Effect of Opencast Mine Floor Inclination on Stability of Back-filled Dump under Varying Hydro-geological Conditions a Case Study

I Roy, Member
Dump/mine floor inclination is an area in which there is no control of mine planners and operators though inclination of dump floor dictates the stability of back-filled dump to a larger extent. Due to continuous formation of back-filled dump and tremendous pressure of coal production on the mine operators, levelling of dump floor is not possible unlike civil engineering embankment. The subject of special interest in this article is to discuss the methodology of stability calculations with emphasis on the influence of mine floor inclination in the stability of back-filled dump. The effect of varying height of ground water table above the dump floor is also discussed in this article. The presentation of the article is in two parts. In the first part, the methodology of stability analysis is discussed in brief. The second part deals with a specific case study of a mine, namely, Dhanpuri Opencast Coal Mine, India which is having abrupt variation in mine floor inclination along with variation of height of ground water table within the mine property.
Keywords: Dump slope stability; Geo-technical engineering; Opencast mining; Reclamation; Waste management

INTRODUCTION Mine planners and operators are always in a difficulty to decide the maximum allowable height and safe slope angle of back-filled dump in an inclined mine floor. Allowable dump height and corresponding slope angle for a stipulated factor of safety varies from one sector to another of the mine for a change in mine floor inclination or hydro-geological conditions when there is no change in other geo-engineering parameters. The geo-engineering parametres1 considered in this investigation are as follows. Geo-technical parameters of (i) dump material, and (ii) interface material between dump and foundation (Figure 1) (after mining of coal, a layer of crushed rock and coal dust submerged under water lies on the floor of the mine in slushy condition which is termed in this study as interface material). Dump/mine floor inclinations Hydro-geological parameters like (i) (ii) upward thrust of water due to accumulated water table within the dump, and seepage force of water due to accumulated water table within the dump.

dump. This article also presents a case study2 showing the influence of the followings : (i) dump/mine floor inclination, and

(ii) ground water table variation on stability of back-filled dump of Dhanpuri Opencast Mine (located in central part of India). METHODOLOGY OF STABILITY ANALYSIS A computer program has been developed using the following computational methods for stability analysis of back-filled dumps1. Back-filled dump in opencast coal mining operation experiences two types of failure surfaces3 (Figure 1 and Figure 2), namely : (i) circular failure surface, and (ii) circular-cum-planar failure surface4. Following sequence of computations is envisaged in stability analysis of back-filled dumps [Figure 1]. Determination of factor of safety of first trial surface ABDC (circular-cum-planar failure surface) by Fellinius Method [ Figure 2]. An iteration method to locate most critical failure surface corresponding to absolute minimum factor of safety by Fellinius Method1 [Figure 3]. Absolute minimum factor of safety corresponding to most critical failure surface by Fellinius Method is further modified by Bishop's Simplified Method. The factor of safety by Bishop's Simplified Method is adjusted comparing with stipulated value of factor of safety to achieve safe and economic combination of back-filled dump profile. Factor of Safety by Fellinius Method [Figure 2] The trial failure surface ABDC is divided into suitable number of sectors, such as, BDFG and it is further divided into fifty number of slices (J=1,50) of equal thickness. The methodology of stability calculation for one of the slice PQRS is documented below (Figure 2). 23

Effect of seismic force on the dump mass. Coal rib / barrier dimension and shear strength parameters of interface material between coal barrier and its floor (Figure 1). This article presents methodology of stability analysis of back-filled
Dr I Roy is with the Central Mine Planning and Design Institute (CMPDI), Ranchi 834 001. This paper (modified) was received on January 10, 2006. Written discussion on the paper will be received until October 30, 2006.

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(Not to scale) 230 220 210 200 190 180 170 160 150 140 130 120 110 100
-130 -120 -110 -100 -90 -80 -70 -60 -50 -40 -30 -20 -10 0.00 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220

Berm at coal rib level

To be rehandled (abcd)

Waste rock dump by haul truck Waste rock dump by dragline Berm at dragline placement level Shoval and truck working level Soil strata Dragling working level a 4m Circular failure Circular cum planar failure Coal rib/barrier 10m d Coal b Rock strata

Interface material

Mine advancing towards dip direction Figure 1 Schematic representation of dump formation in a drag-line opencast mine

Circular cum planner surface E(3, Y3) Circular surface Z Width of failure mass (WT) in strike direction Accumulated water table F G Pa A (0,0) Dip direction B Sector BDFG Interface material D PQRS C H J Hw H U P Q Tk
Seepa

