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DIMENSIONAL STONE RESOURCES IN INDIADIMENSIONAL STONE RESOURCES IN INDIA
AND ENVIRONMENT FRIENDLY MINING ANDAND ENVIRONMENT FRIENDLY MINING ANDPROCESSINGPROCESSING
Dr. S.S.RATHORE
Department of Mining Engineering
o ege o ec no ogy an ng neer ngMaharana Pratap University of Agriculture andTechnology: Udaipur 313001, INDIA
Presented at: Seminar on Sustainable Natuarl Stone during 21-22October, 2009
at Hotel The Atrium Faridabad, India
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INTRODUCTION
Dimensional stones are a major economic commodity in India
The stones sector in India provides employment to over a million
people
India is one of the few countries in the world having mining andprocessing of granite, marble, sandstone, flaggy limestone, slate
quartize etc.
e ca careous s ones are arge y sprea over e or - esand the siliceous stones in the Deccan peninsula in South India
Indian stone industry growing steadily at an annual rate of
about 10% per year
Stones are mostly extracted in the form of blocks and cut in
required sizes to use in construction industries
During the conventional mining waste generation is quite high
and recovery of saleable products is only 20 to 50%
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Now a days wire/chain/belt saw techniques are in practice but insandstone and granite controlled blasting is used at most ofmines
Thus, scientific extraction of blocks at quarry site, processingwith latest techniques and proper utilization of waste generationis need of the hour
Mechanization of quarry operations adopting innovativetechnologies for eliminating wastage and also to increase theproduction capacity
Utilization of waste means conservation of resources in theform cobbles, cubes, binding material, ceramic application etc.
In general, sandstone and granite are extensively used andpreferred for structure, slates for roofing, Kotahstone forindustrial flooring & marble for domestic and monumentalflooring
Huge potential for investors in the fresh mining sector as well asestablishment of industry using mining and processing waste
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Marble Resources of India
MARBLE DEPOSITS IN INDIA
State Total (In million tonnes)
Rajasthan 1144Jammu & Kashmir 405
Madhya Pradesh (estimated) 400
Gujarat 95
Chhattisgarh 83
Maharashtra 59
Haryana 22
Uttaranchal 6
Sikkim2
All India Total 2216
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Granite Resources of India
State Total (In million tonnes)Karnataka 9740
Jharkhand 8847
Rajasthan 8479
Madhya Pradesh 6271Andhra Pradesh 2788
Orissa 2135
Maharashtra 1159
ar 878
Tamil Nadu 713
Assam 584
Uttar Pradesh 495
Gujarat 420
Meghalaya 286
Chhatisgarh 50
Haryana 34
West Bengal 33
Kerala 4
All India Total 42916
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Dimensional Stone Resources
India accounts for 20% of the world resources ofgranite
Sandstone resources in India are estimated ataround 1000 million tonnes in the states of Andhra Pradesh, Assam, Bihar, Gujarat, Haryana,MP Me hala a Mizoram Karnataka Orissa
Punjab, Rajasthan, UP, Tamilnadu, West Bengal Over 90% sandstone deposits are in Rajasthan
spread over the districts of Bharatpur, Dholpur,
Kota, Jodhpur, Sawai Madhopur, Bundi, Jhalawar Slate deposits in India are estimated at around
500 million tonnes in the states of Rajasthan,Haryana, HP, AP and MP
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INDIAN STONES PRODUCTION
( In thousand tones)2000-01 2001-02 2002-03 2003-04 2004-05
2005-06 2006-07 200708
Marble 6831 6318 7511 8460 9608 10904 12243 13684
Granite 5900 6205 6710 7059 7759 8364 9044 9776
Sandstone 6659 6861 6363 8153 9313 8626 8809 8958
FlaggyLimestone
2096 2164 3387 3757 4268 5291 5291 7420
Slate 16 18 14 11 110 98 129 163
Total 21502 21566 23986 27449 31059 33283 36520 40001
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6000
8000
10000
12000
14000
16000
ion
in
thousa
nd
tonnes
MarbleGraniteSandstoneFlaggy limestoneSlate
0
2000
4000
1995-
96
1996-
97
1997-
98
1998-
99
1999-
00
2000-
01
2001-
02
2002-
03
2003-
04
2004-
05
2005-
06
2006-
07
2007-
08
Year
Produ
c
Production of Dimensional Stones in India
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Export Value Rs 45620 Million Rupees ($ 920 Million)
Export of stones in 2005-06
29%
0%
2%
15%
5%
Granite cut blocks/ slabs
Granite monuments
