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A Seminar Report on
(COAL MINING WASTE REUSE IN CONSTRUCTION INDUSTRY)
By
 NAME OF THE CANDIDATE_:-MULLA ALISHA JAHANGIR
SEAT NO: 301C065
T. E. CIVIL
UNDER THE GUIDANCE OF :- K.S.PATIL
of
SAVITRIBAI PHULE PUNE UNIVERSITY
NAME OF THE DEPARTMENT :- CIVIL ENGINEERING
SINHGAD COLLEGE OF ENGINEERING,
VADGAON (Bk.), Pune-411041
Year 2023-24
2
CERTIFICATE
This is to certify that the Seminar Report entitled
(COAL MINING WASTE REUSE IN CONSTRUCTION INDUSTRY)
ALISHA JAHANGIR MULLA has successfully completed the Seminar Presentation under
the supervision of K.P.PATIL for the partial fulfillment of Bachelor of Engineering “CIVIL
ENGINEERING” of Savitribai Phule Pune University. This work has not been submitted
elsewhere for the award of any other degree
Name:- K.S.PATIL
Guide
Name :-S.S.SHASTRI
Head of Department
Name
Examiner
Name:-S.D.LOKHANDE
Principal
3
DECLARATION
I hereby declare that the project work entitled “STABILIZATION OF SOFT
SOIL USING CONSTRUCTION INDUSTRY” Submitted to the Sinhgad college
of engineering pune,is a Record of an work done by under the Guidance of
“Mrs.K.S.PATIL” Department of Civil Engineering project work is submitted in
the partial fulfillment of the Requirements for the award of Degree of Bachelor of
Engineering .
4
ABSTRACT
The exploitation of mineral resources would promote the development of economy and society, but it will also
generate massive waste/tailings that may pollute the environment significantly (in the form of spreading of
waste in and around the mines, siltation of soil/slimes in nearby water bodies, air pollution etc.) Therefore,
developing comprehensive utilization of waste fines/tailings in large scale is the need of the day in order to
improve the surroundings and for sustainable development of resources. Manufacturing of non-fired bricks is
one of the options for utilization of waste generated in mines along with reduction of CO2 emission. If the
waste material is improperly dumped in mine site, the flow of material during rainy season may reduce the
fertility of nearby agricultural land. Hence, waste utilization plays a vital role in natural resource conservation.
Further, building blocks/bricks from mine waste is eco-friendly as it utilizes waste and reduces air, land and
water pollution. It is energy efficient and also cost effective as reported by various investigators in the past.
Hence, it is very much necessary to find alternative for making use of iron ore waste material (fines)/tailings as
an aggregate in construction materials like bricks or paving blocks. This paper provides a critical review of the
utilization of mine waste for brick making in the construction industry.
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INDEX
CHAPTER NO. PARTICULARS PAGE NO
CHAPTER NO. 1 INTRODUCTION 6
CHAPTER NO. 2 LITERATURE REVIEW 8
CHAPTER NO. 3 METHODOLOGY 15
CHAPTER NO. 4 CASE STUDY 17
CHAPTER NO. 5 CONCLUSION 20
CHAPTER NO. 6 REFERANCE 21
6
INTRODUCTION
Approximately 10–15% of the iron ore mined in India is unutilized, even now, and is discarded as
waste/tailings due to lack of cost effective technology in extracting low grade ores (Rudramuniyappa, 1997).
The safe disposal or utilization of such vast mineral wealth in the form of ultra-fines or slimes has remained a
major unsolved and challenging task for the Indian iron-ore industry. Iron-ore waste generated is likely to
increase in future due to higher demand for iron ore as a number of steel plants have been planned in many parts
of the country. In India the production of iron ore was 218.64 million tons (IBM, 2013) and the total production
of iron ore in India is expected to exceed 400 million tons within the next decade. Waste rocks are the unused
material produced during the extraction process, which is dumped in appropriately in the mine lease boundary.
Mainly waste rocks overlying on the ore body needs to be removed in large quantities for ore extraction, which
forms the major mine waste also called as overburden. The overburden ratio for surface mining of metal ores
generally ranges from 1:2 to 1:6 depending on the local conditions. For every ton of metal extracted from the
ore, roughly 212 tons of overburden material is removed. Generally, open cast mines and quarries generate
much more mining wastes compared to underground mines (Mohanty, 2010). The exploitation of mineral
resources would promote the development of economy and society, but it will also generate massive
waste/tailings that may pollute the environment heavily and bring other issues such as occupying land and
wastage of resources. Therefore, developing comprehensive utilization of waste fines/tailings in large scale is
one of the prospective way to promote production efficiency, and also it is important in saving resources,
improving surroundings and for sustainable development (Zang et al. 2006). It is therefore imperative that state-
of-the-art iron-ore mining and processing technologies to be adopted to address and implement effective
utilization of tailings. There is a significant demand of building materials in India and elsewhere. It is therefore
imperative to use the mining and mineral wastes in the production of bricks, concrete blocks and other value
added products. The manufacture of building bricks without burning of solid fuel is one of the options for
utilization of mining and industrial wastes and reduction of CO₂ emission by adopting innovative and
sustainable processes such as mineral polymerization and mineral cementation (Chakravarthi et al. 2007;
Muduli et al. 2010).
India is blessed with abundant natural resources, including coal, iron ore, bauxite, manganese, and
limestone. However, the transformation from an underdeveloped to a developed economy requires enormous
increases in mineral production, which generates additional huge quantities of waste1
. The mining industry is
already facing problems related to land acquisition and environmental clearances. Sustainable development of
the Indian mineral industry requires reprocessing, reuse, and recycling of mine waste.
7
The reuse of mining waste in construction presents two benefits: conserving natural resources and reducing the
environmental impacts of mining. Reprocessing, reuse, and recycling of mine waste are required to achieve
sustainable development of the Indian mineral industry.
There are several ways to reuse coal mining waste in construction. For instance, it can be used as a resource for
minerals and metals, backfilling material, landscaping material, aggregate in embankment, road, pavement,
foundation and building construction, asphalt component, feedstock for cement & concrete and as soil additive.
Dr. Binish Desai has found a way to make coal waste a resource for manufacturing a substitute for concrete
called Gobcrete. However, there is still a major lack of specific legislation regarding the use of mining wastes in
road construction.
8
LITERATURE REVIEW
Researches have been carried throughout the world in the area of manufacturing of bricks using various
materials, both natural resources and waste materials. Further, the bricks were also made by various processes
SHREEKANT R L, ARUNA M AND HARSHA VARDHAN 183 International Journal of Earth Sciences and
Engineering ISSN 0974-5904, Vol. 09, No. 01, February, 2016, pp. 182-195 and technologies. Following
section highlights the types of bricks based on the material used and the process adopted.
 TYPES OF BRICKS BASED ON INDIAN STANDARDS:
A) COMMON BRICKS: Common bricks are multi-purpose bricks manufactured economically without
special reference to its appearance. It is suitable for general building work and widely used for foundations, as a
backing for rendering, plaster or color wash and also popular for inner leaf of cavity walling (Lunch, 1993).
B) FACING BRICKS: Facing bricks are good in appearance and are used for filling in front of building walls
for which a pleasing appearance is desired (Lunch, 1993).