DPPX (J), DPPY (J) DPX (J), DPY (J)

rce ge fo X(J)

Slope angle, L

H1(J)

Upward thrust resisting force Y(J) R S

Seismic force Disturbing force

Slice PQRS

Co-ordinates of R = M (J), N(J) Co-ordinates of S = M (J-1), N(J-1) W1(J)

Figure 2 Factor of safety calculation by Fellinius and Bishop's simplified method

Each slice is subjected to its own weight and other forces like as follows. Upward thrust of water due to accumulated water table within the dump5. Seepage force of water due to accumulated water table within the dump . Seismic force on the dump mass. All these forces acting on each slice [PQRS] are resolved into the components to determine disturbing and frictional force on individual slice. They are suitably added for all slices respectively to determine the cumulative disturbing and frictional forces acting on the entire trial surface. The above forces for slice PQRS are determined as documented below W(J) = [H1(J )+H1 (J-1)] 0.5 T k D WT. (1)

WT, the width of failure block in strike direction, and 0.5{H1(J ) +H1 (J1)} is the average height of the slice. Upward thrust and seepage force of accumulated water on the dump mass is considered in the following manner. Phreatic surface of water {DPX(J),DPY(J)} is determined by following Casagrande's equation. DPY(J)=[( DPX(J) PacosL/2) 2Pa sinL tanL]0.5 (2) where Pa is the length of oozing of water along the slope of dump, that is, inclined plane AF [Figure 2]; Hw, the height of accumulated water table with respect to horizontal plane passing through toe of dump and L is the slope angle of dump. Upward thrust of water can be calculated as {DPY(J)(N(J)+N(J-1))/2.0}T k Dw WT Seepage force [V(J)] can be calculated as T k {DPY(J)(N(J)+N(J1))2.0} WT Dw tan[X(J)] (4) (3)

where W(J) is the weight of slice PQRS; T k, the width of slice; D, the bulk density of dump mass under natural moisture conditions; 24

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where Dw is the density of water and X(J) is the gradient of phreatic surface/ ground water table tan{X(J)}=[{DPPY(J)DPPY(J1)}{DPPX(J)DPPX(J1)}] (5)

earlier, is repeated by selecting in a systematic manner several trial surfaces around the first one to locate the most critical failure surface through a generalized iteration scheme [Figure 3] developed in this investigation as documented below. The iteration scheme is initiated by selecting any point 0, as the centre of first trial failure surface. Therefore, the iteration scheme is adopted to search around this point and locate the point, at which the factor of safety is the absolute minimum. To achieve this situation, following steps are followed in the sequence as given below. Step 1 Having selected the point 0 as the centre of the first trial failure surface passing through toe of the dump (A), the value of the factor of safety(FS1) of the first trial failure surface passing through toe of the dump(A) is determined. Step 2 The point is next changed in the vertical direction RR to the next point 0x and the value of the factor of safety(FS2), for the corresponding failure surface is determined. Step 3 If the value of the factor of safety(FS2) with centre 0x, is found to be less than the previous value of the factor of safety(FS1), next point is selected, beyond this point, along the same direction(RR). The procedure is repeated, at regular intervals along the same vertical line(RR), till the point, at which the value of the factor of safety increases from the previous one (FSm) is located. This abovementioned previous value of factor of safety(FSm) is used for subsequent checking along the next line(RR1). This procedure is repeated along all the other lines, at regular intervals of delta. The point 01, corresponding to which, the value of the factor of safety, is the real minimum, is thus located in this zone. Step 4 Having thus located the centre of the toe circle 01 for the next iteration, this point 01 is adopted as the starting point and steps 1 through 3, as described above, are followed to search and locate the point 02, around the zone-01, which gives the minimum of all the factor of safety probed so far, including the previous zone around 0. Step 5 If the linear differences between the location of the centres thus located in the two zones around 0 and 01 represented by 0-01 and 01-02, respectively, are not within the acceptable accuracy, the iteration scheme continued to subsequent zone 03, as described in step 4, till the desired accuracy of the numerical evaluation is achieved. Step 6 The above process is repeated for trial circles intersecting floor away from the toe of the dump(X1=0,-10,-20,-30 and so on) and the factor of safety of failure surfaces passing through toe and away from toe are compared to find the absolute minimum factor of safety and corresponding failure surface [0n is the centre of failure surface with absolute minimum factor of safety (FSam)]. 25

