MASS UTILISATION OF FLY ASH AS

BACKFILLING MATERIAL IN OPEN PIT MINES

A CASE STUDY

Prof . Singam Jayanthu

Professor
Dept. of Mining Engineering,
National institute of Technology, Rourkela
SDMINER - 2014 - June 20th 22nd 2014 . NEW DELHI

CONTENTS

Introduction

Fly Ash Scenario

Geomining Conditions

Dumping Of Fly Ash As Admixture With Overburden

Experimental Investigation

Slope Stability Analysis

Slope Stability Monitoring

Survey By Total Station

Conclusions

INTRODUCTION

Fly ash generates from the coal based thermal power plant is of great
concern due to its disposal. Therefore proper utilization of the fly ash is

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highly demanded.

This Presentation demonstrates the results of laboratory investigation

through numerical analysis using PLAXIS for understanding the stability of

overburden dump formed by mixing with 25% fly ash in opencast coal mine
at Raigarh, India along with field monitoring of such dumps for the first
time in India. It is observed that dumps with alternative layer of only fly ash
and overburden material are found to be stable with safety factor more than
1.2.

FLY ASH SCENARIO

-----

40 Million Tonne
1 Million Tonne

2008
FA Generation
FA Utilization

-----

160 Million Tonne

80 Million Tonne

2011-2012
FA Generation
FA Utilization

-----

220 Million Tonne

110 Million Tonne

2031-2032
FA Generation

---

1000 Million Tonne

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1994
FA Generation
FA Utilization

UTILISATION
7
5%

6
12%

8
1%

1
47%
1 cement manufacturing
2 Cement substitution
3 Road embankments
4 Low lying area filling
5 Ash bund raising
6 Mine fill

4
10%

7 Brick manufacturing
3
9%

8 Agriculture & others

2
9%

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5
7%

GEOMINING CONDITIONS

Jindal Power Open Cast Coal Mine is captive mine of Jindals 1000

between Longitudes - 8329'40" to 8332'32" (E) and Latitude 2209'15" to 2205'44" (N) falling in the topo sheet number 64 N/12

(Survey of India).

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MW (4 x 250 MW) thermal power plant. The block is located

CONTD

Jindal Power Open Cast Coal Mine is almost flat with small

3-4 m unconsolidated loose soil/alluvium. Below the top soil there is

weathered shale/sandstone up to 68 m depth. The weathered shale

and sandstone are comparatively loose in nature and can be

excavated without blasting.

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undulations from surface. The lithological section comprises about

PLAN OF JPL COAL

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DUMPING OF FLY ASH AS ADMIXTURE WITH

OVERBURDEN

Jindal Power Limited, Tamnar has already have captive thermal power

residue form due to the burning of coal, of nearly 16000 tons per day.
Therefore, quantity of fly ash generated requires large area for its

dumping.

Fly ash was dumped within this area surrounded by overburden in

alternate layers of height not exceeding 5 m in each layer. Therefore, each

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plants of 1000 MW and generating fly ash, a solid coal combustion

layer of overburden was followed by a layer of mixture of fly ash and

overburden (fly ash 25%) and so on up to the height of 30 m.
9

SECTION OF THE DUMP

5m
5m
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Overburden material (OB)

Mixture of Fly ash and OB
10

FLY ASH AND OB MIXED DUMP AT DUMP SITE

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11

DOZING OF FLY ASH AND OB MATERIAL AT THE

DUMP SITE

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12

CLOSE VIEW OF FLY ASH AND OVERBURDEN

AT DUMP SITE

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13

DUMPING OF FLY ASH WITHIN OVERBURDEN AT

DUMP SITE

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14

EXPERIMENTAL INVESTIGATION

Various samples of overburden, soil and fly ash from the dump site were
supplied by the Jindal Power Limited for finding out various
geotechnical properties through the laboratory study. Different

samples collected from the site

Laboratory geotechnical investigation was carried out for determination

of grain size distribution, specific gravity, compaction characteristics
(optimum moisture content and maximum dry density), and shear
strength characteristics following Bureau of Indian standard (BIS)

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geotechnical tests were conducted for the overburden and the fly ash

methods. The parameters like density, and shear parameters cohesion (C)
and angle of internal friction are determined for both overburden and fly
ash to analyze stability of dumped slope.

