IRJET- Assessment of Waste Dump Slope Stability at Iron Ore Mines

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ASSESSMENT OF WASTE DUMP SLOPE STABILITY AT IRON ORE MINES Prabhat Pratap Dev*1, Er. Tripti Goyal 2 *1M. Tech Student, Modern Institute of Engineering & Technology, Mohri (Haryana) of Department, Civil Engineering, Modern Institute of Engineering & Technology, Mohri (Haryana) ---------------------------------------------------------------------***---------------------------------------------------------------------2Head

Abstract: - The iron ore mining in India is becoming increasingly significant with an ever-growing target of iron production from the mines. As a result, waste generation due to mining activity goes on increasing day by day. Under this scenario, the stability and design of waste dump slopes have become vitally important from the viewpoints of safety and economics of the mines. In this study we have purported to investigate the slope stability of the waste dump in Meghahatuburu iron ore mine (MIOM) under the Steel Authority of India (SAIL) located in West Singhbhum district of Jharkhand state.

The investigation is comprised of field studies, lab scale experimental work and numerical modeling. The field studies encompass collection of undisturbed samples from the waste dump as well as geo-mining details of the mine. The laboratory studies mainly include determination of strength properties of waste dump material. The stability analysis is carried out using modeling software. In this work we have used software based on Finite Difference Method (FLAC/Slope) and Finite Element Method (Rocscience phase2) to evaluate the safety aspects of existing and optimized dump. The numerical modeling works suggest that the capacity of existing dump can be substantially increased by increasing dump height and installing retaining wall at the toe of the waste dump with an acceptable range of safety factor.

Key Words: Dump stability, Factor of safety, Shear strength reduction, slope stability 1. INTRODUCTION Iron ores are rocks and minerals from which metallic iron can be economically extracted. The ores are usually rich in iron oxides and vary in colour from dark grey, bright yellow, or deep purple to rusty red. The iron itself is usually found in the form of magnetite (Fe3O4,72.4%Fe), hematite (Fe2O3,69.9%Fe), goethite (FeO(OH),62.9%Fe), limonite(FeO(OH)·n(H2O), 55% Fe) or siderite (FeCO3, 48.2% Fe). Ores containing very high quantities of hematite or magnetite (greater than about 60% iron) are known as "natural ore" or "direct shipping ore", meaning they can be fed directly into iron-making blast furnaces. Iron ore is the raw material used to make pig iron, which is one of the main raw materials to make steel. 98% of the mined iron ore is used to make steel. Indeed, it has been argued that iron ore is "more integral to the global economy than any other commodity, except perhaps oil”. Iron & steel is the driving force behind industrial development in any country. The vitality of the Iron & Steel Industry largely influences a country's economic status. The mining of iron ore, an essential raw material for Iron & Steel Industry, is arguably of prime importance among all mining activities undertaken by any country. With the total resources of over 31.32 billion tons of hematite (Fe 2O3) and magnetite (Fe3O4), India is amongst the leading producers of iron ore in the world.

Factor Affecting Slope Failure:           

Geological discontinuities of Rock Mass Geo-technical Properties of slope Groundwater and Rainfall Slope’s Geometry State of stress Surface erosion due to flow of the water Seismic effect i.e. forces due to earthquakes Dynamic Forces due to Blasting Movement of the Heavy Earth Moving Machinery Modification in the Slope like Under cutting Temperature and Spontaneous Heating Presence of underground galleries

Modes and Mechanism of Slope Failure There are various dump failure modes as described by (Hardygóra, Paszkowska, & Sikora, 2004)and shown in the Figure 1. Surface or edge slide occurs when materials moves down the slope. This mode of failure is most likely to occur in enddump embankments and is best evaluated by equations describing the stability of an infinite slope. If sufficient water

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enters the slope and flows parallel to the face, a shallow flow may occur. Base failure usually occurs if the ground is inclined and when the base ground is covered by a thin layer of weak dumping material. This failure mode may occur both in layer placed embankments and end-dump. Block translation will occur where a dump is formed on inclined ground and the soil is relatively thin and weak. Most often high water tables in the embankment, earthquakes or the decay of organic material beneath the dump may induce such failure. Circular failure does occur if the dump is formed on a competent foundation and the dump material contains a significant percentage of finer grain soil. It may also develop through a deep foundation soil deposit of fine grained soils. Different types of failure in waste dump slope shown is figure 2.