C) ENGINEERING BRICKS: Engineering bricks are strong, impermeable, smooth, table molded, hard and
conform to defined limits of compressive strength and water absorption. These are used for all load bearing
structures, construction of bridge, aqueducts, engine pits, power houses, damp proof courses etc. Their name
derives from their use in civil and allied engineering (Lunch, 1993; Duggal, 2008).
D) SPECIAL BRICKS: Special bricks are classified based on their shape, specification and special purpose
for which they are made. These bricks are different from the commonly used building bricks.
E) SPECIAL SHAPED BRICKS: Special shaped bricks are used to suit the different situation. The
dimensions of these bricks vary. These bricks are used as closers, copings, bullnose bricks, corner bricks, plinth
bricks, culvert bricks, chimney bricks and well type bricks etc.
F) BURNT CLAY FACING BRICKS: Burnt clay facing bricks are used for the exposed face of masonry,
without further surface protection. As per Bureau of Indian Standards (BIS) (IS: 2691:1988) these types of
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bricks are mainly divided into two major classes such as i.e., Class I and Class II. The compressive strength of
Class I should not be less than 100 kg/cm 2 whereas of Class II, it should not be less than 75 kg/cm2 . The water
absorption requirement for 24 hours immersion should not exceed 15 %.
G) HEAVY DUTY BRICKS: Heavy duty bricks have high compressive strength, low water absorption and
should be free from cracks. The compressive strength of these bricks varies from 40 MPa to 45 MPa and total
water absorption is less than 10 %. These types of bricks are mostly used for heavy engineering works, like
bridge structures, industrial foundations etc. (IS-2180:1988).
H) PERFORATED BUILDING BRICKS: Perforated building bricks have better thermal insulation
compared to common type of bricks. Sizes of these bricks are varies from 19 cm × 9 cm × 9 cm to 29 cm × 9
cm × 9 cm (IS:2222-1991). According to the BIS (IS: 3495-1976) a minimum compressive strength of the brick
should be 7 MPa with maximum average water absorption of 15 % by mass.
I) BURNT CLAY HOLLOW BLOCKS:
Burnt clay hollow blocks are light in weight and being hollow, which imparts thermal insulation to the
buildings. It is used in limited scale for walls and partition in our country.
J) SAND LIME BRICKS OR CALCIUM SILICATE BRICKS:
Sand, lime bricks consist of siliceous sands and limes combined by the action of saturated steam under
pressure. Generally, these bricks are used for masonry construction. According to the BIS (IS: 4139-1976) the
size of the sand lime brick is 19 cm × 9 cm × 9 cm and 19 cm × 9 cm × 4 cm. These bricks are classified in to
four classes according to their average compressive strength, which should not be less than 7.5 MPa, 10 MPa,
15 MPa and 20 MPa, respectively.
K) SEWER BRICKS:
Sewer bricks manufactured from clay, fire clay or shale or combination of these materials. As per BIS
(IS: 4885-1988) the size of these bricks are 19 cm × 9 cm × 9 cm and 19 cm × 9 cm × 4 cm. The average
compressive strength of sewer bricks should not be less than 175 Kg/cm 2 . The average value of water
absorption for five bricks after 20 hours in cold water immersion should not exceed 10 % of average dry weight
of bricks.
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L) ACID RESISTANT BRICKS:
Acid resistant bricks are made of clay or shale of suitable composition with low lime, low iron
content, feldspar, sand and vitrified at high temperature in ceramic kiln. It is designed for use in chemical and
allied industries. As per Bureau of Indian Standards (IS: 4860-1968) the dimension of these bricks is 23 cm ×
11.4 cm × 6.4 cm. These types of bricks are manufactured in two classes. The Class I bricks having minimum
average compressive strength of 68.65 MPa and maximum water absorption of 2 %. These classes of bricks are
recommended for corrosive environment like storage tank, pickling tank etc. The 184 Utilisation of Mine Waste
in the Construction Industry – A Critical Review International Journal of Earth Sciences and Engineering ISSN
0974-5904, Vol. 09, No. 01, February, 2016, pp. 182-195 Class II bricks having minimum average compressive
strength of 49.03 MPa and maximum water absorption of 4 %. These bricks are used for floors and working
areas which are subjected to occasional spillage of acid. It is also used for skirting and lining of silos.
M) REFRACTORY BRICKS:
Refractory bricks are manufactured using refractory clays which withstand very high temperature. The
primary requirements of this bricks are its materials properties (physical and chemical) i.e. it should be stable at
high temperature. These bricks are also defined as non-metallic material suitable for the construction of
furnaces which operated at high temperature (Kulkarni, 1999). Table 1 gives the detailed clarification of heavy
duty and commercial burnt clay bricks based on compressive strength (IS: 2180-1988, IS: 1077-1992).
2.2 Classification of the bricks based on manufacturing process and type of ingredients:
A) STEAM CURING-FREE BRICKS:
An experimental study conducted on iron ore tailings shows that a burnt and steam curing-free
bricks (iron tailing, fly ash, sand, CaO, gypsum and cement) has compressive strength of 28.30 MPa and
flexural strength of 5.63 MPa (Gan et al., 2011).
B) NON-FIRED BRICKS:
Youngliang et al. (2011) utilized hematite tailings in manufacturing of non-fired bricks by pressing
and curing process in the presence of cementing material and coarse aggregates. The factors influencing the
mechanical strength of the bricks, like forming water content, forming pressure, content of tailings in raw
material and curing condition were investigated. Results of the study indicates that non-fired brick with 78 %
hematite tailings can be prepared in the optimal condition at 15 % water content and 20 MPa pressure. The
11
suitable curing condition is in room temperature for 28 days. It was also found that comprehensive strength of
products can be up to 15.9 MPa with other physical properties and the durability were well confirmed to
Chinese non-fired gangue brick standard. Muduli et al. (2010) prepared cold setting building bricks from
mining and industrial wastes. It was observed that, in atmospheric temperature ranging 20° - 35° C and hot air
temperature below 100°C, a considerable binding strength is developed. The results of the investigation
indicates that the bricks produced by polymerization reaction using 95 % fly ash, 50 % beneficiated iron ore
tailings and red mud attain 80 to 14.71 MPa crushing strength under atmospheric curing condition. This process
is flexible and cost effective for using the waste materials from any source having thermal and non-thermal
effect in preparation of cold setting building bricks.
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C) FIRED BRICKS:
The experiments performed by Yongliang et al. (2011) shows that the eco-friendly bricks prepared
from hematite tailings and the additives of clay and fly ash improves the brick quality. The bricks were made
through the process of mixing, forming, drying and firing. The results indicated that the mechanical strength
and water absorption of the fired brick specimens were in the range 20.03 - 22.92 MPa and 16.54 - 17.93 %,
respectively. The other physical properties and durability were as per Chinese Fired Common Brick Standard.
D) AUTOCLAVED BRICKS:
An attempt was made by Zhao et al. (2012) for utilizing hematite tailings for preparing high strength
autoclaved bricks to use in the construction industry. To achieve high strength of bricks, the hematite tailings
were added to the mixture of lime and sand which are in 70:15 ratios. The autoclave pressure 1.2 MPa with 6
hour timing, gives the compressive strength 21.2 MPa and flexural strength 4.21 MPa. The requirement in
autoclaved lime-sand brick standard for MU-20 autoclaved bricks satisfied with the mechanical and freezing-
thawing resistance properties.
