Browsing by Author "Kumar Reddy, S.K."

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A Systematic Review on Implementation of Internet-of-Things-Based System in Underground Mines to Monitor Environmental Parameters
(Springer, 2024) Naik, A.S.; Kumar Reddy, S.K.; Raj, G.R.
The automation in the mining industry by adopting Internet of Things (IoT) technology is great potential to improve safety and efficiency. The mining industry is recognized globally for its valuable resources (gold, coal, iron ore, etc.) which are obtained by mining below the surface. The productivity and safety of mine personnel are impacted by several environmental parameters in underground mines, such as toxic gases, flammable gases, elevated levels of carbon dioxide (CO2), and decreased levels of oxygen (O2) concentrations. The presence of these gases is a significant issue and needs to be dealt with suitably. There are various methods to monitor the percentage of gases and provide a suitable course of action in case of an increase in the threshold limit of gases. Each system has its limitations. Wireless monitoring systems are indispensable in underground mines. This paper presents the methodology to adopt IoT in underground mines to measure environmental parameters in underground mine areas, the structure of installation of sensors in underground mines, threshold limits of gases, and underground mine disasters which were caused by gas explosion accidents. Further, it evaluates wireless sensor networks (WSNs) techniques ZigBee and LoRa for underground mines applications. Subsequently, it proposed a real-time industrial safety system in underground mines with its working, effectiveness, and scope are discussed. © The Institution of Engineers (India) 2023.
An Enhanced IoT and LoRa-Based Communication System for Underground Mines
(Springer Science and Business Media Deutschland GmbH, 2023) Kumar Reddy, S.K.; Naik, A.S.
The mining industry is well known for valuable minerals all over the world and the way to get minerals is by mining below the surface. Real-time monitoring of environmental parameters from underground mines is a very complex task to ensure safety. Accidents in the underground area are due to hazardous toxic gas spread beyond the threshold limit value at excavations. These mine gases are a threat to both mine workersâ€™ health and the mine environment and are also very hard for miners to detect. Automation in the mining industry reduces hazardous accidents while improving efficiency and productivity. Adopting the Internet of Things (IoT) with Long Range (LoRa) wireless communication technology to build a robust long-range wireless communication system to monitor environmental parameters and hazardous events. To ensure a safe mine environment for mineworkers at the mine site, Artificial Intelligence techniques are an add-on to automation systems to build predictive modeling for an intelligent early warning alert system. However, current solutions are limited to monitoring, low computing power and processing capability, battery lifetime, suitable at the laboratory level, or reports events in a few cases. The proposed system is comprised of the IoT-based sensor modules, communication protocols, Long-Range (LoRa), and machine learning technologies to establish safe, reliable communication from the underground mine to the surface area. A reliable, robust, and cost-effective communication system should be required that monitors environmental parameters and predicts reports of unusual events by adopting new technology. Â© 2023, The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd.
Analysis of Fault’s Effect on the Highwall Stability of Medapalli Open Pit Coal Mine
(Springer Science and Business Media Deutschland GmbH, 2023) Kumar Reddy, S.K.
Mining operations can have a significant impact on the stability of the surrounding area. One example is the Medapalli open pit coal mine in southern India. The mine is a large excavation working at a depth of 165 m that can reach up to 200 m. The western side highwall has locked-up coal reserves in the mine, but concerns about the geologically disturbed regions have resulted in complications and significant challenges. Surface tension cracks around the excavation became visible in 2018, prompting intensive monitoring, protective measures, and numerous geotechnical analyses. The area, however, has a rich tectonic history, with faults interacting with soil movements. Proper geotechnical investigations were used in this work to analyse the stability of the highwall due to faults' effects on the area's reaction due to mining operations. The findings in the study highlighted the significance of flaws in the ground movement due to improper design of the highwall fault interaction area. The presence of the fault increases the likelihood of tensile cracks and subsidence at the highwall's surface level, significantly worsening the mining activities in the area. The analysis reveals that complex geological features, such as the presence of faults roughly parallel to the highwall slope profile, can exacerbate the mining operations in the surrounding environment. The recommended slope design with protective measures towards the west side disturbed highwall area helps safely excavate the western side highwall locked-up coal reserves in the Medapalli open pit mine. © 2023, The Author(s), under exclusive licence to Springer Nature Switzerland AG.