where X(J) is the gradient of accumulated water table or phreatic surface. Co-ordinates of T : DPPX(J), DPPY(J) Co-ordinates of U : DPPX(J-1), DPPY(J-1) Considering upward thrust of water, the weight of slice W1(J) can be calculated as W1(J) = W(J) Upward thrust of water (6)

where co-ordinates of base point of PQRS, that is, R is denoted by M(J), N(J). Considering all the above forces, disturbing and resisting force is calculated in following manner. Disturbing force = W1(J) sinY(J)+A W1(J) cosY(J)+V(J) cos{Y(J)X(J)} (7) where A is the seismic co-efficient of surrounding area of the Dhanpuri Mines, and Y(J) is the gradient of base plane RS. Frictional force = [W1(J) cos Y[J]A W1(J) sinY(J)V(J) sin{Y(J) X(J)}] tan(angle of internal friction of dump/interface material).

(8)

Cohesive force in slice PQRS is determined in following manner. Surface area of failure mode = (RSWT) Curved length of RS = (Radius of the failure surface) (Z in radian within slice PQRS). Cohesive force = Surface area of failure mode (Cohesion of dump mass). (9) Cohesive force within sector ABG is determined in following manner. Cohesive force = Surface area of AB Cohesion of interface material. (10) After mining of coal, a layer of crushed rock and coal dust submerged under water lies in Indian coal mines which is termed in this study as interface material. Hence, cohesion and angle of internal friction of interface material is determined in the laboratory after keeping the material in submerged condition. Resisting force = Frictional force + Cohesive force +Resisting force due to coal rib (11) The ratio of the cumulative resisting force of all the slices within failure surface to the cumulative disturbing force is the factor of safety of the selected trial surface ABDC by Fellinius Method. Iteration Method to Locate Most Critical Failure Surface [Figure 3] The above method of factor of safety determination, as discussed Vol 87 , August 2006

Factor of Safety by Bishop's Simplified Method As the factor of safety (FS1= FSam) determined by Fellinius Method gives some error, though on lower and safer side, Bishop's Simplified Method is applied to determine fairly accurate results in the following manner [Figure 2] FS2=[Cohesive force + W1(J) tan (angle of internal friction of dump/interface material)] M [W1(J) sin{Y(J)} + A W1(J) cos{Y(J)} + V(J) cos{Y(J)X(J)}] (12) M = [1+{tan{Y(J)} tan(angle of internal friction)} FS1] cos {Y(J)} (13) FS3 = [Cohesive force + W1(J) tan (angle of internal friction)] M [ W1(J) sin{Y(J)} + A W1(J) cos{Y(J)} + V(J) cos{Y(J)X(J)}] (14) M = [1 + {tan{Y(J)} tan (angle of internal friction)} FS2] cos {Y(J)} Similarly, by repetitive convergence method FSn will be equal to FSn-1. where FSn is the factor of safety by Bishop's Simplified Method. Determination of Safe and Economic Combination of Height and Slope of Dump Profile The factor of safety by Bishop's Simplified Method (FSn) is compared with the stipulated value of factor of safety. If the calculated factor of safety is less than the stipulated value, then the slope is to be flattened. Otherwise, if the calculated factor of safety is

more than the stipulated value , then the slope is to be steepened so that factor of safety is equal to 1.2. Factor of Safety After considering all the recommended factor of safety6 suggested by different agencies, such as, 'National Coal Board ,U.K, United States D' Appolonia Consulting Engineers, Mines Branch Canada, Stability of Pit Slopes and Dumps by G L Fiesenko, Russia for surface mine slope design, a factor of safety of 1.20 is envisaged in this study. CASE STUDY Dhanpuri Opencast Mine of South Eastern Coalfield , located in central part of India is divided into two parts, that is, Eastern and Western parts(Figure 4). The mine is characterized by an abrupt change in dump/mine floor inclination from 3o to 8o . There is an accumulated water of 20 m in the western part of the mine and very negligible in the eastern sector. The geo-mining parameters of the mine are as follows2. Maximum height of the back-filled dump', m : 60 - 70. Dump floor inclination, Degree : 3 - 8. As the mine is situated in the seismic zone-I of India, horizontal seismic co-efficient of 0.01 is considered in this study for stability analysis. The floor of the mine is covered with a slushy mixture of crushed rock and coal dust submerged under water. This material is termed here as interface material. Geo-technical properties of dump and interface material is determined in a reputed laboratory of India in the following manner.

