment of Excavability of Rock Mass
中国砂石协会
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Excavalibilty of Jointed Rock Mass using Geological Strength Index (GSI)
• ..
中国砂石协会
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Summary – Excavability of Jointed Rock Mass using GSI
• The Geological Strength Index (GSI) used to assess the ease of excavation
of rock masses :Figure A ( Is50 \3 Mpa ) and Figure B (Is50 C 3 Mpa)
• Blasting required GSI values are greater than 65 when Is50 C 3 MPa and
60 when Is50 \ 3 MPa, hence blasting is usually required in massive, blocky
and very blocky rock masses or when joints are tight.
• Successful ripping is generally achieved for rock masses with GSI values between 20 and 45
• In the transitional zone between the ripping and blasting areas of the GSI charts, excavation with hydraulic breakers is necessary.
• The proposed classification is applicable only for rock masses where discontinuities control the excavation, thus is should not be used for the assessment of excavation in heterogeneous rock masses
中国砂石协会
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Surface Miner
.
中国砂石协会
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Selection of Surface Miners
Geotechnical parameters
• Uniaxial Compressive Strength
(UCS)
• Tensile Strength
• Moisture Content
• Abrasivity
• Brittleness
• Stickiness
• Percentage of silica
Rock properties
• Schmidt hammer – for Rebound Test
• Scan line survey – to determine the discontinuity by carrying out this test at the cutting edge/face created by the surface miner,
• Laboratory investigations
• Point Load Strength Index (PLSI in MPa) using BEMEK tester. 中国砂石协会
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Parameters Influencing Cuttability of Surface Miner
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UCS of Rock Vs Surface Miner
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Rippability based on Excavability Index
• The excavatability index depends upon mass strength number, rock
quality designation (RQD), joint set number of Q – system, relative
ground structure number, joint roughness number of Q – system,
and joint alteration number of Q – system (Kisten, 1982).
中国砂石协会
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Hydraulic Rock Breaker
• Various Manufacturers are
available for supplying Hydraulic
Rock Breakers mounting on Back
Hoe Excavators.
• Suitable application for breaking
boulders to avoid secondary
blasting
• Output 180 to 200 TPH
• Operating pressure 300 PSI
• Still need development to utilize
Hydraulic Rock Breaker as Primary
Breaking 中国砂石协会
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Controlled Foam Injection Technology
• The method uses high-pressure foamto initiate, pressurize and propagatecontrolled fracturing in rock. The foamis injected to the bottom of a relativelyshallow pre-drilled hole in the rock tobe broken by means of a barrelincorporating a hole bottom sealingmet. The pressures required tofracture and excavate rock aresignificantly less than required inmethods based upon the use of smallexplosive.
• Air blast and fly rock are reduced andthus allowing application in urban andenvironment sensitive area
• .
• Controlled Foam Injection (CFI) method uses as high as 83 MPa (12,000 psi) pressure when breaking a hard granite. Breakage efficiencies of 0.06 m3 tof0.24 m3 per break observed during trials.
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Rock Breaking using Chemical Methods
• Expansive Mortar which can fracture rock or concrete with expansive force of 15,000 psi (1034 kg/cm2). Productivity of mechanical breakers is also increased by fracturing rock. Product can be used for pre-splitting rock in sensitive conditions. Expansive Mortar can be used in dry and watery conditions hole diameter upto 76 mm.
• Application : For boulders, depth of hole is 65 to 70% height of boulder.
• 10 times hole diameter is distance between holes and holes are drilled in square or diamond pattern.
• Presplitting Mortar is added to holes and after 6 hours , boulder or surface is cracked. 中国砂石协会
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Rock Splitting Mortar
• Advantages• Eliminates noise, fly rock and vibration
potential caused by blasting or heavymechanical means
• Increases productivity of hydraulic rockbreaker
• Accelerates removal time once fracturingoccurs
• Works underwater in difficult conditions
• Minimizes risk in high exposure situations
• No license for storage of rock splittingmortar中国砂石协会
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Plasma Technology for rock breaking
● A group of scientists at the Korea Instiute of Geology, Mining and Materials (Min et al.,1997) established the plasma blasting method for rock fragmentation.●
中国砂石协会
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Plasma Technology Process
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Conclusion
• Blasting has fly-rock, ground vibration, air-blast and fumes as hazards.