Correlating mineralogical composition, resistivity, and mechanical properties of limestone using response surface methodology (RSM)
(Springer Nature, 2025) Varalakshmi, P.; Kumar Reddy, S.K.; Murthy, C.S.N.
Response Surface Methodology (RSM) is used in this study to predict the interaction of mechanical characteristics, electrical resistivity, and mineralogical composition in limestone. For this purpose, laboratory experiments combined with petrographic, SEM, and resistivity measurements were carried out, and the results were statistically modeled using RSM. Microcrystalline calcite with trace impurities including SiO? and Fe2O?, which affect mechanical behavior and resistivity, was found to be the predominant mineral in petrographic and SEM investigations. Higher porosity (> 4.9%) or extreme resistivity values reduce the Indirect Tensile Strength (ITS), while moderate resistivity (37.5–42.5 ?m) and low porosity (< 4.7%) maximize ITS, according to a quadratic RSM model. Particularly when paired with increased porosity, abrasion resistance shown a less significant but still noticeable effect. According to the findings, porosity is the main factor causing strength loss, and brittleness is further modulated by mineralogy (such as the amount of quartz). The study provides a framework linking resistivity, porosity, and mineralogy with mechanical performance, which can guide limestone selection and processing in geotechnical and construction applications. © Indian National Science Academy 2025.
Development of a Novel Real-Time Environmental Parameters Monitoring System Based on the Internet of Things with LoRa Modules in Underground Mines
(Springer, 2023) Kumar Reddy, S.K.; Naik, A.S.; Raj, M.G.
The mining industry relies on extracting valuable minerals through underground mining. Many industries have implemented automation to enhance workplace safety, optimize operations, improve responses to events, and achieve cost-effectiveness. A real-time communication and monitoring system is indispensable in underground mines to prevent significant hazards and improve safety in underground mines. However, the environmental conditions of underground mines are affected by toxic, flammable, combustible gases and dust. The harmful gases are a significant concern as they can cause gas explosions. Internet of Things (IoT) enabled real-time communication system with Long Range (LoRa) transceiver module is designed and developed to measure the underground mine environmental parameters, temperature, and humidity. The LoRa-based proof of concept (POC) system is tested and evaluated at the surface level and in two underground mines. The LoRa module radio waves range test is carried out to measure the received signal strength indicator (RSSI) value at the surface level. In addition, the developed system is tested and evaluated at different positions of underground mines to measure environmental parameters in straight and curved tunnels. The experimental results represent successful IoT with LoRa-based wireless communication between underground mine tunnels to the surface, wireless transmission of parameters at the straight tunnels, and curved tunnels of underground mines. © The Author(s), under exclusive licence to Springer Science+Business Media, LLC, part of Springer Nature 2024.
Development of a Reliable Wireless Communication System to Monitor Environmental Parameters from Various Positions of Underground Mines to the Surface using ZigBee Modules
(Springer, 2024) Kumar Reddy, S.K.; Naik, A.S.; Raj, G.R.
The mining industry is known for its valuable minerals, and the way to get minerals is by mining below the surface. Many industries benefitted by adopting automation which has improved workplace operational management, enhanced safety, real-time monitoring, and cost-effectiveness. On the basis of challenges in underground mines, a reliable wireless communication and monitoring system is required in underground mines to enhance safety and prevent major hazards. Underground mine environments are affected by various environmental parameters such as toxic gases, flammable and inflammable gases, and dust. The variation in the presence of harmful gases is a major issue that causes gas explosions and damages the mine infrastructure. Currently, most underground mines adopted conventional multi-gas detectors to monitor mine gases manually at regular intervals or once a day. In this paper, a real-time data communication system to monitor mining parameters based on wireless ZigBee modules is established and evaluated in two different underground mines in India. A wireless message communication establishment process between two ZigBee modules is described in detail, and an investigation of radio range tests by measuring received signal strength indication (RSSI) parameters is carried out in the first underground mine site at level 3 with consideration of 10-m intervals apart at each test for the straight tunnel case. In addition, wireless communication is established to monitor the environmental parameters of underground mine levels to the surface. Further, established wireless communication to monitor the environmental parameters of the straight and curved tunnels of a second underground mine. The experimental result represents successful wireless communication between ZigBee modules with a distance of 100 m to 120 m in straight tunnels and a reduction in signal strength and data packet loss in curved tunnels of underground mines. In addition, the results show that the developed ZigBee-based system is suitable for measuring environmental parameters in open surface and underground mines. © The Institution of Engineers (India) 2023.