15

TESTING OF PHYSIO MECHANICAL PROPERTIES

OF DUMP MATERIAL

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16

GRAIN SIZE DISTRIBUTION OF TYPICAL

OVERBURDEN (OB) AND FLY ASH

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17

COMPACTION CHARACTERISTICS OF MIXTURE

OF OVERBURDEN AND FLY ASH (25%)

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18

TRIAXIAL TEST RESULTS FOR OVERBURDEN AND 25% FLY

ASH

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19

ANALYSIS

The stability of dumped slope is analyzed by PLAXIS software,

element program for geotechnical applications in which MohrColoumb models are used to simulate the behavior of dump

material. Its implementation consists of three stages, known as input

stage, calculation stage and post processing (curves) stage.

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Version 9 using the geotechnical parameters. PLAXIS is a finite

20

CONTD

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Different trials were made with overburden and mixture of

overburden and fly ash with overall slope angle of 270. The
trial-1 was made with the overburden and mixture of over
burden with 25% fly ash. The Factor of Safety obtained was
1.75, and as it is much higher than 1.2.
This overburden does satisfy the minimum requirement and can
be used along with the fly ash.

21

CONTD

The trial- 2 was made for the dump prepared by alternate layer of

the incorporation of top soil of nearly 2 meter thickness at the top of

the dump for the reclamation purpose.

The Factor of Safety obtained was 1.78, and as it is more than 1.2.
This indicates that at the end the dump after dozing of top soil, the
dump satisfies the minimum requirement and can be used.

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overburden and mixture of overburden and 25% fly ash along with

22

CONTD.

Slope stability of the overburden dump after mixing of fly ash, it

factor has increased to 1.78, which was only 1.32 with 8% fly ash
mixture with overburden. This increase may be attributed to the

increase in cohesion of the mixture due to self-cementing properties

of fly ash generated from the combustion of sub-bituminous coal.

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was observed that on the application of 25% fly ash mixture safety

23

A VIEW OF THE OVERBURDEN DUMP FORM BY UTILIZING

FLY ASH AT JINDAL POWER LIMITED

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24

SLOPE STABILITY MONITORING BY TOTAL STATION

The height of dump at study site was about 25 m. Final stage dump
consist of 2 m top soil above the layers of OB and OB mixed fly ash

monitoring stations fixed at an interval of 20 to 30 m on the dumps at

a distance of about 5 m from the crest of the dump slope.

The 47 monitoring stations were installed with 1.0 m long pipes and
masonry pillars; 23 stations in the Pit 1 and 24 stations in Pit 2 and total
station was used for measuring RL of the stations.

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material. Stability of Dump slopes was monitored with total station and

25

STATIONS AT AN INTERVAL OF 30M ON

THE DUMPS AT A DISTANCE OF ABOUT 5M
FROM THE CREST OF THE DUMP SLOPE

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26

MONITORING STATIONS INSTALLED WITH 1.0 M

LONG PIPES AND MASONRY

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27

GPS SURVEY FOR MONITORING THE LOCATION

OF THE STATIONS

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28

STATION FOR MEASURING REDUCED LEVELS OF

MONITORING STATIONS

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29

STATUS OF VERTICAL DISPLACEMENT OF DUMP

AT THE MONITORING STATIONS
Zero displacement
Pit-2
KJS6, KJS 7,
KJS 8, KJS 9,
KJS 10, KJS 13,
KJS 14, KJS 15,
KJS 16, KJS 17,
KJS 18, KJS 20,
KJS 22

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Pit-1
AS1, AS 2,
AS 3, AS
12, AS
13,AS14,
AS 15,
A16, AS
18,AS19,
AS 20,
AS21

Downward
Haphazard
displacement
displacement
Pit-1
Pit-2
Pit-1
Pit-2
AS4, AS 6, KJS 1, AS 5, AS KJS3
AS 7 , AS 9, KJS 4, 8, AS 11
, KJS
AS 10, AS KJS
5
17, AS 22, 11,
AS 23
KJS
12,
KJS
19,
KJS
23,
KJS 24

30

LEVEL OF MONITORING STATIONS

INSTALLED AT THE DUMP SITE WITH FLY-ASH
AND OB MATERIAL
Sl. No.