Figure 1: (A) Surface or edge slide, (B) Shallow flow slides, (C) Base failure, (D) Block translation, (E) Circular arc failure, (F) Foundation circular failure.(adopted from (Hoek & Bray, 2014)

Figure 2: Different types of failure in waste dump slopes

2. Objectives: The purpose of this research work is to evaluate the existing overburden slope stabilizing practices as well as propose any change in the design of dump slope. The main objectives of research work are as follow: i) Determination of physic mechanical properties of the dump samples of iron ore mine. ii) Numerical modeling for determination of factor of safety of existing and optimized dump slope. iii) Enhancement of existing dumps capacity by introducing retaining structure.

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3. Collection of waste dump sample The samples were collected from three different places of the dump during the autumn season. Initially the ground was dug up to half meter to take samples of proper moisture content representing the total dump. The locations from where the samples sourced were selected after careful consideration to represent the whole area. The location was first cleared of soft soil cover, and then a trench of about 2 to 3 m deep was dug. Then a hollow cylindrical mould of 10 cm dia and 12 cm long was put into the ground by continuous and careful hammering. Then the cylindrical mould along with the soil inside of it was taken carefully out of the ground which was then properly packed to prevent the passage of air. The packing was done by the help of plastic gunny bags to ensure air tight packing as shown in Figure 4 Proper care was taken to ensure that the parameters of the sample doesn’t change during bringing it to the lab . The preparation process is shown in Figures 3.

Figure 3: Mould filled with sample

Figure 4: Sealing of the sample to preserve MC

4. Experimental Investigation In order to carry out stability analysis of the waste dump, the following physic mechanical properties of the waste dump material are evaluated.

4.1 Unit weight (kN/m3) by Core cutter method 4.2 Cohesion ( kPa ), Angle of internal friction (degree) by Direct shear test method 4.1 Determination of unit weight of soil sample:Core cutter method is used for finding field density of cohesive/clayey soils placed as fill as per standard (ASTMCommittee D-20 on Plastics. Section D20., 1991). It is rapid method conducted in field. It cannot be applied to coarse grained soil as the penetration of core cutter becomes difficult due to increased resistance at the tip of core cutter leading to damage to core cutter.

Observation:

Table 1: Determination of unit weight of soil samples S.N.

Determinants Mass of empty core cutter 1 (M1) Mass of core cutter + soil 2 (M2) 3 Mass of soil (M2-M1) 4 5 6 7

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Volume of core cutter (V) Unit weight of soil= (M2-M1)*9.81/V Mean Unit weight Standard Deviation

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Unit

1

kg

1

Sample No. 2 3 1

1

kg

3.118 3.214 3.097

kg

2.118 2.214 2.097 981.75 981.75 981.75 *10-6 *10-6 *10-6

m3 kN/m3

21.16 22.12 20.95

kN/m3 S.D.

21.41 0.6

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4.2 Determination of Shear strength parameters (cohesion and angle of internal friction) by Direct shear test.(ASTM, 1994) Shear strength is generally employed to describe the strength of rock materials, to resist deformation due to shear stress.

Shear strength parameter that is cohesion and angle of internal friction were determined by Direct shear test as per standard.(ASTM, 1994) Rock resists shear stress by two internal mechanisms, cohesion and internal friction. Cohesion is a measure of internal bonding of the rock material whereas the angle of internal friction is caused by contact between particles, and is denoted by the internal friction angle, φ. Different rocks have of course different cohesions and different friction angles. Shear strength of rock material can be determined by both the direct shear test and by tri-axial compression tests.

Shear strength in a soil arises from the fact that there occurs a surface frictional resistance along the sliding plane, interlocking between individual rock grains and cohesion in sliding surface of soil model. The shear strength of soil is given by Mohr-Coulomb expression.

Observation: For sample no.1 variation of shear stress with normal stress is shown in Chart 1.

