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Evaluation of Some Parameters in Relation to Hydraulic Stowing of Pond Ash

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DOI: 10.1007/s40033-014-0053-5

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Evaluation of Some Parameters in Relation
to Hydraulic Stowing of Pond Ash in
Underground Coal Mines: A Prototype
Study

D. P. Mishra & S. K. Das

Journal of The Institution of

Engineers (India): Series D
Metallurgical & Materials and Mining
Engineering

ISSN 2250-2122
Volume 96
Number 1

J. Inst. Eng. India Ser. D (2015) 96:37-42

DOI 10.1007/s40033-014-0053-5

1 23
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1 23
 Author's personal copy
J. Inst. Eng. India Ser. D (January–June 2015) 96(1):37–42
DOI 10.1007/s40033-014-0053-5
ORIGINAL CONTRIBUTION
Evaluation of Some Parameters in Relation to Hydraulic Stowing
of Pond Ash in Underground Coal Mines: A Prototype Study
D. P. Mishra • S. K. Das
Received: 18 July 2014 / Accepted: 9 September 2014 / Published online: 5 October 2014
 The Institution of Engineers (India) 2014
Abstract Various parameters in relation to hydraulic
stowing of pond ash such as rate of water drainage from the
pond ash, water absorption by the pond ash, percentage of
stowing and percentage of void were evaluated using a
mine goaf model stowed with pond ash slurries of five
concentrations varying from 45 to 65 % at 5 % increment
to identify the suitable slurry concentration for effective
stowing in underground coal mines. The study revealed
that the rate of water drainage from the stowed pond ash is
highest during the initial 15 min of stowing and it gradu-
ally decreases with time. Also, it was observed that the
percentages of water absorption by the pond ash and
stowing increase with the increment of slurry concentra-
tion. It was concluded that pond ash slurries of higher
concentrations such as 60 and 65 %, which yield better
results in terms of higher stowing percentage in the 1st
phase of stowing itself and higher water absorption, may be
considered appropriate for stowing.
Keywords Fly ash
Pond ash
Slurry
Stowing

