Dimensional Stone Mining and Environment

8/11/2019 Dimensional Stone Mining and Environment

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DIMENSIONAL STONE RESOURCES IN INDIADIMENSIONAL STONE RESOURCES IN INDIA

AND ENVIRONMENT FRIENDLY MINING ANDAND ENVIRONMENT FRIENDLY MINING ANDPROCESSINGPROCESSING

Dr. S.S.RATHORE

Department of Mining Engineering

o ege o ec no ogy an ng neer ngMaharana Pratap University of Agriculture andTechnology: Udaipur 313001, INDIA

Presented at: Seminar on Sustainable Natuarl Stone during 21-22October, 2009

at Hotel The Atrium Faridabad, India


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INTRODUCTION

Dimensional stones are a major economic commodity in India

The stones sector in India provides employment to over a million

people

India is one of the few countries in the world having mining andprocessing of granite, marble, sandstone, flaggy limestone, slate

quartize etc.

e ca careous s ones are arge y sprea over e or - esand the siliceous stones in the Deccan peninsula in South India

Indian stone industry growing steadily at an annual rate of

about 10% per year

Stones are mostly extracted in the form of blocks and cut in

required sizes to use in construction industries

During the conventional mining waste generation is quite high

and recovery of saleable products is only 20 to 50%


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Now a days wire/chain/belt saw techniques are in practice but insandstone and granite controlled blasting is used at most ofmines

Thus, scientific extraction of blocks at quarry site, processingwith latest techniques and proper utilization of waste generationis need of the hour

Mechanization of quarry operations adopting innovativetechnologies for eliminating wastage and also to increase theproduction capacity

Utilization of waste means conservation of resources in theform cobbles, cubes, binding material, ceramic application etc.

In general, sandstone and granite are extensively used andpreferred for structure, slates for roofing, Kotahstone forindustrial flooring & marble for domestic and monumentalflooring

Huge potential for investors in the fresh mining sector as well asestablishment of industry using mining and processing waste


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Marble Resources of India

MARBLE DEPOSITS IN INDIA

State Total (In million tonnes)

Rajasthan 1144Jammu & Kashmir 405

Madhya Pradesh (estimated) 400

Gujarat 95

Chhattisgarh 83

Maharashtra 59

Haryana 22

Uttaranchal 6

Sikkim2

All India Total 2216


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Granite Resources of India

State Total (In million tonnes)Karnataka 9740

Jharkhand 8847

Rajasthan 8479

Madhya Pradesh 6271Andhra Pradesh 2788

Orissa 2135

Maharashtra 1159

ar 878

Tamil Nadu 713

Assam 584

Uttar Pradesh 495

Gujarat 420

Meghalaya 286

Chhatisgarh 50

Haryana 34

West Bengal 33

Kerala 4

All India Total 42916


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Dimensional Stone Resources

India accounts for 20% of the world resources ofgranite

Sandstone resources in India are estimated ataround 1000 million tonnes in the states of Andhra Pradesh, Assam, Bihar, Gujarat, Haryana,MP Me hala a Mizoram Karnataka Orissa

Punjab, Rajasthan, UP, Tamilnadu, West Bengal Over 90% sandstone deposits are in Rajasthan

spread over the districts of Bharatpur, Dholpur,

Kota, Jodhpur, Sawai Madhopur, Bundi, Jhalawar Slate deposits in India are estimated at around

500 million tonnes in the states of Rajasthan,Haryana, HP, AP and MP


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INDIAN STONES PRODUCTION

( In thousand tones)2000-01 2001-02 2002-03 2003-04 2004-05

2005-06 2006-07 200708

Marble 6831 6318 7511 8460 9608 10904 12243 13684

Granite 5900 6205 6710 7059 7759 8364 9044 9776

Sandstone 6659 6861 6363 8153 9313 8626 8809 8958

FlaggyLimestone

2096 2164 3387 3757 4268 5291 5291 7420

Slate 16 18 14 11 110 98 129 163

Total 21502 21566 23986 27449 31059 33283 36520 40001


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6000

8000

10000

12000

14000

16000

ion

in

thousa

nd

tonnes

MarbleGraniteSandstoneFlaggy limestoneSlate

0

2000

4000

1995-

96

1996-

97

1997-

98

1998-

99

1999-

00

2000-

01

2001-

02

2002-

03

2003-

04

2004-

05

2005-

06

2006-

07

2007-

08

Year

Produ

c

Production of Dimensional Stones in India


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Export Value Rs 45620 Million Rupees ($ 920 Million)