Chart 1: Variation of shear stress with normal stress for sample no.1 Table 2: Normal stress vs. Shear stress for sample no.1 Normal Stress, N (kPa) 1.36 2.72 4.08

Shear Stress, τ (kPa) 44.61 44.98 45.27

Thus, the values of cohesion and angle of internal friction for sample no.1 are as follows:Cohesion = 44.12 kPa Angle of internal friction= 23.48º For sample no.2 variation of shear stress with normal stress is shown in Chart 2:

Chart 2: Variation of shear stress vs. normal stress for sample no.2

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Table 3: Normal stress vs. Shear stress for sample no.2 Normal Stress, N (kPa) 1.36 2.72 4.08

Shear Stress, τ (kPa) 49.57 50.26 51.177

Thus, the values of cohesion and angle of internal friction for sample no.1 are as follows:Cohesion= 48.89 KPa Angle of internal friction= 26.33° For sample no.3 variation of shear stress with normal stress is shown in Chart 3:

Chart 3: Variation of shear stress vs. normal stress for sample no.3 Table 4: Normal stress vs. Shear stress for sample no.3 Normal Stress, N (kPa)

Shear Stress, τ (kPa)

1.36

45.98

2.72

46.763

4.08

47.29

Thus, the values of cohesion and angle of internal friction for sample no.1 are as follows:Cohesion= 45.271 KPa Angle of internal friction= 27.32º The mean value of cohesion and angle of internal friction of all three samples are mentioned in Table 5.

Table 5: The values of cohesion and angle of internal friction for all 3 samples S.N.

Determinants

Units

1

Cohesion

kPa

2

Angle of internal friction

3

Mean Cohesion

4 5 6

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Sample no.

1 44.12

degree 23.48 kPa

|

3

48.89 45.271 26.33

27.32

46.09

Mean Angle of degree internal friction Standard Deviation kPa for cohesion Standard Deviation for Angle of internal kPa friction

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2

25.71 2.03 1.6

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5. Slope stability analysis software 5.1 FLAC/Slope FLAC/Slope is a mini-version of FLAC which stands for the “Fast Lagrangian Analysis of the Continuum” that is designed specifically to perform calculations of factor-of-safety for slope-stability analysis. This version is operated entirely from FLAC’s graphical interface (the GIIC) which helps in the rapid creation of models for soil and/or rock slopes and then solves the model to analyse the stability condition.

FLAC/Slope provides an alternative approach to traditional “limit equilibrium” programs to determine factor of safety.

Several assumed failure surfaces are tested, and the one giving the lowest factor of safety is chosen. Equilibrium is only satisfied on an idealized set of surfaces.

In contrast, FLAC/Slope provides a full solution of the coupled stress/displacement, equilibrium and constitutive equations. With the assigned set of properties, the system determines that whether the slope is stable or unstable. It automatically performing a series of simulations while changing the strength properties (“shear strength reduction technique), the factor of safety can be found corresponding to the point of stability, and the critical failure (slip) surface can be located.

However, FLAC/Slope does take longer to determine a factor of safety than a limit equilibrium program. But, with the advancement of computer processing speeds (e.g., 1 GHz and faster chips), solutions can now be obtained in a reasonable time.(Itasca, 2002) 5.2 RocScience phase2 (RS2) RS2 is a 2D finite element program that can be used for slope stability analysis using the shear strength reduction method. It can be used for stability analysis of all types of soil or rock slopes, including support and jointed rock.

One of the most exciting features of RS2 is finite element slope stability using the Shear Strength Reduction (SSR) method. This option is fully automated and can be used with either Mohr-Coulomb or Hoek-Brown strength parameters.

With a single mouse click, we can run the SSR analysis and determine the critical strength reduction factor (safety factor) of a slope. The SSR method has many advantages over the traditional limit equilibrium methods of slope stability. For example, SSR analysis does not require any assumptions about the shape or location of the failure surface. The SSR method will automatically determine the most critical failure mode and the corresponding safety factor.