Underground coal mines

Water absorption, water drainage
Stowing percentage
D. P. Mishra (&)
Department of Mining Engineering, Indian School of Mines,
Dhanbad 826 004, Jharkhand, India
e-mail: devi_agl@yahoo.com
S. K. Das
Dr. B. R. Ambedkar National Institute of Technology,
Jalandhar 144 011, Punjab, India
Introduction
Hydraulic stowing of pond ash (a mixture of fly ash and
bottom ash deposited in the ash ponds) in underground coal
mines is gaining popularity in India and in near future, it is
expected to be a major alternative to river sand as a
stowing material. The pond ash stowing in small scale has
been undertaken on trial basis in some of the Indian coal
mines [1]. In India, the hydraulic pond ash stowing was
first tried on trail basis in the PK-I underground mine of
Singareni Collieries Company Ltd. (SCCL), Manuguru
area where approximately 10,000 m3 of pond ash was
stowed in three phases. Based on the experience and
knowledge gained from this trial, about 9,000 m3 of ash
from NTPC, Ramagundam was stowed in GDK 6A Incline
of Ramagundam Region with satisfactory and encouraging
results [2, 3]. From the trial of pond ash stowing under-
taken at Durgapur Rayatwari Colliery (DRC) of Western
Coalfields Ltd. (WCL) in a successive phased manner, it
was concluded that pond ash of above 50 lm grain size is
best suited for mine stowing, which does not require any
additive for quicker settling of the ash particles [4].
The main problems encountered during hydraulic
stowing of pond ash are delayed settling of the ash parti-
cles, poor drainage of water and escape of fines through the
stowing barricade [5, 6]. Moreover, pond ash absorbs a
significant quantity of water and does not readily allow the
water to drain out. As a result, the stowed pond ash remains
in a fluidized state for a longer duration causing rupturing
of the stowing barricades due to increased hydrostatic
pressure and prolongs the stowing cycle. Quicker drainage
not only prevents the build up of hydrostatic pressure
behind the stowing barricades, but also helps in early set-
tling, layer wise deposition and better consolidation of the
stowing material. Therefore, quicker drainage of water
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38
through the hydraulically stowed pond ash is very much
desired for efficient hydraulic stowing.
The drainage of water from the stowed mass mainly
depends on the permeability of the stowing material, which
in turn depends on the particle size of the material. Fly ash
is predominantly a silt-size nonplastic material and
between 60 and 90 % of the fly ash particles are finer than
75 lm. Mishra and Das [7, 8] have observed that the
coefficient of permeability values of both fly ash and pond
ash of Talcher Thermal Power Station are very low and
equivalent to the permeability of silts. It has also been
observed that fly ash particles due to fineness in nature and
being light in weight remain in suspension for a longer time
and settle very slowly in water medium after hydraulic
stowing. Faster settling rate enables faster solid–liquid
separation, quicker drainage of water and eliminates
escaping of the fines through stowing barricade. Studies
showed that addition of flocculant not only enhances the
settling of the ash particles in ash-water suspension, but
also facilitates faster solid–liquid segregation and signifi-
cantly enhances water drainage from the hydraulically
stowed pond ash [6, 9, 10].
In this research, an attempt has been made to evaluate
the various parameters in relation to pond ash stowing
using a mine goaf model stowed with pond ash slurries of
five different concentrations to find out the suitable con-
centration giving better stowing efficacy. It is envisaged
that this study will be very much useful in predicting the
stowing parameters during actual pond ash stowing oper-
ations in underground coal mines.
Materials
In this study the pond ash of Talcher Thermal Power Sta-
tion (TTPS), a subsidiary of National Thermal Power
Corporation (NTPC) located in the state of Odisha, India
was used for stowing in the mine goaf model. The installed
capacity of the power station is 460 MW and it receives
coal as fuel from Jagannath opencast mines of Mahanadi
Coalfields Limited (MCL), Talcher for power generation.
The physical and chemical properties of the pond ash are
presented in Tables 1 and 2 respectively. The particle size
distribution of the pond ash has been shown in Fig. 1. The
results indicate that the coefficient of permeability of the
pond ash is 5.5472 9 10-4 cm/s, which is very low and
equivalent to the permeability of silts. The pond ash pos-
sesses high water holding capacity of 63.56 %. The particle
size analysis results indicate that the specific surface area
and mean particle diameters (D50) of the pond ash are
0.293 m2/cm3 and 28.10 lm respectively, and about 90 %
of the pond ash particles are less than 74.26 lm. Since,
CU \ 6 and 1 \ CC \ 3, the pond ash is poorly graded as
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J. Inst. Eng. India Ser. D (January–June 2015) 96(1):37–42
per the classification and gradation of soils by ASTM
D-2487.
The results of the chemical analysis indicate that the
pond ash is mainly composed of silica (SiO2), alumina
(Al2O3) and iron oxide (Fe2O3) with very small amounts of
calcium (CaO) and some other metal oxides like titanium
and potassium etc. Since the sum total of SiO2, Al2O3 and
Fe2O3 is greater than 70 % and the loss on ignition (LOI) is
less than 6 %, the pond ash conforms to class F fly ash
category as per ASTM C618.
Experimental Work
Experimental Set-up
A mine goaf model fabricated in the laboratory shown in
Fig. 2 was used to conduct hydraulic stowing of the pond
ash. The model was made of transparent Perspex sheet with
a rectangular funnel attached at the top to feed the pond ash
slurries. The front side of the model was open and attached
to a removable barricade fitted with a cotton cloth and
supported by wires to allow free drainage of water after
stowing. A right angled flume was attached to the bottom
of the model to collect the drained out water. The model
had a removable top for measurement of the stowing
heights after each experiment and it was made water tight
to the flanges of the bottom section by rubber lining and
nuts. The water drained out from the stowed pond ash mass
was collected and measured using a measuring cylinder.
The detailed specifications of the model are given in
Table 3.
Experimental Procedure
Pond ash slurries were prepared in five weight concentra-
tions (Cw) by varying the ash concentration from 45 to
65 % Cw with an increment of 5 % for stowing the mine
model. In hydraulic stowing operations, it is generally
observed that the mine void is not completely filled with
the stowing material in a single phase of stowing and after
complete drainage of water from the stowed mass; a void is
left behind between the stowed mass and roof of the mine.
This necessitates another phase of stowing for complete
filling of the mine void. Therefore, in the present study the
stowing operation with the pond ash slurries was carried
out in two phases. In the 1st phase, the model was stowed
completely with the pond ash slurry of a particular con-
centration and the water drained out from the stowed pond
ash mass was measurement at a fixed time interval of
15 min up to two and half hours. The remaining water
drained out beyond this time period was also measured and
added with the previously collected water to obtain the
 Author's personal copy
J. Inst. Eng. India Ser. D (January–June 2015) 96(1):37–42 39

Table 1 Physical properties of the pond ash

Parameters Values

Specific gravity 2.00

Bulk density (g/cm3) 0.95
Porosity (%) 52.50
Coefficient of permeability, k (cm/s) 5.5472 9 10-4
Water holding capacity, % 63.56
Particle size analysis results
D10, lm 8.74
D50, lm 28.10
D90, lm 74.26
D (4, 3), lm 35.17
D (3, 2), lm 20.48
Specific surface area (m2/cc.) 0.293
Coefficient of uniformity, CU 3.89
Coefficient of curvature, CC 1.29