Export of stones in 2005-06

29%

0%

2%

15%

5%

Granite cut blocks/ slabs

Granite monuments

Granite Products n.e.s

9%

5%33%

2%Granite tiles

Marble blocks/ slabs

Marble monuments

Marble tiles

Other stones & Products

Slate Stone


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Global Scenario of Granite Consumption

India accounts for 20% of the world resources ofgranite

In the raw blocks granite exports India is theleader with 31.5% share of the global market as

against 11.5% Brazil and 9.5% China 42% of export of raw blocks of granite from India

to China and 24% export to Italy

having fourth position with 6.6% global marketshare

43% of finished granite export to USA and 13.4%to UAE

China imports raw blocks from India and Braziland after processing finished products exports atlower price to Europe and USA


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Mining Technology

Wedge & feather techniqueWedge & feather technique

Wire/chain/belt saw cutting techniqueZiriZiri cutting techniquecutting technique

Drillin & controlled blastinDrillin & controlled blastin

techniquetechniqueFlame jet cutting technique

Slot drilling techniqueSwelling material

Blind cut technioque


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VARIOUS TECHNIQUES FOR

DAMAGE MEASUREMENTS

Ultrasonic P-wave velocity before and

after blastWater absorption and tensile strength

o e roc qua y es gna onComputerised X-ray tomography

Ultrasonic flaw detection

Petrological studies under microscopeto detect damage at grain levels


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FRACTURE CONTROL DURING BLASTING

& DAMAGE DETECTION Fracture along guided path

Alternate charged anddummy holes

A line of dummy holes Notching of blast holes

Fracture by decoupling

Fracture by explosive

Using a slotted cartridge Charge holder with wedges

Charge holder with twostages of detonation

Damage detection by Ultrasonic p-wave velocity,

flaw detection andtomography


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EXTRACTION WITH NOTCHED BLAST HOLES

Extraction of block withblast hole notching

Formation of eye notchin the hole

Drilling circularholes upto a desireddepth

with jack hammer bystopping rotation

Crack with increasedspacing by notching

Notching effective andcrack initiate at notchlocation


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Mechanized Marble Mining


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Horizontal Cut with Chain/Belt Saw


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Wire Saw Cut in Marble


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Electroplated

CC TOOLS for SAWING: DIAMONDTOOLS for SAWING: DIAMOND--WIRESWIRES

DIAMONDDIAMOND--WIRE CLASSIFICATIONWIRE CLASSIFICATION

Diamond types:Diamond types:

Sintered

1919


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DIAMONDDIAMOND--WIRE SAW TECHNOLOGYWIRE SAW TECHNOLOGY

MAIN ADVANTAGESMAIN ADVANTAGES

Lower labour costs (1 or 2 workers per machine)

Reduces waste material (cutting thickness 1cm max)

High block quality (even cutting face)

High quarry productivity Makes big cuts (also good for very big benches)

Makes each blocks quality easy to inspect due to semi-smooth surfaces

No structural damage or stress to the rock during the cutting

DD PROCESSING CYCLEPROCESSING CYCLE

Easy to move and transport

MAIN DISADVANTAGESMAIN DISADVANTAGES

Requires high-precision drilling as a preliminary

Requires lots of water

Requires highly skilled workers Can influence the quarrys safety system

Medium-high tool cost (diamond-wire minimum 30 meters)

Diamond tools must be carefully selected

Requires electricity

2020


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DD PROCESSING CYCLEPROCESSING CYCLE

Vertical blind cuts: regular geometry of saw and high performancesVertical blind cuts: regular geometry of saw and high performances2121

B h i


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Bench overturning

2222


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Room and Pillar Basic Criteria for Design

Stability of Rooms and PillarsMaximum Recovery of healthy Blocks


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Multi-wire gangsaw with 25 wires

(Year 2001)

MACHINES TO USEMACHINES TO USEBB

Multi Diamond Wire Saw2424


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Uses of Dimensional StonesUses of Dimensional Stones

FlooringFlooring

PavingPaving

Wall CladdingWall Cladding

Garden furnishingGarden furnishing

LandLand scapingscaping

RoofingRoofing


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Application of Dimensional Stones