R.L. on 15.11.12
332.433
333.528
334.313
334.748
334.848
335.083
335.053
335.01
334.218
334.823
334.853
334.608
333.943
332.563
332.458
333.418
334.073
334.478
334.708
334.713
334.823
335.033
335.198

Vertical
R.L. on 31.03.13
Deformation - m
332.433
0
333.528
0
334.313
0
334.747
-0.001
334.843
-0.005
335.065
-0.018
335.038
-0.015
335.01
0
334.203
-0.015
334.807
-0.016
334.853
0
334.608
0
333.943
0
332.563
0
332.458
0
333.418
0
334.072
-0.001
334.478
0
334.708
0
334.713
0
334.823
0
335.031
-0.002
335.195
-0.003

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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

Pillar No.
AS1
AS2
AS3
AS4
AS5
AS6
AS7
AS8
AS9
AS10
AS11
AS12
AS13
AS14
AS15
AS16
AS17
AS18
AS19
AS20
AS21
AS22
AS23

31

STATUS OF VERTICAL DISPLACEMENT OF DUMP AT THE

MONITORING STATIONS
Sl. No.

Pillar No.
1 KJS1
KJS2
KJS3
KJS4
KJS5
KJS6
KJS7
KJS8
KJS9
KJS10
KJS11
KJS12
KJS13
KJS14
KJS15
KJS16
KJS17
KJS18
KJS19
KJS20
KJS21
KJS22
KJS23
KJS24

313.803
314.158
313.928
314.713
314.393
314.998
315.073
315.123
315.263
315.068
314.753
314.188
313.823
313.833
314.003
314.253
315.473
314.693
314.283
314.413
314.543
314.803
315.353

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2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

R.L. on 15.11.12
313.948

Vertical Deformation R.L. on 31.03.13

m
313.948
0
Disturbed due to
movement of machinery
314.158
0
313.908
-0.02
314.713
0
314.393
0
314.998
0
315.073
0
315.123
0
315.263
0
315.058
-0.01
314.748
-0.005
314.188
0
313.823
0
313.833
0
314.003
0
314.253
0
315.473
0
314.692
-0.001
314.283
0
314.413
0
314.543
0
314.801
-0.002
315.348
-0.005

32

VARIATION OF RL OF MONITORING STATIONS

OVER THE DUMP MATERIAL IN PIT 1
335.5

Reduced Level (m)

334.5
334
R.L. on 15.11.12
333.5

R.L. on 08.01.13
R.L. on 20.01.13

333

R.L. on 31.03.13

332.5
332
0

10

15

20

25

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335

Monitoring Station

33

VARIATION OF RL OF MONITORING STATIONS OVER

THE DUMP MATERIAL IN PIT 2
315.6

315.4

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315.2
315

Reduced level (m)

314.8

314.6
314.4
R.L. on 15.11.12

314.2
R.L. on 08.01.13

314
R.L. on 20.01.13

313.8
R.L. on 31.03.13

313.6
0

10

Monitoring Station

15

20

25

30

34

LEVEL OF MONITORING STATIONS INSTALLED AT THE

DUMP SITE WITH FLY-ASH AND OB MATERIAL ON PIT
1 UPTO JUNE 13
Vertical Deformation
m
Nov 12- March13
Sl. No.

Pillar No.

AS1
AS2
AS3
AS4
AS5
AS6
AS7
AS8
AS9
AS10
AS11
AS12
AS13
AS14
AS15
AS16
AS17
AS18
AS19
AS20
AS21
AS22
AS23

0
0
0
-0.001
-0.005
-0.018
-0.015
0
-0.015
-0.016
0
0
0
0
0
0
-0.001
0
0
0
0
-0.002
-0.003

0
0
0
0
0
-0.001
-0.002
0
-0.002
-0.001
0.001
0
0
-0.001
0
-0.001
0
0
0
-0.002
0
0
0

Vertical Deformation
m
Nov12, June13

0
0
0
-0.001
-0.005
-0.019
-0.017
0
-0.017
-0.017
0.001
0
0
-0.001
0
-0.001
-0.001
0
0
-0.002
0
-0.002
-0.003

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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

R.L. on 12.06.13
332.433
333.528
334.313
334.747
334.843
335.064
335.036
335.01
334.201
334.806
334.854
334.608
333.943
332.562
332.458
333.417
334.072
334.478
334.708
334.711
334.823
335.031
335.195

Vertical Deformation
m
March13 June13

35

LEVEL OF MONITORING STATIONS INSTALLED AT THE

DUMP SITE WITH FLY-ASH AND OB MATERIAL ON PIT
2 UP TO JUNE 13
Sl. No.