E) CLAY BRICKS:
A study carried out by Nwofor (2012) on mechanical properties of clay brick masonry in which
mechanical properties of constituent materials of masonry influences its structural behavior. Uniaxial
compressive test was carried out on unreinforced masonry and its SHREEKANT R L, ARUNA M AND
HARSHA VARDHAN 185 International Journal of Earth Sciences and Engineering ISSN 0974-5904, Vol. 09,
No. 01, February, 2016, pp. 182-195 constituents to obtain their basic mechanical properties. The compressive
stress-strain relationships at different confining stress levels were obtained. The nonlinear stress-strain curves
were also obtained for masonry with salient points identified on the stress-strain curves, with stress level of 0.40
Fm corresponding to the limit of the nonlinear region. Simple analytical model was proposed for prediction of
modulus of elasticity of masonry, to aid the numerical analysis of masonry structures. The test results obtained
on brick units and masonry was enough to predict the modulus of elasticity of masonry..
2.3 UTILISATION OF MINE / MINERALS WASTES AS BUILDING MATERIALS:
Significant amounts of research have been carried out worldwide in usage of mine waste and tailings
for the manufacturing of building materials. The mining waste is generally used as aggregate in concrete and
also in manufacturing of bricks, tiles, cement, pozzolana etc. It is also used as pigments for paints. A study
13
carried out by HAMMOND (1 9 9 8 ) stressed that by using mine waste natural resources will be conserved,
energy will be saved and environmental pollution will be reduced. The study conducted by Reddy (2004)
concludes that there is a large scope for R & D in developing alternative building technologies. Application of
intelligent decision support system for comprehensive utilization of tailings and waste rocks in China and
worldwide were developed by Keqing Wang et al. (2011). The idea was implemented and the system was built
by combining engineering practice of comprehensive utilization of tailings and waste rocks with other subjects
like artificial intelligence, neural network, fuzzy mathematics and decision making technology. A study
carried out by Robert and Richard (2011) on utilization of mining and mineral processing wastes in the United
States, describes the principle classifications of solid wastes from mining and mineral processing based on
physical and chemical properties of each type of waste material. The principle locations and approximate
quantities of each category of mining and mineral processing waste were also included in this study. Pertinent
technical, economic and environmental considerations involved in specific uses of these wastes were also
discussed. The need for research and efforts involving particular waste material are also documented in this
investigation.
Suitability of iron ore tailings (IOT) in building construction to examine the compressive strength of the IOT
concrete for construction work. Analysis made using Minitab software for the statistical analysis was studied.
The Results obtained showed that, with increased period of curing ages and an optimal combination of the sand
and cement replacement resulted in an optimal high strength of IOT concrete. The quantity of materials utilized
for concrete was reduced (sand and cement quantity), and thereby reducing the cost of production and on the
other hand reducing the pollution of environment by utilizing the iron ore tailings as building materials. From
the analysis of variance it was observed that there is no specific interaction between the factors and their levels
but, there is significance in strength of the IOT concrete increasing as curing age increases. Since both sand and
cement replacement are of the same percentage (20 %) Lasisi et al. (2014).
2.3.2 MANGANESE RESIDUE:
Waste residue produced during the electrolytic preparation process of manganese cause serious
environmental problems. Baking-free brick, a promising building material can be produced from manganese
slag with addition of quicklime and cement. Several analyses were done by Ping et al. (2013) to measure the
physical properties, chemical composition and mechanical performances of the brick samples. The study
revealed that the production of electrolytic manganese residue (EMR) baking- free brick, with 25~30 MPa of
14
moulding force was economically feasible and the pressure during forming process was beneficial for
obtainment of the brick strength. Baking- free brick prepared from EMR having cement aggregate ratio as 1:1,
water solid ratio as 0.15 and the moulding pressure as 30 MPa had excellent compressive strength. The results
also showed that EMR-sand-lime-cement production system was the optimum with 50 % of EMR, 25 % of river
sand, 10 % quick lime and 15 % of cement. Similar study carried out on preparation of baking free brick from
manganese residue and its mechanical properties by Wang et al. (2013). The mechanical compressive strength
observed from bricks made using Electrolytic Manganese Residue (EMR) with cement aggregate ratio 1:1 and
water solid ratio 0.15 was 13.5 MPa and 14.7 MPa at moulding pressure 25 MPa with 7 days curing. Similarly,
17.4 MPa and 21.3 MPa at moulding pressure 30 MPa with 28 days curing. The density observed through the
study was 1.72. Further, it was also concluded that the 50 % of EMR, 25 % of river sand, 10 % of quicklime
and 15 % of cement production system was optimum.
15
METHODOLOGY
The study follows a qualitative approach for gaining in-depth insight on wastes generated from steel
industries and mines and yield effective utilization routes for reusing them in the field of low-carbon
construction practices, preferably in geopolymer concrete. Case studies were conducted during August 2019 to
analyse the current scenario of utilization and management of the generated wastes. Potential use of GGBS in
the production of cement free concrete i.e., fly ash or slag based geopolymer concrete have been highlighted.
Re-usability of mine wastes in a number of civil engineering applications thus serves as an effective pathway
for integrated industrial solid waste management. Two types of data collection methods were adopted for the
case studies. The primary source being the personal interviews while online database reports, articles, research
papers, annual reports of the industries being the secondary sources
In this study, use was made of two types of material for making concrete: (a) natural aggregate obtained from
quarry (mainly the granite) in the range of 12.5–20 mm, and (b) aggregates from mine (mainly the laterite). The
latter was collected randomly, from different fresh waste dumps as recommended ASTM D75; C702 sampling
of aggregates. These mine wastes were sieved and paticles between 12.5 and 20 mm size were used as coarse
aggregate in preparing concrete mix in the current study. In order to ascertain various physico mechanical
properties of the mine waste the following experiments were carried out in accordance with and ASTM C/109C
and 109M standards for concrete testing: Sieve analysis for coarse and fine aggregates (ASTM C 136);
elongation index: flakiness index; aggregate crushing value; aggregate impact value; specific gravity and water
absorption (ASTM C127); determination of bulk density and percentage voids (ASTM C29/C29M);
determination of aggregate abrasion value; and determination of aggregate angularity number (ASTM C/109C
and 109M). To study the mechanical properties of concrete made from both mine waste aggregate and normal
aggregate, the con crete cubes of 15 cm × 15 cm × 15 cm were prepared with ratio of 1:2:4 (cement :sand
:aggregate) with better workability by flow tests. For each series triplicate specimens were cast using 15 cm ×
15 cm × 15 cm molds. A thin layer of oil was applied on the internal faces of molds to ensure that demolding of
casted specimens was easy. Mixing and casting procedures were performed in accordance with ASTM
C192/C192M standards for concrete test ing. All the specimens were demolded after 24 h and immersed into
water for further curing. Addition of PC was calculated on dry aggregate basis (wt/wt). Uniaxial compressive
strengths (UCSs) were determined after 7, 14, and 28 days. Also, the UCS studies on cubical specimens with
cement, sand and aggregate ratios as fol lowing 1:2:5; 1:2:6; and 1:2:10 were conducted. Tests were also
conducted on the laterite bricks, which are predominant construction materials in the Sate of Goa, to measure
16
the wet UCS. The chemical analyses of these wastes were reviewed in the context of their high concentrations
of heavy metals and presence of acid producing mineral phases.