Development of Regression Model and Optimization of Mechanical Properties of Geopolymer Concrete Prepared Using Gold Ore Tailings
(American Society of Civil Engineers (ASCE), 2023) Lokesha, E.B.; Mangalpady, M.; Kumar Reddy, S.K.; Srinivasa, A.S.
In this study, 11 mix proportions of geopolymer concrete (GPC) beam and cylinder samples were prepared by partially replacing the class F fly ash (FA) as the binder with ground granulated blast furnace slag (GGBFS) in steps from 10% to 100%, along with gold ore tailings (GOTs) [as a partial substitute to the river sand (RS) in steps from 5% to 30%] and recycled coarse aggregates (RCAs). The laboratory tests demonstrated a maximum split tensile strength of 5.99 MPa and flexural strength of 7.98 MPa for Sample GOT-11-15 (11 indicates Mix Proportion-XI and 15 indicates 15% of GOTs) of Mix Proportion-XI. In addition to the previous 11 mix proportions, one more set of cylinders and beams was prepared using FA, GOTs, and natural coarse aggregates (NCAs), which are designated as Mix Proportion-XII. For Mix Proportion-XII, the highest split tensile strength of 4.17 MPa and flexural strength of 6.13 MPa was achieved for Sample GOT-15 (15 indicates 15% of GOTs). Among the 12 types of mix proportions, Sample GOT-0 of Mix Proportion-XII (i.e., FA 100%, GOT 0%, and NCAs 100%) showed a maximum slump value of 89.3 mm. Sample GOT-1-0 of Mix Proportion-I (i.e., FA 100%, GOT 0%, and RCA 100%) exhibited the maximum slump of 65.3 mm. The field emission scanning electron microscopy (FESEM) analysis indicated that silicon (Si) and aluminum (Al) were the two main constituents of the GOTs and FA. In addition, this analysis revealed the existence of uneven forms of quartz particles in GOTs and the spherical shapes of the FA particles that adhered to the RCAs. The multiple regression analysis exhibited the root mean square (R2) values of 89.0% and 85.5%, respectively, for the split tensile and flexural strengths. The p-value for the developed model was <0.05; therefore, the developed model was considered significant and the best-fit model. © 2023 American Society of Civil Engineers.
Durability characteristics of geopolymer concrete produced using gold ore tailings along with recycled coarse aggregates
(Nature Research, 2025) Lokesha, E.B.; Mangalpady, M.; Kumar Reddy, S.K.
The Gold Ore Tailings (GOTs) are one of the major waste materials in the mining sector. The disposal of these tailings could be a problem for human health and a major environmental concern for several years. In this research work, the GOTs were used as an alternative material to the River Sand (RS) in the production of Geopolymer Concrete (GPC). Thus developed GPC samples were tested for its durability characteristics, such as resistance to sulphates and chlorides. The sulphate attack test was conducted by immersing the Conventional Concrete (CC) and GPC samples in 5% Magnesium Sulphate (MgSO4) solution for various curing periods. In this test, the GPC samples showed a reduction in compressive strength and weight, which is slightly more when compared to CC samples. The Rapid Chloride Penetration Test (RCPT) was also conducted to know the chloride ion penetration in which GPC samples exhibited less chloride penetration when compared to CC samples. Further, the Toxic Characteristic Leaching Procedure (TCLP) analysis showed that the GOTs have very high concentrations of hazardous metals. However, the concentration of Cyanide (CN?) was minimal in GOTs. In this regard, geopolymerization would be a better method for immobilizing the hazardous metals in GOTs. © The Author(s) 2025.
Effect of Surcharge on Analysis of Anchored Sheet Piles Embedded in Cohesionless Soil
(Springer Science and Business Media Deutschland GmbH, 2025) Dinesh, G.; Nayak, S.; Kumar Reddy, S.K.