Zone for centres critical circles

of 01, 02, 03......0n-1 : Centres of circles having the least factor of safety of the trial circles selected around 0,01,02...0n-2, respectively. 02 On-centre of most potential failure surface with absolute minimum factor of safety ABC : Failure surface which comprises of AB and BC. AB : Planar failure surface through interface material BC : Circular failure surface through dump material 0 x - Second centre of failure surfaces RR RR1 0X 0 270
o

0n

01

Delta = 36 degree (360/20) as there are 10 lines around point 0.

Delta 90 C H
o

X1 A Figure 3 Iteration method to locate most critical failure surface X1 = 0, -10, -20

Dump mass B Interface material at dump floor

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Laboratory Testing The dump material of around 6-cm size was pre-compacted at an average stress of whole dump mass, that is, for a height of 60-m dump mass with an average bulk density of 20 kN/m3, the average pre-compaction pressure was 600 kN/m2 [30m20 kN/m3]. Then the dump material was subjected to direct shear test in a large shear box [30cm 30cm] for different normal stresses prevailing at different levels of dump mass. The dump materials and interface materials were tested under natural moisture condition and submerged condition, respectively for representation of actual site conditions. The value of cohesion determined in the laboratory was verified with the value of cohesion determined by back stability analysis of an existing dump standing at limiting equilibrium ( that is, total disturbing force = total resisting force) using the laboratory determined value of angle of internal friction. The strength parameters adopted for stability calculations are given in Table 1. Management of opencast coal mines in India applies a new technique of leaving a very small part of coal seam/strata at the toe of the dump(which is termed here as coal rib/ barrier) [Figure 1]. In this project , the present practice is to keep a coal rib with minimum width of 10-m at the base and 4-m at the top. Cohesive resistance and frictional resistance per 10-m width in strike direction (that is, WT=10-m) [Figure 2] at the bedding plane between coal rib and its floor is calculated as 20 000 kN and 10 227 kN, respectively taking into consideration following parameters of coal rib [Figure 2]. Base width of coal rib, m : 10. Top width of coal rib, m : 4. Height of coal rib, m : 14 ( full coal seam thickness) Width(WT) of dump failure mass in strike direction [Figure 1], m : 10. Bulk density of coal, kN/m3 : 24. Cohesion at the bedding plane between coal rib and its floor, kN/m2 : 200. Frictional angle at the bedding plane, Degree : 23.5. The geo-technical parameters of bedding plane which is fractured
Table 1 Geo-technical parameters of materials Strength Parameters Cohesion, kN/m2 Angle of internal friction, Degree Bulk density, kN/ m3 Dump Materials in Natural Moisture Condition 80 22 18 Interface Material in Submerged Condition 30 13 20

due to blasting in coal are determined from drilled core through bedding plane. RECOMMENDATION Safe slopes for different heights of back-filled dumps considering all the above parameters with factor of safety of 1.2 are calculated and documented in Table 2 - Table 5. To explain the application of computer simulated programme, input parameters considered for stability calculation of 70m high dump (Table 2) is documented below Height of dump (H), m : 70 Slope angle of dump with respect to dump floor (L), Degree : 26 As discussed earlier, the slope angle of 26 corresponding to 70-m high dump is obtained by trial and error method in such a manner that the factor of safety becomes equal to 1.2. Dump floor inclination (I), Degree : 3 Geo-technical parameters considered as mentioned in Table 1 are given below Pa (length of oozing of water along the slope of dump) as observed o in case of Western sector with dump floor inclination of 3 = 7-m [Figure 2 and equation (2)]. Seismic co-efficient (A) as per seismic zone map of India = 0.01 [Figure 2 and equation (7)]. Cohesive and frictional resistance (that is, WT=10-m) [Figure 2] at the bedding plane between coal rib and its floor is calculated as 20 000 kN and 10 227 kN, respectively. Method of Mining for Maintaining the Recommended Slopes In Dhanpuri Opencast Coal Mine, rock overburden above coal
Table 3 Details of safe slope of the Western Sector ( Ground water table, m : 20, Dump floor inclination, Degree : 8) Height of Dump, m 70 60 Table 4 Details of safe slope of the Eastern Sector ( Ground water table, m : 0, Dump floor inclination, Degree : 3 ) Height of Dump, m 70 60 Table 5 Details of safe slope of the Eastern Sector ( Ground water table, m : 0, Dump floor inclination, Degree : 8 ) Height of Dump, m 70 60 Slope of Dump with Respect to Horizontal, Degree 27 30 Slope of Dump with Respect to Horizontal, Degree 31 34 Slope of Dump with Respect to Horizontal, Degree 26 28
o

