Faculty Publications

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    Optimization of shovel-dumper system in surface mines by using match factor method
    (2009) Mangalpady, M.
    Computers have brought a revolution in almost every realm of life and become an indispensable part of human activities. Mining industry is no such exception. One of the major problems in surface mining is materials handling, which involves transportation of both ore and overburden. Most of the projects make use of shovel-dumper system due to its high degree of flexibility. This paper addresses application of match factor method for optimization of shovel-dumper fleet in surface mine projects. A surface iron ore mine was simulated using the computer model developed and the match factor was calculated for existing system. To make match factor unity compared to existing match factor of 0.43, it was found that the number of dumpers would have to be increased to 54, in addition to existing trucks. The model attempts to quantify the apparent balance between the number of loading devices and the number of haulage equipment needed.
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    A comparison of limit equilibrium method of slope stability analysis with finite element modelling
    (2009) Mangalpady, M.
    Stability analysis of slopes susceptible to different types of failures can be performed with different techniques. The selection of an appropriate technique is, therefore, very important in a process of slope stability evaluation. In this paper, slopes of a large surface iron ore mine was analyzed by limit equilibrium method and by finite element modelling. GALENA software was used for analysis by limit equilibrium method and ANSYS for finite element modelling (FEM). Factor of safety (FOS) was calculated by both the methods and they are compared for their applicability. Based on the results obtained by the analysis, conclusions were drawn on the application of these methods. It was found that FEM analysis gives factor of safety value which is found to be lesser than the values determined by limit equilibrium method. This is because it considers more parameters and performs a detailed analysis of stress and strain conditions in the strata under consideration.
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    Studies on iron tailings towards usage for paving blocks manufacture
    (2010) Mangalpady, M.; Sampath Kumar, N.N.
    Disposal of mill tailings is one of the major problems in mining industry. Investigations are being done all over the world to utilize tailings for useful purposes. The scope of this work is to study the utilization of iron ore tailings in manufacture of concrete paving blocks. Five reference mixes were prepared using cement, jelly dust and baby jelly. Ten paving blocks were prepared from each type of mix, out of which five specimens were cured for 7 days and five were cured for 28 days. By using sand and tailings as fine aggregates, two modified mixes were prepared by replacing jelly dust partly in reference mixes. Similar to reference mix, five mix ratios were made and ten paving blocks were prepared from each type of mixtures. From each set of paving blocks, five specimens were cured for 7 days and the other five specimens were cured for 28 days. Laboratory tests were conducted to assess water absorption and compressive strength of specimens, and graphs were plotted for their comparison among each type of respective mix ratios. In all the comparisons, compressive strength of tailing based mix was higher than the respective reference mix. Similar trend is shown by the graphs plotted for water absorption. © 2010 CAFET-INNOVA TECHNICAL SOCIETY. All rights reserved.
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    A comprehensive assessment of increased iron ore production on the environment - A case study
    (2011) Thimmaiah, S.A.; Rao, Y.; Murthy, C.H.S.N.
    There has been a significant increase in iron ore production in the Bellary- Hospet-Sandur sector of Karnataka, India due to sudden increase in the demand of iron ore from other countries as well as by local steel plants set up in the region. An attempt has been made in this paper to study the effect of increase in the iron ore production on various environmental parameters like air, water, soil and noise. For this purpose a study area of 10 Km radius was taken and the various environmental parameters were monitored before and after increase in iron ore production in the region. Study shows that there is no significant change in the air quality in terms of SPM, RPM, SO2 and NOx in the region. In many locations, there is decrease in the concentrations of these parameters. This is mainly due to improvement of roads by asphalting, effective covering of iron ore trucks by tarpaulin, awareness among mine owners about the protection of environment by following various pollution control measures, dust suppression measures on the public road using water sprinklers and stringent monitoring of the environmental protective measures by various regulatory authorities. The concentration of SO2 and NOx was found to increase due to increase in traffic by movement of tippers in the public/village road. The deployment of heavy earth moving machinery at mine site also contributed for increase of SO2 and NOx. The surface water quality parameters were found to be within the acceptable limits in the study area. There is no possibility of disturbing/altering ground water table due to mining operations as the mining is being carried out on hill top which is above the general ground level. In agricultural soil, except that of potassium and electrical conductivity, variations in other parameters are insignificant as the agricultural lands are located 2 to 3 Kms away from the active mining area. Increase in noise level is found at most of the locations of the study area. Therefore, serious attempts should be made by mine owners as well as statutory bodies to reduce the sound level at various locations for increasing the quality of life in these locations in terms of sound level. © 2011 CAFET-INNOVA technical society. All right reserved.