17
CASE STUDY
I.CASE STUDIES OF REPROCESSING, REUSE AND RECYCLING OF MINING WASTE:-
1.1 PROCESSED SAND:-
The waste material from coal mining in India comprises mainly of sandstone, bands of clay and other
metamorphic rocks. The sandstone ranges from coarse grain to fine grain. The waste rock generated to expose
coal is normally backfilled, still a major volume is stacked over non coal area. As the environmental laws for
extracting sand from river bed have become stringent, sand is in short supply. Western Coalfields Limited
(WCL) which is a subsidiary company of Coal India Limited( CIL), world’s largest coal producing company,
has started crushing and washing of sandstone from its waste dumps and is now major supplier of sand. This
sand is being used for construction of roads and structures. The sand also find use as filling materials in
underground mines of nearby region (6). Other subsidiaries of CIL are also launching now sandstone processing
for supply of sand from waste dumps. A large portion of land which is presently being occupied by sandstone
dumps will be released for better economic use.
1.2 CLAY BAND USE :
In surface mining method it is possible to mine bands like clay separately and then use them for making
bricks, stemming material and potteries. Clay band at Kampti opencast mine in WCL is being used for such
purposes.
1.3 MINE WATER:-
The water from underground mines which was initially discharged into local water bodies is now
treated and used for drinking and industrial purpose. WCL has established a RO plant of capacity 10,000 liters
per hour in Patansaongi village catering to drinking water needs of around 1,00,000 local populace.
Additionally, the plant has a bottling facility through which “COAL NEER” brand of packaged drinking water
is also being launched. Many subsidiaries of CIL are treating water and are supplying it to local townships and
industrial units. Other subsidiaries of CIL have also started treating underground mine water and are supplying
it to local townships and industries.
18
1.4 ECO PARK :-
There are many case studies in the mines of CIL wherein water bodies created from mining are converted
to picnic spots. One such case study which has attracted attention of all is Eco park at Saoner underground
mines lease hold area of WCL. The park utilizes mine water for gardening, water conservation, boating and
amusement purposes. The park showcases several demonstrable technologies such as Solar electrification of
water pump, Rain water harvesting, micro irrigation, etc. along with a science park and several adventure rides.
The park also has an artificial mine tunnel showcasing different mining job profiles, machinery and methods
used in the coal mines. The annual tourist footfall is more than 50,000 (10). Coal mine waste Yash Pande and
others have carried out study for replacing natural aggregates by thermal power station coal rejects in granular
sub-base and bituminous layers in road construction. The study has confirmed coal rejects as an alternative to
natural aggregate in road construction works (11).
1.5 IRON ORE TAILINGS (IOT) :-
Yelli shetty used iron ore waste from Goa and conducted an experimental study. In the concrete mix,
40% of coarse aggregates were replaced with iron ore tailings and concrete blocks were made for 28 days
curing. It resulted in the compressive strength of 21.93MPa to that of granite aggregate of 19.91 MPa. Hence,
the increase in the compressive strength was noticed with iron ore tailings with respect to the conventional
coarse aggregate (8).
1.6 IRON ORE WASTE ROCK :-
Gayana B C reported that the workability of all the concrete mixes increased upto 40%, where natural
aggregate in concrete was replacement with iron ore overburden / waste rock along with upward trend in
compressive strength (9).
1.7 FLY ASH :-
FLY ash is produced by coal-fired electric and steam generating plants. It is commonly used in Portland
cement concrete for applications in highway construction, in soil improvement, as mineral filler in hot mixed
asphalt and in grouts for pavement sub sealing. It is also used in making ash bricks and clinkers for stowing in
underground mines (12).
19
1.8 BLAST FURNACE SLAG:-
Blast furnace slag is generated during the melting process in steel making operations. It is very as a
cementitious binder in road construction. It is very commonly used road base material in France. In areas near
to steel plants it is also used as aggregate in road construction. (12).
1.9 WASTE DUMP MINING:-
The low grade rejects of past which were dumped are now being mined for metal extraction.
Common example is of manganese ore. The dumps created near Ramtek in Nagpur district are presently being
mined. The grade of the ore is more than 20%.
1.10 MINE WASTE FOR PRODUCTION OF DIFFERENT TYPES OF BRICKS:-
It is found from the detailed literature review that there is a lot of scope for utilization of mine
waste/industrial waste in the construction industry in the form of manufacturing of bricks, paving blocks, tiles
etc. Manufacturing of building bricks without burning of solid fuel is one of the options for reducing the
emission of CO2 gas. Srikant etc has given a detailed use of different type of mine waste for producing different
types of bricks.
20
CONCLUSION
The ore grades and quality have decreased over the decades. Due to the decreasing grades, more inputs in the
form of energy, water, capital and labour are required for the same output and at the same time larger volumes
of waste are generated. Total resource utilization, where all of the material mined is put to good use, is a
challenging concept for researchers and miners. To achieve near zero waste production circular economy
business model has to be employed for sustainable development of mineral resources. Developed nations should
make available innovative technologies to under developed nations so that total resource utilization is possible.
After all no nation is self sufficient in there mineral needs.
21
REFERANCE
1. www.ibef.org, Metals and Mining industry in India
2. Dr. B. K. Pal, etc Problems of mining wastes management in India and its suggestive measures – case
studies.
3. Maedeh Tayebi-Khorami etc, Re-thinking mining waste through an integrative approach led by circular
economy aspirations, www.mdpi.com .
4. Bernd G Lottermoser, Recycling, reuse and rehabilitation of mine waste, www.element magazine.org,
Decemmber2011.
5. Larisa CHINDRIS, Valorization of mining waste in the construction industry, General considerations,
6. Anup Kumar Gupta etc, A review on utilization of coal mine overburden dump waste as underground mine
filling material: a sustainable approach of mining, International Journal of Mining and Mineral Engineering,
2015 Vol.6 .
7. Jeroen Spoorena etc, Near-zero-waste processing of low-grade, complex primary ores and secondary raw
materials in Europe: technology development trends, Journal of Resource, conservation and recycling, May,
2020.
8. Yellishetty, M., etc. “Reuse of iron ore mineral wastes in civil engineering constructions: A case study -
resources”, Journal of .Conservation and .Recycling., Vol. 52, 2008.
9. B C Gayana etc , A study on suitability of iron ore overburden waste rock for partial replacement of coarse
aggregates in concrete pavements, 14th International Conference on Concrete Engineering and Technology,
IOP publication, 2018.
10. Mishra R R, Inaugural Address of national conference, Geomine 2019, Nagpur 2019.
11. Yash Pandey etc.,Utilization of Coal Mixed Waste Aggregates available at Thermal Power Plants for GSB
and Asphalt Mixtures, The 3rd International Conference on Transportation Geotechnics, Procedia Engineering,
2016.
12. Tara Sen etc, Usage of Industrial Waste Products in Village Road Construction, International Journal of
Environmental Science and Development, Vol. 1, No. 2, June 2010 .