• In environmentally sensitive areas, various technologies are being tried for
more than 2 decades
• Aggregates .produced from granites, basalts, quartzite, chert, limestone, etc
• Study of compressive strength, tensile strength, geological strength Index
for excavation are necessary to decide type of excavation method
• Surface Miners, Hydraulic Rock Breaker, Rippers are suitable for certain
rock types with geological features (very blocky to disintegrated), for blast
free mining
• Hydraulic Rock Breaker is used mainly for boulder breaking. Further
development required for primary breaking.
• Rock splitting Mortar with Hydraulic Rock Breaker can give advantage of
rapid breaking of rock.
• Rock Splitting Mortar ,Foam Injection technology and Plasma Technology
are immerging technologies which need to be established for aggregate
quarry application
中国砂石协会
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Points for discussion Status of Blast Free Mining at China
• Whether proven technologies like Surface Miner or Hydraulic Rock Breaker are in use at China?
• Any other blast free technologies being used in China.
• Future scope of blast free technologies in China.中国砂石协会
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.
• .
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References
• [1]. Atkinson, T.: Selection of Open Pit Excavating and Loading Equipment. Transaction Institute of Mining and Metallurgy – Section A, A101–A129 (1971)
• [2] Barendsen, P.: Tunneling with Machines Working on the Undercutting Principle. In: Goodman, J.A. (ed.) The Technology and Potential of Tunneling, Proceedings of South African Tunneling Conference, pp. 53–58 (July 1970)
• [3 ] Janus Res, K. Wladzietczyk, Ajoy K Ghose Book- Environment Friendly Techniques of Rock Breaking
• [4] Min, J. S., Chung, Y. W., Lee, H. J., & Lee, D. N. (1997). A study on the environmental and safety problems and their remediation around mining areas. Korea Institute of Geology, Mining and Materials (Vol. 32). Research Report KR-97 (C).
• [5] Pettifer GS, Fookes PG (1994) A revision of the graphical method for assessing the excavability of rock. Q J Eng Geol 27:145–164
• [6] Pradhan, G. K., Prakash, O., & Thote, N. R. (2014). Blast Free Mining in Indian Surface Coal Mines–Current Trend. In Mine Planning and Equipment Selection(pp. 335-357). Springer International Publishing
• [7] Swamy R. N. (1992) Book- Alkali Silica Reaction ,
• [8] Tsiambaos, G., & Saroglou, H. (2010). Excavatability assessment of rock masses using the Geological Strength Index (GSI). Bulletin of engineering geology and the environment, 69(1), 13-27.
• [8] Venkatesh, H. S., Bhatawdekar, R. M., Adhikari, G. R., & Theresraj, A. I. (1999). Assessment and Mitigation of Ground Vibrations and Fly rock at a Limestone Quarry. In Proceedings of the Annual Conference on Explosives and Blasting Technique (Vol. 2, pp. 145-152). International Society of Explosives Engineers.
• [9] Young, C. (1999). Controlled-foam injection for hard rock excavation. In Rock Mechanics for Industry, Proceedings of 37th US Rock Mechanics Symposium, Vail, Colorado (Vol. 1, pp. 115-122).
• [10] YOUNG, C., & GRAHAM, C. (1999). CONTROLLED FOAM INJECTION PROGRESS TOWARDS AUTOMATED HARD ROCK EXCAVATION. In Proceedings of the 5th International Symposium on. Mine Mechanization and Automation, Sudbury, Ontario (p. 39).
• [11] http://www.daighcompany.com/products.asp
• [12] https://www.youtube.com/watch?v=zzoatmX_Xh8
• [13] http://www.wirtgen.de/en/products/surface-miners/
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