Important modern buildings in India like

the Presidential House, Parliament House,and Supreme Court of India made fromhigh quality sandstone of Rajasthan

testimony to the relevance of marble inmodern Indian Architecture

Innumerable temples, forts and palaces of

Ancient Indian Civilization have beencarved out of locally available stones


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HEAP OF WASTAGEHEAP OF WASTAGE


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B) Muds produced by sawing and

polishing operations on slabs

TWO MAIN TYPES OF WASTE

A) Small shapeless blocks deriving by

cutting and sawing of stone

Air dried filter-pressed mud


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USES OF WASTE GENERATEDUSES OF WASTE GENERATED

COBBLESCOBBLES

FREE SIZE TILESFREE SIZE TILES ROUGH BLOCKSROUGH BLOCKS

PRODUCTION OF BINDERSPRODUCTION OF BINDERS

USE AS FERTILISER IN AGRICULTUREUSE AS FERTILISER IN AGRICULTURE

PRODUCTION OF BINDER FORPRODUCTION OF BINDER FORCONSTRUCTIONCONSTRUCTION


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COBBLES PREPARINGCOBBLES PREPARING


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HEAP OF COBBLESHEAP OF COBBLES


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COLORS AVAILABLE IN COBBLESCOLORS AVAILABLE IN COBBLES


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APPLICATION OF COBBLESAPPLICATION OF COBBLES


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STEPS MADE FROM SANDSTONESTEPS MADE FROM SANDSTONE

TILES MADE FROM SANDSTONETILES MADE FROM SANDSTONE


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TILES MADE FROM SANDSTONETILES MADE FROM SANDSTONE


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The scientific partnership

Research

WorkGROUP

R. K MARBLEIndia

MAHARANA PRATAP

UNIVERSITY

OFAGRICULTURE and

TECHNOLOGY

India

IS.I.M.International Marble Institute

Italy


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Purpose of Research Work

Scientific programs between Italyand India, on stone technologies

and environmental aspects Promote a specific technical and

scientific research on diamond

wire technologies on the whitedolomitic marble of Rajasthan

Value addition to marble blocks at

quarry site; Reduce the cost of blocks

extraction

DIAMONDDIAMOND WIRE MACHINESWIRE MACHINESMACHINES to USEMACHINES to USEBB


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UDAIPUR QUARRY R.K. MARBLE

DIAMONDDIAMOND--WIRE MACHINESWIRE MACHINES

Machines comparing

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ITALIAN INDIAN

Utilization of Granite Waste Powder


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Utilization of Granite Waste Powder

Scope of Investment in India


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Scope of Investment in India

Optimization of production cost of thefinished product to compete with China

By selling finished products compared to

rough blocks, profit realization can beincreased to 2.5 times

India to set up industry for manufacturing ofconsuma es suc as amon oo s, s eeblades, steel grits.

China and Italy are having their ownconsumables

Adoption of multi-wire diamond sawingmachine which can produce one container2cm slabs (About 300 sq. m.) in 8 hours

CONCLUSIONSCONCLUSIONS


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CONCLUSIONSCONCLUSIONS NewNew miningmining techniquetechnique maymay bebe adoptedadopted toto reducereduce wastewaste

MechanizationMechanization ofof quarryquarry operationsoperations mandatorymandatory forforeliminatingeliminating wastewaste generationgeneration andand toto increaseincrease productionproductioncapacitycapacity

NewNew improvedimproved controlledcontrolled blastingblasting techniquestechniques maymay bebeadoptedadopted inin sandstonesandstone andand granitegranite miningmining toto improveimproverecoveryrecovery percen agepercen age

SecondarySecondary wastewaste shouldshould bebe utilizedutilized inin civilcivil constructionconstruction

GovtGovt.. PoliciesPolicies shouldshould supportsupport inin exportingexporting thethe productsproductsproducedproduced fromfrom thethe wastewaste generatedgenerated

ThereThere isis hugehuge scopescope inin wastewaste utilization,utilization, generatedgenerated fromfrom

miningmining andand processingprocessing ofof dimensionaldimensional stonesstones inin civilcivil asas wellwellasas agricultureagriculture applicationsapplications


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THANKS

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Dimensional Stone Mining and Environment