13. Shrikant R Lamani etc, Utilization of mine waste in the construction industry - A Critical Review,
International Journal of Earth sciences and Engineering, vol 9, feb. 2016.
22

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T.E. Seminar_Title Page.doc

  • 1. 1 A Seminar Report on (COAL MINING WASTE REUSE IN CONSTRUCTION INDUSTRY) By  NAME OF THE CANDIDATE_:-MULLA ALISHA JAHANGIR SEAT NO: 301C065 T. E. CIVIL UNDER THE GUIDANCE OF :- K.S.PATIL of SAVITRIBAI PHULE PUNE UNIVERSITY NAME OF THE DEPARTMENT :- CIVIL ENGINEERING SINHGAD COLLEGE OF ENGINEERING, VADGAON (Bk.), Pune-411041 Year 2023-24
  • 2. 2 CERTIFICATE This is to certify that the Seminar Report entitled (COAL MINING WASTE REUSE IN CONSTRUCTION INDUSTRY) ALISHA JAHANGIR MULLA has successfully completed the Seminar Presentation under the supervision of K.P.PATIL for the partial fulfillment of Bachelor of Engineering “CIVIL ENGINEERING” of Savitribai Phule Pune University. This work has not been submitted elsewhere for the award of any other degree Name:- K.S.PATIL Guide Name :-S.S.SHASTRI Head of Department Name Examiner Name:-S.D.LOKHANDE Principal
  • 3. 3 DECLARATION I hereby declare that the project work entitled “STABILIZATION OF SOFT SOIL USING CONSTRUCTION INDUSTRY” Submitted to the Sinhgad college of engineering pune,is a Record of an work done by under the Guidance of “Mrs.K.S.PATIL” Department of Civil Engineering project work is submitted in the partial fulfillment of the Requirements for the award of Degree of Bachelor of Engineering .
  • 4. 4 ABSTRACT The exploitation of mineral resources would promote the development of economy and society, but it will also generate massive waste/tailings that may pollute the environment significantly (in the form of spreading of waste in and around the mines, siltation of soil/slimes in nearby water bodies, air pollution etc.) Therefore, developing comprehensive utilization of waste fines/tailings in large scale is the need of the day in order to improve the surroundings and for sustainable development of resources. Manufacturing of non-fired bricks is one of the options for utilization of waste generated in mines along with reduction of CO2 emission. If the waste material is improperly dumped in mine site, the flow of material during rainy season may reduce the fertility of nearby agricultural land. Hence, waste utilization plays a vital role in natural resource conservation. Further, building blocks/bricks from mine waste is eco-friendly as it utilizes waste and reduces air, land and water pollution. It is energy efficient and also cost effective as reported by various investigators in the past. Hence, it is very much necessary to find alternative for making use of iron ore waste material (fines)/tailings as an aggregate in construction materials like bricks or paving blocks. This paper provides a critical review of the utilization of mine waste for brick making in the construction industry.
  • 5. 5 INDEX CHAPTER NO. PARTICULARS PAGE NO CHAPTER NO. 1 INTRODUCTION 6 CHAPTER NO. 2 LITERATURE REVIEW 8 CHAPTER NO. 3 METHODOLOGY 15 CHAPTER NO. 4 CASE STUDY 17 CHAPTER NO. 5 CONCLUSION 20 CHAPTER NO. 6 REFERANCE 21
  • 6. 6 INTRODUCTION Approximately 10–15% of the iron ore mined in India is unutilized, even now, and is discarded as waste/tailings due to lack of cost effective technology in extracting low grade ores (Rudramuniyappa, 1997). The safe disposal or utilization of such vast mineral wealth in the form of ultra-fines or slimes has remained a major unsolved and challenging task for the Indian iron-ore industry. Iron-ore waste generated is likely to increase in future due to higher demand for iron ore as a number of steel plants have been planned in many parts of the country. In India the production of iron ore was 218.64 million tons (IBM, 2013) and the total production of iron ore in India is expected to exceed 400 million tons within the next decade. Waste rocks are the unused material produced during the extraction process, which is dumped in appropriately in the mine lease boundary. Mainly waste rocks overlying on the ore body needs to be removed in large quantities for ore extraction, which forms the major mine waste also called as overburden. The overburden ratio for surface mining of metal ores generally ranges from 1:2 to 1:6 depending on the local conditions. For every ton of metal extracted from the ore, roughly 212 tons of overburden material is removed. Generally, open cast mines and quarries generate much more mining wastes compared to underground mines (Mohanty, 2010). The exploitation of mineral resources would promote the development of economy and society, but it will also generate massive waste/tailings that may pollute the environment heavily and bring other issues such as occupying land and wastage of resources. Therefore, developing comprehensive utilization of waste fines/tailings in large scale is one of the prospective way to promote production efficiency, and also it is important in saving resources, improving surroundings and for sustainable development (Zang et al. 2006). It is therefore imperative that state- of-the-art iron-ore mining and processing technologies to be adopted to address and implement effective utilization of tailings. There is a significant demand of building materials in India and elsewhere. It is therefore imperative to use the mining and mineral wastes in the production of bricks, concrete blocks and other value added products. The manufacture of building bricks without burning of solid fuel is one of the options for utilization of mining and industrial wastes and reduction of CO₂ emission by adopting innovative and sustainable processes such as mineral polymerization and mineral cementation (Chakravarthi et al. 2007; Muduli et al. 2010). India is blessed with abundant natural resources, including coal, iron ore, bauxite, manganese, and limestone. However, the transformation from an underdeveloped to a developed economy requires enormous increases in mineral production, which generates additional huge quantities of waste1 . The mining industry is already facing problems related to land acquisition and environmental clearances. Sustainable development of the Indian mineral industry requires reprocessing, reuse, and recycling of mine waste.
  • 7. 7 The reuse of mining waste in construction presents two benefits: conserving natural resources and reducing the environmental impacts of mining. Reprocessing, reuse, and recycling of mine waste are required to achieve sustainable development of the Indian mineral industry. There are several ways to reuse coal mining waste in construction. For instance, it can be used as a resource for minerals and metals, backfilling material, landscaping material, aggregate in embankment, road, pavement, foundation and building construction, asphalt component, feedstock for cement & concrete and as soil additive. Dr. Binish Desai has found a way to make coal waste a resource for manufacturing a substitute for concrete called Gobcrete. However, there is still a major lack of specific legislation regarding the use of mining wastes in road construction.