After the SSR analysis has been computed, the results for the critical Strength Reduction Factor (SRF) will automatically be displayed. Maximum shear strain contours are shown by default, as this tends to highlight the critical failure zone. The results for other values of SRF can be viewed by selecting the desired stage tab. Each stage tab represents the analysis results at a particular value of SRF. The critical SRF is the maximum value of SRF at which convergence is achieved for the finite element analysis. If the SRF is higher than the critical value the model is unstable (i.e. the finite element analysis does not converge within the specified number of iterations).(Curran & Corkum, 1998)

6. Stability analysis of waste dump The active existing waste dump at Meghahatuburu iron ore mine (MIOM) is having the total height of 26 m and it has capacity of 1680m3/m of length of waste dump. The overall slope angle of existing dump is approximately 34°. The dump has 3.benches of height 8 m each and width of each bench is 10 m. The bench slope angle for each bench is approximately 69°.

6.1UsingFLAC /slope

Figure 5: Design of existing Waste dumps (FLAC/Slope).

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Figure 6: Output of existing waste dump after factor of safety analysis.

6.2 Using RS2

Figure 7: Design of existing waste dump (RS2).

a) Maximum shear strain contours

b) Total displacement contours Figure 8: Output of existing waste dump after Factor of safety analysis using RS2

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From the above analysis of existing waste dump, we get the following results as shown in Table 6.

Table 6: FOS of existing dump using FLAC/Slope and RS2 S.N. 1 2

Software FLAC/Slope RS2

Factor of safety 1.76 1.74

6.3 Optimization of existing waste dump From the existing dump slope analysis it is observed that the slope is stable in condition with Factor of safety 1.76 (FLAC/Slope) and 1.74 (RS2). Thus optimization of dump is possible in order to increase its capacity.

Case 1: Increase in the height of each bench by 1 m Height of each bench = 9 m Total height of dump =29 m.

Figure 9: Design of waste dump having total height of 29 m using FLAC/Slope.

Figure 10: Output of waste dump having total height of 29 m using FLAC/Slope.

Figure 11: Design of waste dump having total height of 29 m using RS2

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a) Maximum shear strain contours

b) Total displacement contours Figure 12 Output of waste dump having Total height of 29 m using RS2 Case 2: Increase in the height of each bench by 2 m Height of each bench = 10 m Total height of dump = 32 m.

Figure 13: Design of waste dump having total height of 32 m using FLAC/Slope.

Figure 14: Output of waste dump having total height of 32 m using FLAC/Slope.

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Figure 15: Design of waste dump having total height of 32 m using RS2.

a) Maximum shear strain contours

b) Total displacement contours Figure 16: Output of waste dump having total height of 32 m using RS2 Case 3: Increase in the height of each bench by 3 m Height of each bench = 11 m Total height of dump = 35 m.

Figure 17: Design of waste dump having total height of35 m using FLAC/Slope

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Figure 18: Output of waste dump having total height of 35 m using FLAC/Slope.

Figure 19: Design of waste dump having total height of 35 m using RS2.

a) Maximum shear strain contours

b) Total displacement contours Figure 20: Output of waste dump having total heightof35 m using RS2.

Case 4: Increase in the height of each bench by 4 m Height of each bench = 12 m Total height of dump = 38 m.

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Figure 21: Design of waste dump having total height of 38 m using FLAC/Slope.

Figure 22: Output of waste dump having total height of 38 m using FLAC/Slope.

Figure 23: Design of waste dump having total height of 38 m using RS2.

a) Maximum shear strain contours Š 2019, IRJET

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b) Total displacement contours Figure 24: Output of waste dump having total height of 38 m using RS2 Table 7: Factor of safety, Maximum shear strain and Total displacement for different dump heights.

Factor of Safety Total Dump Maximum Displacement S.No heights Shear (RS2) 2 Strain (RS2) FLAC/Slope RS (meters) (meters) 1

26

1.76

1.74 6.85*10-2

7.62*10-2

2

29

1.44

1.42 8.24*10-2

1.65*10-1

3

32

1.29

1.29

1.5*10-1

2.14*10-1

4

35

1.16

1.16 2.43*10-1

3.71*10-1

5

38

1.05

1.03 4.16*10-1

4.73*10-1

Chart 4: Variation of factor of safety with dump height

Chart 5: Variation of maximum shear strain with dump height

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Chart 6: Variation of total displacement with dump height Here from the Table 7, it is ascertained that factor of safety from both the software analysis are more or less same and marginally stable at dump height 32 m which is 1.29. Again if we increase the dump height, factor of safety goes on decreasing. Chart 5 and Chart 6 portrays same trend where maximum shear strain and total displacement values goes on increasing with dump height.

