RI 8062 Physical property data on fine coal refuse · Report of Investigations 8062 Physical...
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Report of Investigations 8062 Physical Property Data on Fine Coal Refuse By R. A. Busch, R. R. Backer, L. A. Atkins, and C. D. Kealy Spokane Mining Research Center, Spokane, Wash. UNITED STATES DEPARTMENT OF THE INTERIOR Stanley K. Hathaway, Secretary Jack W. Carlson, Assistant Secretary-Energy and Minerals BUREAU OF MINES Thomas V. Falkie, Director
Transcript of RI 8062 Physical property data on fine coal refuse · Report of Investigations 8062 Physical...
Report of Investigations 8062
Physical Property Data on FineCoal Refuse
By R. A. Busch, R. R. Backer, L. A. Atkins,
and C. D. KealySpokane Mining Research Center, Spokane, Wash.
UNITED STATES DEPARTMENT OF THE INTERIORStanley K. Hathaway, Secretary
Jack W. Carlson, Assistant Secretary-Energy and Minerals
BUREAU OF MINESThomas V. Falkie, Director
This publication has been cataloged as follows:
Busch, Richard APhysical property data on fine coal refuse, by R. A. Busch
[and others. Washington] U.S. Bureau of Mines [1975]
40 p, illus., tables. (U.S. Bureau of Mines. Report of investi-gations 8062)
Includes bibliography.
1. Coal mine waste. I. U.S. Bureau of Mines. II. Title.(Series)
TN23.U7 no. 8062 622.06173
U.S. Dept. of the Int. Library
CONTENTS
Abstract. . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Si te se lee tion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Method of drilling and sampling.......................................... 6Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Discussion of results....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 10Conclusions and recommendations 19References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 22Appendix.--Direct shear computer program and example data output 23
ILLUSTRATIONS
1. Tripod setup on sludge zone at WDH-l................................ 22. Sampling setup on WDH-2,............................................ 33. Site and location of BDH-l and BDH-2................................ 44. Site and location of WDH-land WDH-2................................ 55. Brazing casing sections prior to driving................... 66. Constant head permeability setup. 77. Sedigraph 5000 for determining minus 200-mesh particle size......... 78. Direct shear device................................................. 89. Triaxial shear testing apparatus.................................... 9
10 Particle size ranges for drill hole samples 12
TABLES
1. In situ properties......................... 102. Shelby tube shear data... 113. Composi te samples. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174. Standard coal analysis...... 185. Chemical composition of ash......................................... 196. X-ray diffraction analysis of coal refuse 197. Spectrographic analysis of coal ash................................. 19
PHYSICAL PROPERTY DATA ON FINE COAL REFUSE
by
R. A. Busch, 1 R. R. Backer, 2 L. A. Atkins, 3 and C. D. Kealy 2
ABSTRACT
Sludge ponds of fine coal, fine soil, and water created behind largepiles of coarse coal waste can present hazardous conditions; this is a Bureauof Mines report of the subsurface physical property data developed on the finecoal waste materials that make up the core areas of two typical coal wasteimpoundments. These data will help define more completely the engineeringproperties of this problem area of the structures.
Additional calorific, chemical, and mineralogical data were obtained onthe coal waste materials to determine possible uses or development ofbyproducts. The possibility of extracting alumina from coal ash was alsoinvestigated.
INTRODUCTION
Since the early 1960's, the coal industry has been under constant pres-sure by environmental legislation to clean up liquid discharge into streams.Consequently, rather large sludge ponds have developed which consist of finecoal, fine soil, and water. These ponds are generally formed behind largepiles of coarse coal waste and in conjunction therewith formulate the of ten-criticized coal waste impoundments. As a sequel to Bureau of Mines RI 7964(1),4 this report deals primarily with the physical and chemical properties ofthe fine coal wastes in the pond.
The previous report was most concerned with the coarse material and con-tained only a minimum of sludge information from a few surface samples. Toobtain more information on coal sludge, especially at various depths, a sam-pling program was carried out on two typical waste piles. Four holes weredrilled and sampled at 5-foot intervals. These samples were carefullyextracted from the drill holes and shipped back to the laboratory in a manner
lCivil engineer.2Mining engineer.3Engineering technician.4Underlined numbers in parentheses refer to items in the list of references
preceding the appendix.
2
that would minimize disturbance. Laboratory tests were performed on thesesamples to provide data that could be used to evaluate problems involvingdrainage, liquefaction, strength, and stability. In addition, these samples,plus coarse refuse and red dog from previous sampling, were subjected to atypical coal analysis which could provide information as to the possible useof the waste products as a fuel or as a source for marketable byproducts.
SITE SELECTION
The sites chosen for sampling were selected on the basis of availabilityas well as being considered representative. They were inactive at the time ofsampling, which allowed access by the sampling crew with light equipment(fig. 1). Heavy drilling equipment could not be used because the deposit wassaturated and the support capability was poor. Consequently, drilling andsampling were carried out by hand methods (fig. 2).