  • 8. 8 LITERATURE REVIEW Researches have been carried throughout the world in the area of manufacturing of bricks using various materials, both natural resources and waste materials. Further, the bricks were also made by various processes SHREEKANT R L, ARUNA M AND HARSHA VARDHAN 183 International Journal of Earth Sciences and Engineering ISSN 0974-5904, Vol. 09, No. 01, February, 2016, pp. 182-195 and technologies. Following section highlights the types of bricks based on the material used and the process adopted.  TYPES OF BRICKS BASED ON INDIAN STANDARDS: A) COMMON BRICKS: Common bricks are multi-purpose bricks manufactured economically without special reference to its appearance. It is suitable for general building work and widely used for foundations, as a backing for rendering, plaster or color wash and also popular for inner leaf of cavity walling (Lunch, 1993). B) FACING BRICKS: Facing bricks are good in appearance and are used for filling in front of building walls for which a pleasing appearance is desired (Lunch, 1993). C) ENGINEERING BRICKS: Engineering bricks are strong, impermeable, smooth, table molded, hard and conform to defined limits of compressive strength and water absorption. These are used for all load bearing structures, construction of bridge, aqueducts, engine pits, power houses, damp proof courses etc. Their name derives from their use in civil and allied engineering (Lunch, 1993; Duggal, 2008). D) SPECIAL BRICKS: Special bricks are classified based on their shape, specification and special purpose for which they are made. These bricks are different from the commonly used building bricks. E) SPECIAL SHAPED BRICKS: Special shaped bricks are used to suit the different situation. The dimensions of these bricks vary. These bricks are used as closers, copings, bullnose bricks, corner bricks, plinth bricks, culvert bricks, chimney bricks and well type bricks etc. F) BURNT CLAY FACING BRICKS: Burnt clay facing bricks are used for the exposed face of masonry, without further surface protection. As per Bureau of Indian Standards (BIS) (IS: 2691:1988) these types of
  • 9. 9 bricks are mainly divided into two major classes such as i.e., Class I and Class II. The compressive strength of Class I should not be less than 100 kg/cm 2 whereas of Class II, it should not be less than 75 kg/cm2 . The water absorption requirement for 24 hours immersion should not exceed 15 %. G) HEAVY DUTY BRICKS: Heavy duty bricks have high compressive strength, low water absorption and should be free from cracks. The compressive strength of these bricks varies from 40 MPa to 45 MPa and total water absorption is less than 10 %. These types of bricks are mostly used for heavy engineering works, like bridge structures, industrial foundations etc. (IS-2180:1988). H) PERFORATED BUILDING BRICKS: Perforated building bricks have better thermal insulation compared to common type of bricks. Sizes of these bricks are varies from 19 cm × 9 cm × 9 cm to 29 cm × 9 cm × 9 cm (IS:2222-1991). According to the BIS (IS: 3495-1976) a minimum compressive strength of the brick should be 7 MPa with maximum average water absorption of 15 % by mass. I) BURNT CLAY HOLLOW BLOCKS: Burnt clay hollow blocks are light in weight and being hollow, which imparts thermal insulation to the buildings. It is used in limited scale for walls and partition in our country. J) SAND LIME BRICKS OR CALCIUM SILICATE BRICKS: Sand, lime bricks consist of siliceous sands and limes combined by the action of saturated steam under pressure. Generally, these bricks are used for masonry construction. According to the BIS (IS: 4139-1976) the size of the sand lime brick is 19 cm × 9 cm × 9 cm and 19 cm × 9 cm × 4 cm. These bricks are classified in to four classes according to their average compressive strength, which should not be less than 7.5 MPa, 10 MPa, 15 MPa and 20 MPa, respectively. K) SEWER BRICKS: Sewer bricks manufactured from clay, fire clay or shale or combination of these materials. As per BIS (IS: 4885-1988) the size of these bricks are 19 cm × 9 cm × 9 cm and 19 cm × 9 cm × 4 cm. The average compressive strength of sewer bricks should not be less than 175 Kg/cm 2 . The average value of water absorption for five bricks after 20 hours in cold water immersion should not exceed 10 % of average dry weight of bricks.
  • 10. 10 L) ACID RESISTANT BRICKS: Acid resistant bricks are made of clay or shale of suitable composition with low lime, low iron content, feldspar, sand and vitrified at high temperature in ceramic kiln. It is designed for use in chemical and allied industries. As per Bureau of Indian Standards (IS: 4860-1968) the dimension of these bricks is 23 cm × 11.4 cm × 6.4 cm. These types of bricks are manufactured in two classes. The Class I bricks having minimum average compressive strength of 68.65 MPa and maximum water absorption of 2 %. These classes of bricks are recommended for corrosive environment like storage tank, pickling tank etc. The 184 Utilisation of Mine Waste in the Construction Industry – A Critical Review International Journal of Earth Sciences and Engineering ISSN 0974-5904, Vol. 09, No. 01, February, 2016, pp. 182-195 Class II bricks having minimum average compressive strength of 49.03 MPa and maximum water absorption of 4 %. These bricks are used for floors and working areas which are subjected to occasional spillage of acid. It is also used for skirting and lining of silos. M) REFRACTORY BRICKS: Refractory bricks are manufactured using refractory clays which withstand very high temperature. The primary requirements of this bricks are its materials properties (physical and chemical) i.e. it should be stable at high temperature. These bricks are also defined as non-metallic material suitable for the construction of furnaces which operated at high temperature (Kulkarni, 1999). Table 1 gives the detailed clarification of heavy duty and commercial burnt clay bricks based on compressive strength (IS: 2180-1988, IS: 1077-1992). 2.2 Classification of the bricks based on manufacturing process and type of ingredients: A) STEAM CURING-FREE BRICKS: An experimental study conducted on iron ore tailings shows that a burnt and steam curing-free bricks (iron tailing, fly ash, sand, CaO, gypsum and cement) has compressive strength of 28.30 MPa and flexural strength of 5.63 MPa (Gan et al., 2011). B) NON-FIRED BRICKS: Youngliang et al. (2011) utilized hematite tailings in manufacturing of non-fired bricks by pressing and curing process in the presence of cementing material and coarse aggregates. The factors influencing the mechanical strength of the bricks, like forming water content, forming pressure, content of tailings in raw material and curing condition were investigated. Results of the study indicates that non-fired brick with 78 % hematite tailings can be prepared in the optimal condition at 15 % water content and 20 MPa pressure. The
  • 11. 11 suitable curing condition is in room temperature for 28 days. It was also found that comprehensive strength of products can be up to 15.9 MPa with other physical properties and the durability were well confirmed to Chinese non-fired gangue brick standard. Muduli et al. (2010) prepared cold setting building bricks from mining and industrial wastes. It was observed that, in atmospheric temperature ranging 20° - 35° C and hot air temperature below 100°C, a considerable binding strength is developed. The results of the investigation indicates that the bricks produced by polymerization reaction using 95 % fly ash, 50 % beneficiated iron ore tailings and red mud attain 80 to 14.71 MPa crushing strength under atmospheric curing condition. This process is flexible and cost effective for using the waste materials from any source having thermal and non-thermal effect in preparation of cold setting building bricks.