Thus optimization is possible by increasing the height of each bench by 2 m which makes 32 m overall height of waste dump The comparison between capacities of existing dump and optimize dump is as mentioned in Table 8.

Table 8: Increase in capacity of optimized dump Capacity S.N.

Dump

FOS

(m3/ meter length of dump)

1

Existing (ht =26 m)

1.74

1680

Increase in capacity (%)

22.32% 2

Optimized (ht =32 1.29 m)

2055

7. Slope stability analysis after retaining wall formation 7.1 Retaining wall with shear key The stability of the slope can be ameliorated by constructing retaining wall at the toe of the waste dump. The retaining wall provides additional resistance which is mobilized by further deformation of slope.(Tanah & Ir, n.d.)

Design: Depth of foundation by Rankine’s formula: Df =

2

Stem: Top width 200 mm to 400 mm Base slab width b= 0.4H to 0.6H, 0.6 to 0.75H for surcharged wall Base slab thickness= H/10 to H/14

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Toe projection= (1/3-1/4) Base width Here, SBC of soil sample is assumed as 450 kN/m2 as it contains soft shale, hard or stiff clay in deep bed.

Where:Df

=

Depth of foundation

S.B.C. =

Soil bearing Capacity

Y

=

Unit weight

Ă˜ tp

= =

Angle of internal friction Toe projection.

Figure 25: Design of waste dump having total height of 32 m with provision of retaining wall using RS2.

a) Maximum shear strain contours

a) Total displacement contours Figure 26: Output of waste dump having total height of 32 m with provision of retaining wall using RS2 After the provision of retaining wall at the toe of the dump having height 32 m, the following results were observed.

Table 9: Factor of safety, Maximum shear strain and total displacement for dump with and without retaining wall at dump height of 32 m S.N. 1 2 3

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Parameter Factor of safety Maximum Shear Strain Total Displacement

|

Waste dump (ht= 32 m) without retaining wall with retaining wall 1.29 1.49 1.5*10-1 6.30*10-3 2.14*10-1 6.70*10-2

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The above results clearly states that after installation of retaining wall at the toe of the waste dump, the stability gets increased and also there is considerable reduction in maximum shear strain and total displacement as the wall provides additional resistance which is mobilized by further deformation of the slope.

8. CONCLUSION The following conclusions are drawn from the research study carried out in Meghahatuburu Iron Ore Mine (MIOM), Jharkhand, India.

1.The soil of waste dump consists of mainly clay and silt with little proportion of gravel and sand in all three locations of the dump. The average values of unit weight, cohesion, and angle of internal friction of the soil of the waste dump are 21.41kN/m3, 46.09 kPa, and 25.71 º respectively.

2.The existing dump having total height 26 meters and overall slope angle 34° is found to be geotechnically stable with factor of safety 1.76 (FLAC/Slope) and 1.74 (RS2).

3.From the optimization, it is observed that factor of safety goes on decreasing with increasing dump height.

4.Capacity of existing dump can be increased by 22.32 %, if we increase the height of each bench by 2 meters. This leads to the total dump height = 32 meters and overall slope angle = 41° having factor of safety = 1.29.

5.Furthermore, it is observed the after installation of the retaining wall as a stability structure at the toe of the waste dump, the factor of safety further increased from 1.29 to 1.49.

9. Future Scope of Work 1.

2.

3.

4.

In order to carry out detail study both drained and untrained samples are required to be collected.

Performing stability analysis by considering ground water table in numerical modeling.

Performing stability analysis by considering effect of tension cracks, phreatic surfaces in numerical modelling.

Performing 3D stability analysis using software like RocScience RS3, PLAXIS, FLAC3D and ANSYS to enhance the credibility of the results obtained in 2D analysis.

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