Table 2 Chemical composition of the pond ash Fig. 2 The mine goaf model used for stowing with pond ash slurries
Compounds Compounds % (by mass)

SiO2 61.85 Table 3 Specifications of the mine goaf model

Al2O3 30.48 Model dimension 30 cm 9 30 cm 9 12.7 cm
Fe2O3 3.23 Volume of the model 11,430 cm3
SiO2 ? Al2O3 ? Fe2O3 95.56 Material Transparent Perspex sheet
TiO2 2.19 Base area 30 cm 9 30 cm
CaO 0.72 Height of the model 12.7 cm
K2O 0.90 No. of pillar in the goaf 01
P2O5 0.64 model
LOI 1.27 Size of the pillar 10 cm 9 10 cm 9 12.7 cm
Barricade Made of cotton cloth and supported by
wires
Gradient maintained 1 in 12.5
Percent finer

model at distances of 5, 15, 20, 25 and 30 cm (dip most

Particle size, µm
Fig. 1 Particle size distribution of the pond ash
total quantity of drained out water. Finally, the total per-
centages of drainage and absorption of water were com-
puted for stowing with each slurry concentration.
After complete drainage of water from the 1st phase
stowing, the stowing heights were measured at six loca-
tions along the dip starting from the rise most point of the
point) and labeled as h0, h5, h15, h20, h25 and h30 respec-
tively. The side view of the model stowed with pond ash
slurry of 45 % concentration after 1st phase stowing is
shown in Fig. 3. The schematic side view of the model
showing the stowing contours for stowing with different
slurry concentrations and measurement of stowing heights
has been shown in Fig. 4. The purpose of measurement of
stowing heights was to draw the stowing contours for each
slurry concentration and measure the area under the con-
tours for measurement of the stowed volume. Thereafter,
the percentages of stowing and void were calculated. The
void remaining after 1st phase stowing with a particular
slurry concentration was again completely stowed with the
pond ash slurry of same concentration in the 2nd phase.
The same procedure of measurement of stowing heights
was followed after complete drainage of water in the 2nd

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40 J. Inst. Eng. India Ser. D (January–June 2015) 96(1):37–42

Stowing with pond ash slurries

12
45% Cw
50% Cw
10
55% Cw

Drainage %
60% Cw
8
65% Cw

0
0 15 30 45 60 75 90 105 120 135 150 165
Time (min)

Fig. 5 The trend of water drainage from the stowed pond ash at
different time intervals of stowing with various slurry concentrations

Fig. 3 Side view of the model stowed with pond ash slurry of 45 %
concentration 100
87.53
90 83.03
80

Water absorption, %
Slurry loading funnel 71.68
70 62.25
Stowing contours
Cw Mine model 60 52.42
65 %
50
60 %
Measured 40
55 % stowing heights
50 %
30
45 %
h30 20
h0 h5 h15 h20 h25 Barricade
10
0
40 45 50 55 60 65 70
Slurry concentration, % Cw
Measuring
Stand cylinder
Fig. 6 The trend of water absorption by the pond ash stowed at
various slurry concentrations
Fig. 4 Schematic side view of the model showing the stowing
contours for stowing with different slurry concentrations and
measurement of stowing heights rate of drainage was found to be lower at higher slurry
concentrations for all time intervals.
The trend of total water absorption by the stowed pond
phase and the percentages of stowing and void were cal- ash at various slurry concentrations has been shown in
culated for all the slurry concentrations. Fig. 6. The figure shows that the water absorption increases
with the slurry concentration. A minimum of 52.42 % and
maximum of 87.53 % of the total water used in stowing
Results and Discussion was absorbed by the pond ash in the cases of slurries of 45
and 65 % concentration respectively. The higher percent-
Drainage and Absorption of Water age of water absorption by the stowed pond ash at higher
slurry concentrations indicates lower water drainage, which
The percentage of water drainage from the stowed pond may be advantageous in reducing the pumping cost of the
ash versus time curves for stowing with pond ash slurries of drained out water.
different concentrations is shown in Fig. 5. The results
indicate that the rate of water drainage decreases with Percentage of Stowing
increment of time as well as slurry concentration. Water
drainage was highest after 15 min of stowing, which The stowing contours plotted based on the measurement of
gradually decreased with time in all slurry concentrations. stowing heights after 1st and 2nd phase stowing with dif-
In the case of stowing with slurries of 45 and 65 % con- ferent pond ash slurry concentrations are shown in Fig. 7.
centrations, highest water drainage of 10.85 and 5.89 % From the figure it may be observed that the contours in 1st
respectively were recorded after 15 min of stowing. The phase stowing with lower slurry concentrations such as