  • 12. 12 C) FIRED BRICKS: The experiments performed by Yongliang et al. (2011) shows that the eco-friendly bricks prepared from hematite tailings and the additives of clay and fly ash improves the brick quality. The bricks were made through the process of mixing, forming, drying and firing. The results indicated that the mechanical strength and water absorption of the fired brick specimens were in the range 20.03 - 22.92 MPa and 16.54 - 17.93 %, respectively. The other physical properties and durability were as per Chinese Fired Common Brick Standard. D) AUTOCLAVED BRICKS: An attempt was made by Zhao et al. (2012) for utilizing hematite tailings for preparing high strength autoclaved bricks to use in the construction industry. To achieve high strength of bricks, the hematite tailings were added to the mixture of lime and sand which are in 70:15 ratios. The autoclave pressure 1.2 MPa with 6 hour timing, gives the compressive strength 21.2 MPa and flexural strength 4.21 MPa. The requirement in autoclaved lime-sand brick standard for MU-20 autoclaved bricks satisfied with the mechanical and freezing- thawing resistance properties. E) CLAY BRICKS: A study carried out by Nwofor (2012) on mechanical properties of clay brick masonry in which mechanical properties of constituent materials of masonry influences its structural behavior. Uniaxial compressive test was carried out on unreinforced masonry and its SHREEKANT R L, ARUNA M AND HARSHA VARDHAN 185 International Journal of Earth Sciences and Engineering ISSN 0974-5904, Vol. 09, No. 01, February, 2016, pp. 182-195 constituents to obtain their basic mechanical properties. The compressive stress-strain relationships at different confining stress levels were obtained. The nonlinear stress-strain curves were also obtained for masonry with salient points identified on the stress-strain curves, with stress level of 0.40 Fm corresponding to the limit of the nonlinear region. Simple analytical model was proposed for prediction of modulus of elasticity of masonry, to aid the numerical analysis of masonry structures. The test results obtained on brick units and masonry was enough to predict the modulus of elasticity of masonry.. 2.3 UTILISATION OF MINE / MINERALS WASTES AS BUILDING MATERIALS: Significant amounts of research have been carried out worldwide in usage of mine waste and tailings for the manufacturing of building materials. The mining waste is generally used as aggregate in concrete and also in manufacturing of bricks, tiles, cement, pozzolana etc. It is also used as pigments for paints. A study
  • 13. 13 carried out by HAMMOND (1 9 9 8 ) stressed that by using mine waste natural resources will be conserved, energy will be saved and environmental pollution will be reduced. The study conducted by Reddy (2004) concludes that there is a large scope for R & D in developing alternative building technologies. Application of intelligent decision support system for comprehensive utilization of tailings and waste rocks in China and worldwide were developed by Keqing Wang et al. (2011). The idea was implemented and the system was built by combining engineering practice of comprehensive utilization of tailings and waste rocks with other subjects like artificial intelligence, neural network, fuzzy mathematics and decision making technology. A study carried out by Robert and Richard (2011) on utilization of mining and mineral processing wastes in the United States, describes the principle classifications of solid wastes from mining and mineral processing based on physical and chemical properties of each type of waste material. The principle locations and approximate quantities of each category of mining and mineral processing waste were also included in this study. Pertinent technical, economic and environmental considerations involved in specific uses of these wastes were also discussed. The need for research and efforts involving particular waste material are also documented in this investigation. Suitability of iron ore tailings (IOT) in building construction to examine the compressive strength of the IOT concrete for construction work. Analysis made using Minitab software for the statistical analysis was studied. The Results obtained showed that, with increased period of curing ages and an optimal combination of the sand and cement replacement resulted in an optimal high strength of IOT concrete. The quantity of materials utilized for concrete was reduced (sand and cement quantity), and thereby reducing the cost of production and on the other hand reducing the pollution of environment by utilizing the iron ore tailings as building materials. From the analysis of variance it was observed that there is no specific interaction between the factors and their levels but, there is significance in strength of the IOT concrete increasing as curing age increases. Since both sand and cement replacement are of the same percentage (20 %) Lasisi et al. (2014). 2.3.2 MANGANESE RESIDUE: Waste residue produced during the electrolytic preparation process of manganese cause serious environmental problems. Baking-free brick, a promising building material can be produced from manganese slag with addition of quicklime and cement. Several analyses were done by Ping et al. (2013) to measure the physical properties, chemical composition and mechanical performances of the brick samples. The study revealed that the production of electrolytic manganese residue (EMR) baking- free brick, with 25~30 MPa of
  • 14. 14 moulding force was economically feasible and the pressure during forming process was beneficial for obtainment of the brick strength. Baking- free brick prepared from EMR having cement aggregate ratio as 1:1, water solid ratio as 0.15 and the moulding pressure as 30 MPa had excellent compressive strength. The results also showed that EMR-sand-lime-cement production system was the optimum with 50 % of EMR, 25 % of river sand, 10 % quick lime and 15 % of cement. Similar study carried out on preparation of baking free brick from manganese residue and its mechanical properties by Wang et al. (2013). The mechanical compressive strength observed from bricks made using Electrolytic Manganese Residue (EMR) with cement aggregate ratio 1:1 and water solid ratio 0.15 was 13.5 MPa and 14.7 MPa at moulding pressure 25 MPa with 7 days curing. Similarly, 17.4 MPa and 21.3 MPa at moulding pressure 30 MPa with 28 days curing. The density observed through the study was 1.72. Further, it was also concluded that the 50 % of EMR, 25 % of river sand, 10 % of quicklime and 15 % of cement production system was optimum.
  • 15. 15 METHODOLOGY The study follows a qualitative approach for gaining in-depth insight on wastes generated from steel industries and mines and yield effective utilization routes for reusing them in the field of low-carbon construction practices, preferably in geopolymer concrete. Case studies were conducted during August 2019 to analyse the current scenario of utilization and management of the generated wastes. Potential use of GGBS in the production of cement free concrete i.e., fly ash or slag based geopolymer concrete have been highlighted. Re-usability of mine wastes in a number of civil engineering applications thus serves as an effective pathway for integrated industrial solid waste management. Two types of data collection methods were adopted for the case studies. The primary source being the personal interviews while online database reports, articles, research papers, annual reports of the industries being the secondary sources In this study, use was made of two types of material for making concrete: (a) natural aggregate obtained from quarry (mainly the granite) in the range of 12.5–20 mm, and (b) aggregates from mine (mainly the laterite). The latter was collected randomly, from different fresh waste dumps as recommended ASTM D75; C702 sampling of aggregates. These mine wastes were sieved and paticles between 12.5 and 20 mm size were used as coarse aggregate in preparing concrete mix in the current study. In order to ascertain various physico mechanical properties of the mine waste the following experiments were carried out in accordance with and ASTM C/109C and 109M standards for concrete testing: Sieve analysis for coarse and fine aggregates (ASTM C 136); elongation index: flakiness index; aggregate crushing value; aggregate impact value; specific gravity and water absorption (ASTM C127); determination of bulk density and percentage voids (ASTM C29/C29M); determination of aggregate abrasion value; and determination of aggregate angularity number (ASTM C/109C and 109M). To study the mechanical properties of concrete made from both mine waste aggregate and normal aggregate, the con crete cubes of 15 cm × 15 cm × 15 cm were prepared with ratio of 1:2:4 (cement :sand :aggregate) with better workability by flow tests. For each series triplicate specimens were cast using 15 cm × 15 cm × 15 cm molds. A thin layer of oil was applied on the internal faces of molds to ensure that demolding of casted specimens was easy. Mixing and casting procedures were performed in accordance with ASTM C192/C192M standards for concrete test ing. All the specimens were demolded after 24 h and immersed into water for further curing. Addition of PC was calculated on dry aggregate basis (wt/wt). Uniaxial compressive strengths (UCSs) were determined after 7, 14, and 28 days. Also, the UCS studies on cubical specimens with cement, sand and aggregate ratios as fol lowing 1:2:5; 1:2:6; and 1:2:10 were conducted. Tests were also conducted on the laterite bricks, which are predominant construction materials in the Sate of Goa, to measure
  • 16. 16 the wet UCS. The chemical analyses of these wastes were reviewed in the context of their high concentrations of heavy metals and presence of acid producing mineral phases.