An anchored sheet pile wall is a flexible retaining structure stabilized by anchors placed at a specific depth to resist external forces. The design of these walls is influenced by two key factors: the embedment depth into the foundation soil and the maximum bending moment experienced by the wall. This study presents design charts for anchored sheet piles in cohesionless soil subjected to surcharge loads. Both the conventional free earth support method and finite element analysis using PLAXIS 2D were employed. Multiple scenarios were simulated in PLAXIS 2D using the Mohrâ€“Coulomb model, with an internal friction angle of 34Â° for the soil and a combination of fixed base boundary conditions. The study also examined different water table positions at the surface, middle, dredge level, and deep below the surface and generated design charts for embedment depth (D) and maximum bending moment (Mmax). Results revealed that the conventional free earth support method tends to overestimate the maximum bending moment. In contrast, the finite element analysis, with detailed mesh refinement and boundary conditions, provided a better assessment of soilâ€“structure interaction, yielding more reliable outcomes. Â© The Author(s), under exclusive license to Springer Nature Singapore Pte Ltd. 2025.
Investigation on Estimation and Prediction of Resistivity of Limestone Rocks based on Physico-Mechanical Properties of Rocks
(World Researchers Associations, 2025) Varalakshmi, P.; Kumar Reddy, S.K.; Murthy, C.S.N.
Prediction of rock resistivity indirectly is of paramount importance in several geophysical and civil engineering applications. Physico-mechanical properties such as p-wave velocity, porosity and dry density tend to have a good correlation with electrical resistivity of rocks. Conventional approaches for measuring resistivity produce results which may consume more time and efforts and are not accessible every location. To overcome this, an Artificial Neural Network (ANN) model was evolved in this study, using Python and TensorFlow. The model was trained using known values to predict electrical resistivity of unknown and similar materials. Actual results of resistivity were compared with resistivity values obtained from ANN model. The obtained values were evaluated for reliability using non-linear regression models. It was observed that predicted resistivity values generated using p-wave velocity were more reliable. Also, validations made based on the ANN model, using mean absolute error (MAE) and average residuals indicate that P-wave velocity is the most reliable predictor, achieving the lowest MAE (4.638) and near-zero residuals (-0.005), while porosity and dry density showed higher errors and weaker correlations. This study revealed that the ANN model developed results in reliable predictions of rock resistivity based on p-wave values. © 2025, World Researchers Associations. All rights reserved.
Monitoring and Prediction of Slope Failure Instability in a Limestone Mine
(Books and Journals Private Ltd., 2023) Kumar Reddy, S.K.
In a mining operation, maintaining safe and cost-effective slope geometries is critical. Monitoring has often proven to be a valuable method in dealing with potential slope instability when design analysis and engineering judgment have dictated conservative and usually more expensive problem solutions. Unexpected pit wall collapses could have a significant impact on the safety and profitability of an openpit operation. As a result, a well-planned and executed monitoring programme can permit operation with a lower theoretical margin of safety. Monitoring provides an important check on design parameters and can measure the effects of corrective actions, which lead to increased significant production and reduced economic losses. Often, early warning of impending failure can be established. In this paper, a slope failure of a pit wall stability on the north side of a limestone mine which leads to stopping the workings by the regulatory body was studied. A comprehensive slope monitoring strategy has been implemented to improve safety and mine more economically using different slope monitoring techniques like visual inspection, prism monitoring, piezometer and wireline extensometers are also used to predict the instability of the failure area of a limestone mine. All of these monitoring tools offer primary monitoring, which is used to determine the riskiness of a failure area or zone. It gives early warning of further failure or instability if the slope is detected in challenging conditions. Today’s mining regulations place a strong emphasis on the proactive identification and mitigation of risks to employees and the operation. This paper focuses on reducing operational and safety risks through an approved monitoring programme. Based on slope monitoring results of the failure area, remedial measures to improve the stability of the workings are presented for a limestone mine. © 2023, Books and Journals Private Ltd.. All rights reserved.
Physicomechanical Properties and Characterization of Gold Ore Tailings and the Utilization in Manufacturing of Geopolymer Concrete with Class F Fly Ash and Recycled Coarse Aggregates
(American Society of Civil Engineers (ASCE), 2023) Lokesha, E.B.; Mangalpady, M.; Kumar Reddy, S.K.; Srinivasa, A.S.