Table 2 Details of safe slope of the Western Sector ( Ground water table, m : 20, Dump floor inclination, Degree : 3) Height of Dump, m 70 60 Slope of Dump with Respect to Horizontal, Degree 29 32

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Mi

ne

St

rik

Di

of

the

External dump

di

re

Final surface boundary of the Mine/Quarry

ct io n

Present surface boundary of the Mine/Quarry

+ 475m Site for collection of dump material samples for laboratory testing
42 0m

+ 480m Back-filled dump (Western Sector)

45 0m

+ 485m

Back-filled dump (Eastern Sector)

Present floor boundary of the Mine/Quarry

Figure 4 Working plan of Dhanpuri Opencost Mine

seam/strata are blasted by explosives and excavated by following two techniques [Figure 4]. Overburden Rock Removal by Dragline The dragline excavates the blasted rock and dumps the fragmented rock immediately in the earlier de-coaled area. The dragline also rehandles some portion of waste rock (ABCD )[Figure 1] which needs to be kept minimum considering the economics of the mine. Overburden Rock Removal by Shovel Truck Combination The shovel excavates the rock and dumps back to the haul truck. The haul-truck moves along the haul road and dumps the waste fragmented rock above the dragline dump [Figure 1]. The above recommended slopes of dump are maintained by increasing/decreasing following three parameters of dump profile [Figure 1]. Berm width at the dragline placement level. Berm width at the coal rib level. Slope angle below dragline sitting level. The re-handling volume (ABCD) dictates the above three parameters. But the amount of re-handling also needs to be kept minimum considering economics of the mine. Hence, a compromise is to be made by mine management in optimising the volume of re-handling (ABCD) so that overall slope is within the permissible limits as mentioned in Table 2 - Table 5. 28

Other than maintaining the above-mentioned recommended slopes, the interface material (that is, the water submerged layer of waste rock and coal dust) is recommended to be cleaned as far as possible to make the mine/dump floor competent. CONCLUSION Following inferences are drawn based on the above study. Dump slope stability analysis should be made mandatory for all the major opencast mines in India. In Dhanpuri Opencast Coal Mine, there is an abrupt variation in inclination of mine floor and also variation of accumulated water table within the dump mass. As evident from Table 2 - Table 5, both of the above parameters play an important role in the stability of dump. Hence, in every opencast coal mine of India, separate dump profile (height and slope) should be followed for different mine floor inclinations and for different position of accumulated water tables within the back-filled dump mass. Optimization of height and slope of dump for a stipulated factor of safety should be carried out by stability analysis considering all the geo-engineering parameters like geotechnical, hydro-geological and seismic parameters . The safe and economic combination of dump profile can be maintained by optimizing the re-handling volume (ABCD) as shown in Figure 1. To reduce the overall slope angle of IE(I) JournalMN

dump profile, the re-handling volume by dragline is to be increased. But, the re-handling volume is to be kept minimum as far as possible considering the mine economics. Hence, the stability analysis helps in deciding the optimum volume of re-handling by dragline from both safety and economical point of view. ACKNOWLEDGMENT The author is thankful to South Eastern Coalfields Limited, India for sponsoring this study to Central Mine Planning and Design Institute, India and for providing necessary facilities and information during the course of this study. REFERENCES
1. I Roy. 'Influence of Geo-engineering Parameters on the Stability of Dumps, (PhD Dissertation)'. Indian Institute of Technology, Kharagpur, India, 1999.

2. 'Consultancy Report on Internal Dump Stability of Dhanpuri Opencast Mine, South Eastern Coalfield Limited, India'. Central Mine Planning and Design Institute, 2003. 3. K E Hebil. 'Spoil Pile Stabilisation at the Paintearth Mine, Forestburg, Alberta'. 'International Symposium on Geo-technical Stability in Surface Mining, Calgary, Canada, 1986, p 181. 4. D B Cambell. 'Stability and Performance of Waste Dumps on Steeply Sloping Terrain'. International Symposium on Geo-technical Stability in Surface Mining, Calgary, Canada, 1986, p 317. 5. G W Wilson. 'Embankment Hydrology and Unsaturated Flow in Waste Rock'. Society for Mining, Metallurgy and Exploration , 2001, p 305. 6. W L Gerhard. 'Steepened Spoil Slopes at Bridger Coal Company'. Society for Mining, Metallurgy and Exploration , 2001, p 351. 7. S K Das. 'Problems of Highwall and Spoil Dump Stability and Various Preventive Measures in Highly Mechanised Opencast Mines'. The Indian Mining and Engineering Journal, 2001, p 63.

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