Granite Products n.e.s
9%
5%33%
2%Granite tiles
Marble blocks/ slabs
Marble monuments
Marble tiles
Other stones & Products
Slate Stone
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Global Scenario of Granite Consumption
India accounts for 20% of the world resources ofgranite
In the raw blocks granite exports India is theleader with 31.5% share of the global market as
against 11.5% Brazil and 9.5% China 42% of export of raw blocks of granite from India
to China and 24% export to Italy
having fourth position with 6.6% global marketshare
43% of finished granite export to USA and 13.4%to UAE
China imports raw blocks from India and Braziland after processing finished products exports atlower price to Europe and USA
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Mining Technology
Wedge & feather techniqueWedge & feather technique
Wire/chain/belt saw cutting techniqueZiriZiri cutting techniquecutting technique
Drillin & controlled blastinDrillin & controlled blastin
techniquetechniqueFlame jet cutting technique
Slot drilling techniqueSwelling material
Blind cut technioque
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VARIOUS TECHNIQUES FOR
DAMAGE MEASUREMENTS
Ultrasonic P-wave velocity before and
after blastWater absorption and tensile strength
o e roc qua y es gna onComputerised X-ray tomography
Ultrasonic flaw detection
Petrological studies under microscopeto detect damage at grain levels
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FRACTURE CONTROL DURING BLASTING
& DAMAGE DETECTION Fracture along guided path
Alternate charged anddummy holes
A line of dummy holes Notching of blast holes
Fracture by decoupling
Fracture by explosive
Using a slotted cartridge Charge holder with wedges
Charge holder with twostages of detonation
Damage detection by Ultrasonic p-wave velocity,
flaw detection andtomography
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EXTRACTION WITH NOTCHED BLAST HOLES
Extraction of block withblast hole notching
Formation of eye notchin the hole
Drilling circularholes upto a desireddepth
with jack hammer bystopping rotation
Crack with increasedspacing by notching
Notching effective andcrack initiate at notchlocation
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Mechanized Marble Mining
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Horizontal Cut with Chain/Belt Saw
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Wire Saw Cut in Marble
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Electroplated
CC TOOLS for SAWING: DIAMONDTOOLS for SAWING: DIAMOND--WIRESWIRES
DIAMONDDIAMOND--WIRE CLASSIFICATIONWIRE CLASSIFICATION
Diamond types:Diamond types:
Sintered
1919
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DIAMONDDIAMOND--WIRE SAW TECHNOLOGYWIRE SAW TECHNOLOGY
MAIN ADVANTAGESMAIN ADVANTAGES
Lower labour costs (1 or 2 workers per machine)
Reduces waste material (cutting thickness 1cm max)
High block quality (even cutting face)
High quarry productivity Makes big cuts (also good for very big benches)
Makes each blocks quality easy to inspect due to semi-smooth surfaces
No structural damage or stress to the rock during the cutting
DD PROCESSING CYCLEPROCESSING CYCLE
Easy to move and transport
MAIN DISADVANTAGESMAIN DISADVANTAGES
Requires high-precision drilling as a preliminary
Requires lots of water
Requires highly skilled workers Can influence the quarrys safety system
Medium-high tool cost (diamond-wire minimum 30 meters)
Diamond tools must be carefully selected
Requires electricity
2020
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DD PROCESSING CYCLEPROCESSING CYCLE
Vertical blind cuts: regular geometry of saw and high performancesVertical blind cuts: regular geometry of saw and high performances2121
B h i
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Bench overturning
2222
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Room and Pillar Basic Criteria for Design
Stability of Rooms and PillarsMaximum Recovery of healthy Blocks
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Multi-wire gangsaw with 25 wires
(Year 2001)
MACHINES TO USEMACHINES TO USEBB
Multi Diamond Wire Saw2424
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Uses of Dimensional StonesUses of Dimensional Stones
FlooringFlooring
PavingPaving
Wall CladdingWall Cladding
Garden furnishingGarden furnishing
LandLand scapingscaping
RoofingRoofing
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Application of Dimensional Stones