Pillar No.
KJS1
KJS2
KJS3
KJS4
KJS5
KJS6
KJS7
KJS8
KJS9
KJS10
KJS11
KJS12
KJS13
KJS14
KJS15
KJS16
KJS17
KJS18
KJS19
KJS20
KJS21
KJS22
KJS23
KJS24

313.948
313.69
314.158
313.907
314.713
314.393
314.998
315.072
315.123
315.263
315.058
314.748
314.188
313.822
313.833
314.001
314.253
315.473
314.692
314.283
314.412
314.543
314.801
315.347

Vertical
Vertical
Deformation m
Deformation m
March13 June13 Nov12, June13
0

Disturbed due to movement of machinery

0
-0.02
0
0
0
0
0
0
-0.01
-0.005
0
0
0
0
0
0
-0.001
0
0
0
-0.002
-0.005

0
-0.001
0
0
0
-0.001
0
0
0
0
0
-0.001
0
-0.002
0
0
0
0
-0.001
0
0
-0.001

0
-0.021
0
0
0
-0.001
0
0
-0.01
-0.005
0
-0.001
0
-0.002
0
0
-0.001
0
-0.001
0
-0.002
-0.006

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1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

R.L. on
12.06.13

Vertical
Deformation m
Nov 12- March13

36

STATUS OF VERTICAL DISPLACEMENT OF DUMP AT THE

MONITORING STATIONS DURING MARCH13 TO
JUNE13
Zero displacement

Gradual displacement

Haphazard
displaceme
nt

AS11

4.34

PIT-1

23

AS1,AS2,AS3,AS4,AS5,AS8,A
S12,AS13,AS15,AS17,AS18,A
S19,AS21,AS22,AS23(15 NOS)

65.23

AS6,AS7,AS9,AS10,A
S14,AS16,AS20(7
NOS)

30.43

PIT-2

23

KJS1, KJS3, KJS5, KJS6, KJS7,

KJS9, KJS10, KJS11, KJS12,
KJS13, KJS15, KJS17,
KJS18,KJS19, KJS20, KJS22,
KJS23(17)

73.91

KJS4, KJS8, KJS14,

KJS16, KJS21,
KJS24(6NOS)

26.09

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TOTAL
NO OF
STATION
S

37

CONCLUSIONS

Dump with alternative layer of overburden and overburden mixed

more than 1.2 for total height of the dump, Number of decks:
Height of individual deck, and Slope of each deck as 120 m, 4,: 30

m, and 32.

Dump form with alternate layer of overburden and mixture of fly ash
and overburden after dozing the top soil of nearly 2 m thick at the

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with fly ash (only 25%) are found to be stable with safety factor

top, the slope also found stable with safety factor 1.78 for the above
geometry.
38

FIELD MONITORING OF SLOPES USING TOTAL

STATION INDICATED THE FOLLOWING:

Displacement pattern of the monitoring stations during November

Overburden dumps with fly ash ensuring stability of the dump near
majority of the stations.

During November12 to March13, the dump was in the process of

continuous settlement near 1/3rd of the stations. About 65% , and
74% of the monitoring stations in Pit 1, and Pit 2, respectively

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2012 to June 2013 indicated no significant displacement in the

showed no perceptible deformation of the dump material near the

stations during March13 to June13.
39

Decelerated movement was noticed during March13 to June 13 with a

displacement of 1 mm in about 30% , and 26% of the monitoring

settlement of the dump material with 75% OB and 25% Fly Ash after
March13.

Based on the above monitoring results, it is recommended to continue

further monitoring of reduced levels of the stations till all the stations
show complete settlement for formulation of guidelines on settlement

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stations in Pit 1, and Pit 2, respectively. This indicates the tendency of

for similar dump materials. Using wireless sensor nodes at respective

slope stability monitoring stations, and other instruments in mines, data
can be acquired and interpreted online in future studies.

40

REFERENCES

Jayanthu S et al, 2012, Stability Of Fly Ash And Overbuden Material As

Back Filling In Opencast Mines A Case Study, Proceedings of

(ICCEE'2012) that will take place on March 24-25, 2012 in Dubai (UAE).

Singam Jayanthu, and

SDMINER - 2014 June 20-Jue 22 2014 NEW

DELHI

International Conference on Chemical, Civil and Environment engineering

Simantini Behera, 2013, Field Monitoring Of

Stability of Dump With 25% Fly Ash And 75% Overburden Materials
Related To JPOCCM MINE, JPL, unpublished report.

Anon, 2005, Micro seismic monitoring of open pit slopes. Proceedings of

rock bursts and seismicity in mines 6, Perth, March Australian centre for
Geomechanics. Papoulis, a. Probability, random variables, and stochastic
41

processes, 2nd Ed. New York: McGraw-hill, 1984. Pp. 37-38.

SDMINER - 2014 June 20-Jue 22 2014 NEW

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42