DIMENSIONAL STONE RESOURCES IN INDIA DIMENSIONAL STONE RESOURCES IN INDIA

AND ENVIRONMENT FRIENDLY MINING AND AND ENVIRONMENT FRIENDLY MINING AND
PROCESSING PROCESSING
Dr. S.S.RATHORE
Department of Mining Engineering
College of Technology and Engineering College of Technology and Engineering
Maharana Pratap University of Agriculture and
Technology: Udaipur 313001, INDIA
Presented at: Seminar on Sustainable Natuarl Stone during 21-22
October, 2009
at Hotel The Atrium Faridabad, India
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 and
processing of granite, marble, sandstone, flaggy limestone, slate
quartize etc.
The calcareous stones are largely spread over the North-West The calcareous stones are largely spread over the North-West
and 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%
Now a days wire/chain/belt saw techniques are in practice but in
sandstone and granite controlled blasting is used at most of
mines
Thus, scientific extraction of blocks at quarry site, processing
with latest techniques and proper utilization of waste generation
is need of the hour
Mechanization of quarry operations adopting innovative
technologies for eliminating wastage and also to increase the
production capacity
Utilization of waste means conservation of resources in the
formcobbles, cubes, binding material, ceramic application etc.
In general, sandstone and granite are extensively used and
preferred for structure, slates for roofing, Kotahstone for
industrial flooring & marble for domestic and monumental
flooring
Huge potential for investors in the fresh mining sector as well as
establishment of industry using mining and processing waste
Marble Resources of India
MARBLE DEPOSITS IN INDIA
State Total (In million tonnes)
Rajasthan 1144
Jammu & Kashmir 405
Madhya Pradesh (estimated) 400
Gujarat 95
Chhattisgarh 83
Maharashtra 59
Haryana 22
Uttaranchal 6
Sikkim
2
All India Total 2216
Granite Resources of India
State Total (In million tonnes)
Karnataka 9740
Jharkhand 8847
Rajasthan 8479
Madhya Pradesh 6271
Andhra Pradesh 2788
Orissa 2135
Maharashtra 1159
Bihar 878 Bihar 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
Dimensional Stone Resources
India accounts for 20%of the world resources of
granite
Sandstone resources in India are estimated at
around 1000 million tonnes in the states of
Andhra Pradesh, Assam, Bihar, Gujarat, Haryana,
MP, Meghalaya, Mizoram, Karnataka, Orissa, MP, Meghalaya, 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
INDIAN STONES PRODUCTION
( In thousand tones)
2000-01 2001-02 2002-03 2003-04 2004-05
2005-06 2006-07 2007-
08
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
Flaggy
Limestone
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
6000
8000
10000
12000
14000
16000
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Marble
Granite
Sandstone
Flaggy limestone
Slate
0
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4000
1995-
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1996-
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1997-
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1998-
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2001-
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Production of Dimensional Stones in India
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
Global Scenario of Granite Consumption
India accounts for 20%of the world resources of
granite
In the raw blocks granite exports India is the
leader 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
In export of finished product of granite, India is In export of finished product of granite, India is
having fourth position with 6.6% global market
share
43%of finished granite export to USA and 13.4%
to UAE
China imports raw blocks from India and Brazil
and after processing finished products exports at
lower price to Europe and USA
Mining Technology
Wedge & feather technique Wedge & feather technique
Wire/chain/belt saw cutting technique
Ziri Ziri cutting technique cutting technique
Drilling & controlled blasting Drilling & controlled blasting
technique technique
Drilling & controlled blasting Drilling & controlled blasting
technique technique
Flame jet cutting technique
Slot drilling technique
Swelling material
Blind cut technioque
VARIOUS TECHNIQUES FOR
DAMAGE MEASUREMENTS
Ultrasonic P-wave velocity before and
after blast
Water absorption and tensile strength
Modified rock quality designation Modified rock quality designation
Computerised X-ray tomography
Ultrasonic flaw detection
Petrological studies under microscope
to detect damage at grain levels
FRACTURE CONTROL DURING BLASTING
& DAMAGE DETECTION
Fracture along guided path
Alternate charged and
dummy 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 two
stages of detonation
Damage detection by
Ultrasonic p-wave velocity,
flaw detection and
tomography
EXTRACTION WITH NOTCHED BLAST HOLES
Extraction of block with
blast hole notching
Formation of eye notch
in the hole
Drilling circular
holes upto a desired
depth
Hammering action Hammering action