Important modern buildings in India like
the Presidential House, Parliament House,and Supreme Court of India made fromhigh quality sandstone of Rajasthan
testimony to the relevance of marble inmodern Indian Architecture
Innumerable temples, forts and palaces of
Ancient Indian Civilization have beencarved out of locally available stones
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HEAP OF WASTAGEHEAP OF WASTAGE
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B) Muds produced by sawing and
polishing operations on slabs
TWO MAIN TYPES OF WASTE
A) Small shapeless blocks deriving by
cutting and sawing of stone
Air dried filter-pressed mud
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USES OF WASTE GENERATEDUSES OF WASTE GENERATED
COBBLESCOBBLES
FREE SIZE TILESFREE SIZE TILES ROUGH BLOCKSROUGH BLOCKS
PRODUCTION OF BINDERSPRODUCTION OF BINDERS
USE AS FERTILISER IN AGRICULTUREUSE AS FERTILISER IN AGRICULTURE
PRODUCTION OF BINDER FORPRODUCTION OF BINDER FORCONSTRUCTIONCONSTRUCTION
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COBBLES PREPARINGCOBBLES PREPARING
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HEAP OF COBBLESHEAP OF COBBLES
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COLORS AVAILABLE IN COBBLESCOLORS AVAILABLE IN COBBLES
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APPLICATION OF COBBLESAPPLICATION OF COBBLES
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STEPS MADE FROM SANDSTONESTEPS MADE FROM SANDSTONE
TILES MADE FROM SANDSTONETILES MADE FROM SANDSTONE
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TILES MADE FROM SANDSTONETILES MADE FROM SANDSTONE
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The scientific partnership
Research
WorkGROUP
R. K MARBLEIndia
MAHARANA PRATAP
UNIVERSITY
OFAGRICULTURE and
TECHNOLOGY
India
IS.I.M.International Marble Institute
Italy
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Purpose of Research Work
Scientific programs between Italyand India, on stone technologies
and environmental aspects Promote a specific technical and
scientific research on diamond
wire technologies on the whitedolomitic marble of Rajasthan
Value addition to marble blocks at
quarry site; Reduce the cost of blocks
extraction
DIAMONDDIAMOND WIRE MACHINESWIRE MACHINESMACHINES to USEMACHINES to USEBB
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UDAIPUR QUARRY R.K. MARBLE
DIAMONDDIAMOND--WIRE MACHINESWIRE MACHINES
Machines comparing
3838
ITALIAN INDIAN
Utilization of Granite Waste Powder
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Utilization of Granite Waste Powder
Scope of Investment in India
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Scope of Investment in India
Optimization of production cost of thefinished product to compete with China
By selling finished products compared to
rough blocks, profit realization can beincreased to 2.5 times
India to set up industry for manufacturing ofconsuma es suc as amon oo s, s eeblades, steel grits.
China and Italy are having their ownconsumables
Adoption of multi-wire diamond sawingmachine which can produce one container2cm slabs (About 300 sq. m.) in 8 hours
CONCLUSIONSCONCLUSIONS
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CONCLUSIONSCONCLUSIONS NewNew miningmining techniquetechnique maymay bebe adoptedadopted toto reducereduce wastewaste
MechanizationMechanization ofof quarryquarry operationsoperations mandatorymandatory forforeliminatingeliminating wastewaste generationgeneration andand toto increaseincrease productionproductioncapacitycapacity
NewNew improvedimproved controlledcontrolled blastingblasting techniquestechniques maymay bebeadoptedadopted inin sandstonesandstone andand granitegranite miningmining toto improveimproverecoveryrecovery percen agepercen age
SecondarySecondary wastewaste shouldshould bebe utilizedutilized inin civilcivil constructionconstruction
GovtGovt.. PoliciesPolicies shouldshould supportsupport inin exportingexporting thethe productsproductsproducedproduced fromfrom thethe wastewaste generatedgenerated
ThereThere isis hugehuge scopescope inin wastewaste utilization,utilization, generatedgenerated fromfrom
miningmining andand processingprocessing ofof dimensionaldimensional stonesstones inin civilcivil asas wellwellasas agricultureagriculture applicationsapplications
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THANKS