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    Experimental studies on Iron-ore tailing based interlocking paver blocks
    (2012) Ravi Kumar, C.M.; Anil, A.; Prashanth, M.H.; Venkat Reddy, D.
    Interlocking concrete block pavers (ICBP) has been extensively used in many of the countries due to concern with durability. They are utilized in a variety of commercial, municipal and industrial applications. The superior engineering properties, low maintenance, ease of placement and removal, aesthetic appeal and immediate availability are the primary reasons for choosing concrete block pavement over other paving surfaces. ICBP are colored using iron oxide pigments. The present investigation details the properties of ICBPs mixed with iron ore tailings as a partial replacement for cement. The paper discusses the experimental studies on strength characteristics and water absorption of iron ore tailings based concrete paver blocks by considering actual area and plan area and results has been compared with that of conventional concrete paver blocks. © 2012 Cafet-innova technical society. © 2012 Cafet-Innova Technical Society.
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    An economic analysis of environmental pollution and health - a case study of Bellary-Hospet sector
    (2012) Thimmaiah, S.A.; Ravi, D.R.; Rao, Y.V.; Murthy, C.S.N.
    The Earth's natural ecosystem is the basis for our life-supporting system and provides marketable goods to human and other living organisms. The natural environment has always been exploited to fulfill human needs. The green revolution and industrial revolution has caused serious threat to sustainable development for both developed and developing countries. The degradation of air, water and land has directly affected the livelihood and human health. The environmental damage increases, as the economic activity increases, in view of the fact that the association between economy and the environment are multiple, complex and important. Mining is one such activity, which significantly results in the degradation of the environment, apart from generating huge economy to the country. Hence, the identification and quantification of socio economic impact of environmental pollution caused due to increased mining activity is necessary in the broader economic analysis. The present study is envisaged with the objective to identify and evaluate the impacts of mining activity on Social, Economical and Environmental Aspects of the area and to measure its economic burden on the affected people. The ambient air quality in the selected stations of study area reveals that, the increase in iron ore production has significantly resulted in the deterioration of air quality. High particulate matter to an extent of 310 ?g/nm3 in case of SPM concentration and 160 ?g/nm3 in case of RSPM. The health data collected from the respondents have revealed, significantly more number of respondents who are suffering from dust allergy, skin allergy in the study area, where there are mines and are working as workers in those mines, contributing for higher health cost incurred through treatment. © 2012 CAFET-INNOVA TECHNICAL SOCIETY.
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    Utilisation of mine waste in the construction industry - A Critical Review
    (CAFET INNOVA Technical Society 1-2-18/103, Mohini Mansion, Gagan Mahal Road, Domalguda, Hyderabad 500029, 2016) Shreekant, R.L.; Mangalpady, M.; Vardhan, H.
    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. © 2016 CAFET-INNOVA TECHNICAL SOCIETY. All rights reserved.
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    Corrosion behavior of high and low temperature austempered ductile iron (ADI) in iron ore slurry
    (ASTM International, 2017) Aithal, P.M.; Vijayan, V.; Surendranathan, A.O.; Udupa, K.R.; Samuel, K.G.