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J. Inst. Eng. India Ser. D (January–June 2015) 96(1):37–42 41

1st phase stowing 1st phase stowing % 2nd phase stowing %

(a) 1st phase void % 2nd phase void %
45% Cw 50% Cw 55% Cw 60% Cw 65% Cw
100

12 90
80
Stowing height, cm

10
70
8 60

%
50
6
40
4 30
20
2
10
0
0
0 5 10 15 20 25 30
40 45 50 55 60 65 70
Measuring distance, cm Slurry concentration, Cw (%)

(b) 2nd phase stowing Fig. 8 Variations of stowing and void percentages with slurry
45% Cw 50% Cw 55% Cw 60% Cw 65% Cw concentrations after 1st and 2nd phase stowing

12
Stowing height, cm

10 50 and 55 % concentrations, the goaf was stowed 90.16,

95.08 and 99.34 % respectively, whereas, the goaf was
8
completely filled up when stowed with slurry concentra-
6
tions of 60 % and 65 % leaving no void after complete
4 drainage of water. Thus, at lower slurry concentrations like
2
45–55 %, some voids still remain unfilled even after 2nd
phase stowing giving improper confinement to the roof.
0
0 5 10 15 20 25 30 This suggests that stowing with higher concentration slur-
Measuring distance, cm ries like 60 and 65 % gives better results in terms of higher
percentage of stowing requiring only two cycles of stowing
Fig. 7 Stowing contours at different pond ash slurry concentrations to completely fill the voids. Since at 60 and 65 % slurry
after a 1st phase and b 2nd phase stowing
concentrations more than 90 % of the goaf is filled in the
1st phase stowing itself, it will serve the purpose of mini-
from 45 to 55 % follow a curved shape, whereas, they
mizing surface subsidence even without requiring 2nd
straighten at higher slurry concentrations. In stowing with
phase stowing. Further, pond ash stowing with higher
all slurry concentrations, a rise in the stowed pond ash level
slurry concentrations would result in lesser water con-
subsequently touching the roof towards dip side of the goaf
sumption and reduced water drainage, which in turn would
was noticed. Total covering of the barricade with the
minimize the pumping cost.
stowed pond ash was also observed in case of stowing with
all slurry concentrations, which was responsible for poor
water drainage rate from the stowed mass.
Conclusions
The variations of stowing and void percentages deter-
mined after 1st and 2nd phase stowing with pond ash
The present study investigates the various stowing
slurries of different concentrations have been shown in
parameters in relation to hydraulic stowing of pond ash to
Fig. 8. From the results it is evident that the stowing per-
identify the suitable pond ash slurry concentration for
centage increases or in other words the percentage of void
effective stowing in underground coal mines. Based on the
decreases with the increment in slurry concentration. A
results obtained from this study, the following conclusions
minimum of 70.60 % stowing was achieved in the 1st
may be drawn:
phase stowing with slurry concentration of 45 %. At 65 %
concentration, highest of 96.85 % stowing was recorded in • The rate of water drainage from the stowed pond ash
the 1st phase stowing, leaving behind only 3.15 % of void decreases with increment of time as well as slurry
to be subsequently filled in the 2nd phase. Thus the concentration.
requirement of stowing material in the 2nd phase stowing • The water absorption by the pond ash increases with
reduces in the case of stowing with higher slurry concen- slurry concentration. A minimum of 52.42 % and
trations. In case of 2nd phase stowing with slurries of 45, maximum of 87.53 % of the total water used in

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 Author's personal copy
42
stowing was absorbed by the pond ash stowed at 45 and
65 % slurry concentrations respectively.
• The stowing percentage increases or in other words the
percentage of void decreases with the increment in
slurry concentration. A minimum of 70.60 % and
maximum of 96.85 % stowing were achieved in the
1st phase stowing with slurry concentrations of 45 %
and 65 % respectively.
• Since more than 90 % goaf is filled in the 1st phase
stowing itself when stowed with 60 and 65 % slurry
concentrations, it may serve the purpose of minimizing
surface subsidence without requiring 2nd phase
stowing.
• Stowing with higher concentration slurries like 60 and
65 % gives better results in terms of higher percentage
of stowing requiring only two cycles of stowing to
completely fill the mine voids, lesser water consump-
tion, reduced water drainage and lower pumping cost.
Acknowledgments Authors are thankful to Technology Informa-
tion, Forecasting and Assessment Council (TIFAC), New Delhi an
autonomous organization under the Department of Science and
Technology (DST), India for providing financial support for the study.
The authors also gratefully acknowledge the authority of Talcher
Thermal Power Station of NTPC for supplying the pond ash to carry
out the experiments.
10. H. Kumar, D.P. Mishra, S.K. Das, Settling characteristics of fly
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