with jack hammer by
stopping rotation
Crack with increased
spacing by notching
Notching effective and
crack initiate at notch
location
Mechanized Marble Mining
Blasting for Removal of Overburden
Horizontal Cut with Chain/Belt Saw
Wire Saw Cut in Marble
Electroplated
CC
TOOLS for SAWING: DIAMOND TOOLS for SAWING: DIAMOND- -WIRES WIRES
DIAMOND DIAMOND- -WIRE CLASSIFICATION WIRE CLASSIFICATION
Diamond types: Diamond types:
Sintered
19 19
DIAMOND DIAMOND- -WIRE SAW TECHNOLOGY WIRE SAW TECHNOLOGY
MAIN ADVANTAGES MAIN 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
Increase block value
DD
PROCESSING CYCLE PROCESSING CYCLE
Increase block value
Easy to move and transport
MAIN DISADVANTAGES MAIN 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
20 20
DD
PROCESSING CYCLE PROCESSING CYCLE
Vertical blind cuts: regular geometry of saw and high performances Vertical blind cuts: regular geometry of saw and high performances
21 21
Bench overturning
22 22
Room and Pillar Basic Criteria for Design
Stability of Rooms and Pillars
Maximum Recovery of healthy Blocks
Multi-wire gangsaw with 25 wires
(Year 2001)
MACHINES TO USE MACHINES TO USE
BB
Multi Diamond Wire Saw
24 24
Uses of Dimensional Stones Uses of Dimensional Stones
Flooring Flooring
Paving Paving
Wall Cladding Wall Cladding
Stairs cases Stairs cases Stairs cases Stairs cases
Garden furnishing Garden furnishing
Land Land scaping scaping
Roofing Roofing
Application of Dimensional Stones
Important modern buildings in India like
the Presidential House, Parliament House,
and Supreme Court of India made from
high quality sandstone of Rajasthan
The Lotus temple of New Delhi stands The Lotus temple of New Delhi stands
testimony to the relevance of marble in
modern Indian Architecture
Innumerable temples, forts and palaces of
Ancient Indian Civilization have been
carved out of locally available stones
HEAP OF WASTAGE HEAP OF WASTAGE
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
USES OF WASTE GENERATED USES OF WASTE GENERATED
COBBLES COBBLES
FREE SIZE TILES FREE SIZE TILES
ROUGH BLOCKS ROUGH BLOCKS
STEPS STEPS STEPS STEPS
PRODUCTION OF BINDERS PRODUCTION OF BINDERS
USE AS FERTILISER IN AGRICULTURE USE AS FERTILISER IN AGRICULTURE
PRODUCTION OF BINDER FOR PRODUCTION OF BINDER FOR
CONSTRUCTION CONSTRUCTION
COBBLES PREPARING COBBLES PREPARING
HEAP OF COBBLES HEAP OF COBBLES
COLORS AVAILABLE IN COBBLES COLORS AVAILABLE IN COBBLES
APPLICATION OF COBBLES APPLICATION OF COBBLES
STEPS MADE FROM SANDSTONE STEPS MADE FROM SANDSTONE
TILES MADE FROM SANDSTONE TILES MADE FROM SANDSTONE
The scientific partnership
Research
Work
GROUP
R. K MARBLE
India
MAHARANA PRATAP
UNIVERSITY
OF
AGRICULTURE and
TECHNOLOGY
India
IS.I.M.
International Marble Institute
Italy
Purpose of Research Work
Scientific programs between Italy
and India, on stone technologies
and environmental aspects
Promote a specific technical and
scientific research on diamond
wire technologies on the white wire technologies on the white
dolomitic marble of Rajasthan
Value addition to marble blocks at
quarry site;
Reduce the cost of blocks
extraction
UDAIPUR QUARRY R.K. MARBLE
DIAMOND DIAMOND- -WIRE MACHINES WIRE MACHINES
MACHINES to USE MACHINES to USE
BB
Machines comparing
38 38
ITALIAN
INDIAN
Utilization of Granite Waste Powder
Scope of Investment in India
Optimization of production cost of the
finished product to compete with China
By selling finished products compared to
rough blocks, profit realization can be
increased to 2.5 times
India to set up industry for manufacturing of
consumables such as diamond tools, steel consumables such as diamond tools, steel
blades, steel grits.
China and Italy are having their own
consumables
Adoption of multi-wire diamond sawing
machine which can produce one container
2cm slabs (About 300 sq. m.) in 8 hours
CONCLUSIONS CONCLUSIONS
New New mining mining technique technique may may be be adopted adopted to to reduce reduce waste waste
Mechanization Mechanization of of quarry quarry operations operations mandatory mandatory for for
eliminating eliminating waste waste generation generation and and to to increase increase production production
capacity capacity
New New improved improved controlled controlled blasting blasting techniques techniques may may be be
adopted adopted in in sandstone sandstone and and granite granite mining mining to to improve improve
recovery recovery percentage percentage recovery recovery percentage percentage
Secondary Secondary waste waste should should be be utilized utilized in in civil civil construction construction
Govt Govt.. Policies Policies should should support support in in exporting exporting the the products products
produced produced from fromthe the waste waste generated generated
There There is is huge huge scope scope in in waste waste utilization, utilization, generated generated from from
mining mining and and processing processing of of dimensional dimensional stones stones in in civil civil as as well well
as as agriculture agriculture applications applications
THANKS THANKS