  • 17. 17 CASE STUDY I.CASE STUDIES OF REPROCESSING, REUSE AND RECYCLING OF MINING WASTE:- 1.1 PROCESSED SAND:- The waste material from coal mining in India comprises mainly of sandstone, bands of clay and other metamorphic rocks. The sandstone ranges from coarse grain to fine grain. The waste rock generated to expose coal is normally backfilled, still a major volume is stacked over non coal area. As the environmental laws for extracting sand from river bed have become stringent, sand is in short supply. Western Coalfields Limited (WCL) which is a subsidiary company of Coal India Limited( CIL), world’s largest coal producing company, has started crushing and washing of sandstone from its waste dumps and is now major supplier of sand. This sand is being used for construction of roads and structures. The sand also find use as filling materials in underground mines of nearby region (6). Other subsidiaries of CIL are also launching now sandstone processing for supply of sand from waste dumps. A large portion of land which is presently being occupied by sandstone dumps will be released for better economic use. 1.2 CLAY BAND USE : In surface mining method it is possible to mine bands like clay separately and then use them for making bricks, stemming material and potteries. Clay band at Kampti opencast mine in WCL is being used for such purposes. 1.3 MINE WATER:- The water from underground mines which was initially discharged into local water bodies is now treated and used for drinking and industrial purpose. WCL has established a RO plant of capacity 10,000 liters per hour in Patansaongi village catering to drinking water needs of around 1,00,000 local populace. Additionally, the plant has a bottling facility through which “COAL NEER” brand of packaged drinking water is also being launched. Many subsidiaries of CIL are treating water and are supplying it to local townships and industrial units. Other subsidiaries of CIL have also started treating underground mine water and are supplying it to local townships and industries.
  • 18. 18 1.4 ECO PARK :- There are many case studies in the mines of CIL wherein water bodies created from mining are converted to picnic spots. One such case study which has attracted attention of all is Eco park at Saoner underground mines lease hold area of WCL. The park utilizes mine water for gardening, water conservation, boating and amusement purposes. The park showcases several demonstrable technologies such as Solar electrification of water pump, Rain water harvesting, micro irrigation, etc. along with a science park and several adventure rides. The park also has an artificial mine tunnel showcasing different mining job profiles, machinery and methods used in the coal mines. The annual tourist footfall is more than 50,000 (10). Coal mine waste Yash Pande and others have carried out study for replacing natural aggregates by thermal power station coal rejects in granular sub-base and bituminous layers in road construction. The study has confirmed coal rejects as an alternative to natural aggregate in road construction works (11). 1.5 IRON ORE TAILINGS (IOT) :- Yelli shetty used iron ore waste from Goa and conducted an experimental study. In the concrete mix, 40% of coarse aggregates were replaced with iron ore tailings and concrete blocks were made for 28 days curing. It resulted in the compressive strength of 21.93MPa to that of granite aggregate of 19.91 MPa. Hence, the increase in the compressive strength was noticed with iron ore tailings with respect to the conventional coarse aggregate (8). 1.6 IRON ORE WASTE ROCK :- Gayana B C reported that the workability of all the concrete mixes increased upto 40%, where natural aggregate in concrete was replacement with iron ore overburden / waste rock along with upward trend in compressive strength (9). 1.7 FLY ASH :- FLY ash is produced by coal-fired electric and steam generating plants. It is commonly used in Portland cement concrete for applications in highway construction, in soil improvement, as mineral filler in hot mixed asphalt and in grouts for pavement sub sealing. It is also used in making ash bricks and clinkers for stowing in underground mines (12).
  • 19. 19 1.8 BLAST FURNACE SLAG:- Blast furnace slag is generated during the melting process in steel making operations. It is very as a cementitious binder in road construction. It is very commonly used road base material in France. In areas near to steel plants it is also used as aggregate in road construction. (12). 1.9 WASTE DUMP MINING:- The low grade rejects of past which were dumped are now being mined for metal extraction. Common example is of manganese ore. The dumps created near Ramtek in Nagpur district are presently being mined. The grade of the ore is more than 20%. 1.10 MINE WASTE FOR PRODUCTION OF DIFFERENT TYPES OF BRICKS:- It is found from the detailed literature review that there is a lot of scope for utilization of mine waste/industrial waste in the construction industry in the form of manufacturing of bricks, paving blocks, tiles etc. Manufacturing of building bricks without burning of solid fuel is one of the options for reducing the emission of CO2 gas. Srikant etc has given a detailed use of different type of mine waste for producing different types of bricks.
  • 20. 20 CONCLUSION The ore grades and quality have decreased over the decades. Due to the decreasing grades, more inputs in the form of energy, water, capital and labour are required for the same output and at the same time larger volumes of waste are generated. Total resource utilization, where all of the material mined is put to good use, is a challenging concept for researchers and miners. To achieve near zero waste production circular economy business model has to be employed for sustainable development of mineral resources. Developed nations should make available innovative technologies to under developed nations so that total resource utilization is possible. After all no nation is self sufficient in there mineral needs.
  • 21. 21 REFERANCE 1. www.ibef.org, Metals and Mining industry in India 2. Dr. B. K. Pal, etc Problems of mining wastes management in India and its suggestive measures – case studies. 3. Maedeh Tayebi-Khorami etc, Re-thinking mining waste through an integrative approach led by circular economy aspirations, www.mdpi.com . 4. Bernd G Lottermoser, Recycling, reuse and rehabilitation of mine waste, www.element magazine.org, Decemmber2011. 5. Larisa CHINDRIS, Valorization of mining waste in the construction industry, General considerations, 6. Anup Kumar Gupta etc, A review on utilization of coal mine overburden dump waste as underground mine filling material: a sustainable approach of mining, International Journal of Mining and Mineral Engineering, 2015 Vol.6 . 7. Jeroen Spoorena etc, Near-zero-waste processing of low-grade, complex primary ores and secondary raw materials in Europe: technology development trends, Journal of Resource, conservation and recycling, May, 2020. 8. Yellishetty, M., etc. “Reuse of iron ore mineral wastes in civil engineering constructions: A case study - resources”, Journal of .Conservation and .Recycling., Vol. 52, 2008. 9. B C Gayana etc , A study on suitability of iron ore overburden waste rock for partial replacement of coarse aggregates in concrete pavements, 14th International Conference on Concrete Engineering and Technology, IOP publication, 2018. 10. Mishra R R, Inaugural Address of national conference, Geomine 2019, Nagpur 2019. 11. Yash Pandey etc.,Utilization of Coal Mixed Waste Aggregates available at Thermal Power Plants for GSB and Asphalt Mixtures, The 3rd International Conference on Transportation Geotechnics, Procedia Engineering, 2016. 12. Tara Sen etc, Usage of Industrial Waste Products in Village Road Construction, International Journal of Environmental Science and Development, Vol. 1, No. 2, June 2010 . 13. Shrikant R Lamani etc, Utilization of mine waste in the construction industry - A Critical Review, International Journal of Earth sciences and Engineering, vol 9, feb. 2016.
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