The mining industry generates a large amount of waste, particularly in the form of tailing dumps, which creates major environmental difficulties such as air pollution, water pollution, soil erosion, and acid mine drainage. Previous studies confirmed that the mine waste could be used in making building materials, such as bricks, tiles, concrete blocks, pavement blocks, and precast concrete elements. However, gold ore tailings (GOTs) are recognized as major mine residues in the mining industry. In this study, GOTs were utilized as partial replacement material (0%, 5%, 10%, 15%, 20%, 25%, and 30% by weight) to fine aggregates such as river sand (RS) and low calcium fly ash (FA) as binder material in the manufacture of geopolymer concrete (GPC) along with recycled coarse aggregates. The GPC samples were cast and cured at room temperature until the curing ages; subsequently, the compressive strength of the samples was determined. This study demonstrated that the RS can be partially substituted in the manufacture of GPC by GOTs up to 15% with a slump value of 38.6 mm and the maximum compressive strength of 35.8 MPa. The mineralogical and chemical composition of raw materials (i.e., GOTs and FA) was analyzed using X-ray diffraction (XRD) and X-ray fluorescence (XRF), respectively. The XRD analysis revealed that the quartz has the highest peak intensity of 55% in GOTs and 50% of corundum in FA. The XRF analysis exhibited that GOTs and FA have high silicon oxides up to 39% and 38%, respectively. The crushed GPC samples were analyzed using field emission scanning electron microscopy to observe the morphological changes. The GPC sample comprised 15% GOTs exhibited denser and compacted microstructures. © 2023 American Society of Civil Engineers.
RTEPMS: Real-Time Environmental Parameters Monitoring System Using IoT-Based LoRa 868-MHz Wireless Communication Technology in Underground Mines
(Institute of Electrical and Electronics Engineers Inc., 2024) Naik, A.S.; Kumar Reddy, S.K.; Raj, M.G.
In underground mining, the real-time monitoring of environmental parameters plays a pivotal role in ensuring the safety of mining operations and personnel. This article explores the integration of Long Range (LoRa) wireless communication technology and the Internet of Things (IoT) to bolster safety measures and prevent potential accidents within underground mines. The environmental parameters in underground mines include Oxygen (O2), Carbon Dioxide (CO2), Carbon Monoxide (CO), Methane (CH4), Nitric Oxide (NO), Nitrogen Dioxide (NO2), Sulphur Dioxide (SO2), Hydrogen Sulfide (H2S), Ethylene Oxide (EO), Temperature and Humidity. Currently, underground mines in India use portable multi-gas detector devices to measure environmental parameters. HPD13A LoRa 868 MHz based Real Time Environmental Parameters Monitoring System (RTEPMS) is designed and developed to facilitate real-time data collection in underground mines. In addition, the developed RTEPMS system is tested and evaluated at the open surface level and in one of the underground mines in India. The experimental results represent successful LoRa-based wireless communication established in an underground mine with data acquisition and real-time processing. Major parameters exceeding threshold limits in the underground mine environment include O2, CO, CO2, NO2, and EO. The data correlation between LoRa-based RTEPMS and multi-gas detector devices is 69.47% for CO2 and 72.38% for CO, while the values for CH4 and H2S are nearly zero, indicating their presence in underground mines is almost negligible. The RTEPMS is an affordable solution for smaller and less affluent underground mines. It alerts mine workers if environmental parameters exceed threshold limits during emergencies. © 2013 IEEE.
Stability Assessment and Optimal Excavated Design of a Rock Slope in an Opencast Limestone Mine
(Books and Journals Private Ltd., 2023) Kumar Reddy, S.K.
The stability of rock slopes in an opencast limestone mine throughout the mining process was investigated using the limit equilibrium approach (SlopeW). The optimal excavation method with a substantially steeper slope angle of 450 rather than 350 was successfully accomplished at the critical geological section of the pit slope under numerous geologically disturbed area such as joints, faults and folds on a geotechnical basis in order to ensure adequate stability against any failure while working in the mine. The primary objective of this paper is to use the limit equilibrium approach in the SlopeW programme to predict the slope’s safety factor and critical failure surface geometry due to the imposed of a surcharge loading of dump on top of the open pit slope for a 110m deep rock cut in the limestone mine. Geotechnical studies covering field geological mapping, laboratory experiments on rock samples cored from exploration drilling and different rock blocks retrieved straight from the mine were used to determine the physico-mechanical characteristics of the rock components, and numerical analysis using limit equilibrium technique (SlopeW) was carried out. It is also recommended that no activity or construction take place on the top of the pit slope crest in order to prevent further slope failures in old scheme and shifting dump 25m away from the top of pit slope for future safe workings in the mine. © 2023, Books and Journals Private Ltd.. All rights reserved.