    Corrosion behavior of austempered ductile iron (ADI) and forged EN31 steel balls in a ground iron ore slurry was studied as a function of time in the slurry, while the microstructure of ADI developed due to different tempering temperature and tempering time. The corrosion rates of the grinding balls immersed in the iron ore slurry were determined using electrochemical analysis and weight loss methods. It was found that the pH of the iron ore slurry increased with time and the corrosion behavior was influenced by the pH of the slurry. The corrosion rate of forged EN31 steel balls increased with the increase in time and pH of the slurry, whereas the corrosion rate of ADI balls depended on the austempering treatment. In general, the forged EN31 steel ball offered better corrosion resistance than ADIs during the early stages of exposure in the slurry (low pH values of the slurry), but at higher pH values of the slurry, the ADIs yielded better corrosion resistance than forged EN31 steel balls. The ADI austempered at higher temperatures showed better corrosion resistance than the ones austempered at lower temperatures. © © 2017 by ASTM International.
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    Investigating the Utility of Iron Ore Waste in Preparing Non-fired Bricks
    (Springer India sanjiv.goswami@springer.co.in, 2017) Lamani, S.R.; Mangalpady, M.; Vardhan, H.
    Iron ore waste is a major problem for mine owners due to the difficulty involved in its storage, handling and other environmental related issues. An alternative solution to this is utilisation of iron ore waste (IOW) as some value added product in construction industry. An attempt has been made in this paper in examining the possibility of making non-fired bricks from iron ore waste with some additives like cement and fly-ash. Each of the additives were mixed with IOW in different ratios and different sets of bricks were prepared. The prepared IOW bricks were cured for 7, 14, 21 and 28 days and their respective compressive strength and percentage of water absorption were determined. The results show that IOW bricks prepared with 9% and above cement and with 28 days of curing are suitable for brick making and meet the IS specifications. It was also observed that the weight of the prepared bricks with 9% cement with 28 days of curing varies between 2.35 and 2.45 kg whereas the weight of compressed fire clay bricks varies from 2.80 to 2.89 kg. Results also show that the cost of bricks prepared with cement ranging from 9 to 20% is comparable to that of commercially available compressed bricks. © 2016, The Institution of Engineers (India).
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    Primary Fragmentation Behavior of Indian Coals and Biomass during Chemical Looping Combustion
    (American Chemical Society service@acs.org, 2018) Pragadeesh, K.S.; Ruben Sudhakar, D.R.
    Devolatilization and fragmentation are important physical phenomena occurring during solid fuel chemical looping combustion (CLC). Primary fragmentation during devolatilization strongly affects the rate of fuel conversion, emissions, and fine particulates generation in a fuel reactor of a fluidized bed CLC unit, thus forming a critical design input. The present study focuses on investigating the primary fragmentation behavior of large coal and biomass (wood) particles during the devolatilization phase of CLC. Three types of coals (two Indian coals, one Indonesian coal) and one type of Casuarina wood of three sizes in the range of 8-25 mm, at different fuel reactor bed temperatures (800, 875, and 950 °C) are studied for primary fragmentation. Iron ore with 64% Fe is used as the oxygen carrier bed material, with steam as the fluidizing medium in the fuel reactor. The fragmentation behavior is expressed in terms of the number of fragments, fragmentation index, frequency of fragmentation, and particle size distribution of fragments at different residence times of coal during devolatilization in the fuel reactor. Under the conditions of study, the number of fragments increases with an increase in particle size and temperature, for all fuels studied. Also, it is found that the number of fragments increases with the decrease in compressive strength of both coal and biomass particles. The Indian coals are found to fragment in the earlier stages of devolatilization, while the Indonesian coal and the biomass particles begin to fragment in the later stages of devolatilization. The maximum fragmentation index is found with Indian coal - IC1, which has the highest fixed carbon content among the fuels studied, and the least value is observed in biomass. Different modes of fragmentation exhibited by each fuel type is discussed. Indian coals do not show any volumetric changes as such, whereas Indonesian coal indicates some degree of volumetric expansion. © 2018 American Chemical Society.