FIGURE 1. . Tripod setup on sludge zone at WDH-1.
3
FIGURE 2•• Sampl ing setup on WDH·2 (note WDH·l at left of photo).
The difficulty of obtaining the samples and the limitations on time andfunds narrowed the fieldwork down to two holes per site. It was decided toconcentrate the sampling in what was considered the most hazardous materials--the saturated fine sludge farthest from the discharge line (figs. 3-4). Itshould be noted, however, that the history of the discharge location was notavailable so there may be discrepancies in the uniformity of the sludge withvarying depths in anyone hole.
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METHOD OF DRILLING AND SAMPLING
The holes were drilled by hand auger. Because of the tendency of thesaturated material to flow into the hole, it was necessary to case the holeimmediately. The casing was 5-foot-long sections of 4-inch diameter pipe.Figure 5 shows how the coupling was slipped over this pipe at connections andwelded. The casing was driven ahead of the augered hole by a weight suspendedfrom a tripod and raised by a cathead mounted on one leg of the tripod. Aftera length of casing was driven, the hole was drilled by hand auger. At 5-footintervals, the hole was sampled by pushing a thin-walled sampler into thesludge ahead of the casing and retrieving the sample. To break the suction atthe bottom of the thin-walled tube and prevent the sample from being suckedout, an air line was attached to the outside of the tube and air was pumpedinto the area at the bottom of the tube as the tube was being extracted. Thismethod of driving casing, drilling, and sampling was performed until it becameimpractical to continue.
FIGURE 5. - Brazing casing sections prior to driving.
FIGURE 6. - Constant head permeabi I ity setup.
FIGURE 7. - Sedigraph 5000 for determining minus 200-mesh particle size.
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PROCEDURES
The laboratory testswere performed in the Bureauof Mines Spokane MiningResearch Center (SMRC) labo-ratory using the followingprocedures:
1. Permeability of theundisturbed Shelby5 tubesamples was determined by aSMRC-developed method usinga constant head (fig. 6).
2. Grain-size distri-bution was performed accord-ing to ASTM StandardD-422-63, part II. Theminus 200-mesh portion wastested with a Sedigraph50005 particle size analyzer.The Sedigraph operates onthe principle of Stokes' law,utilizing X-ray absorption(fig. 7).
3. Specific gravitywas determined according toASTM Standard D-854-58,part II.
4. Maximum density andoptimum moisture contentwere determined according toASTM D-698-70. Minimum den-sity was determined accord-ing to ASTM D-2049-69.
5. The one-dimensionalcompression tests were
5Reference to specific makesor models of equipment ismade to facilitate under-standing and does notimply endorsement by theBureau of Mines.
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performed in a SMRC-designed test chamber by a method developed in this labo-ratory by Nicholson and Busch (2)'
6. The direct shear test on undisturbed samples extruded from the Shelbytubes was performed on a direct shear device with the method outlined byLambe 0.) (fig. 8).
7. The triaxial shear on undisturbed samples extruded from the Shelbytubes was performed primarily according to ASTM D-2850-70. The pressure ofthe pore fluid was continuously monitored throughout the test, and failure wasdetermined using effective stresses (fig. 9).
8. The liquid limit was determined according to ASTM D-423-66.
9. The plastic limit was determined according to ASTM D-424-59 (1971).
FIGURE 8. - Direct shear device.
9
FIGURE 9. - Triaxial shear testing apparatus.
The following tests were performed by others:
1. Ultimate and proximate coal analyses and chemical composition of ashwere determined according to Bulletin 638 (1). The ultimate and proximatecoal analyses were performed by the Pittsburgh Energy Research Center. Thechemical composition of ash was determined by the Aluminum Co. of America(Alcoa) Laboratories.
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2. Mineralogical analysis was done through X-ray diffraction on a sample ofpulverized material. Tests were done by the Alcoa Laboratories.
3. Spectrographic analyses were performed on ash by the Salt Lake City Metal-lurgy Research Center.
DISCUSSION OF RESULTS
The permeability of the material within an embankment or mine waste dump is oneof the most important factors to be considered in drainage and water seepage control.Table 1 shows the permeability of the undisturbed Shelby tube samples which are inthe low-to-very-low permeability range. This can be substantiated by the smalleffective size and the high coefficient of uniformity, indicating a well-graded,fine-grained material.
TABLE 1. - In situ properties
Assumed Inplace Inplace Effec- Coeffi- Spe-Drill Shelby eleva- moisture dry Vertical tive cient cific
Location1 hole tube tion, content, density, permeability, size, of grav-No. No. feet percent lb/ft''3 cm/sec romS uni- ity
formitvW •••••••• DH-l l4A 99.1 63.2 48.1 5.77 X 10-5 0.00062 10.97 1.54w ........ DH-l 7 94.4 51.0 55.6 5.31 X 10-6 .00049 14.90 1.64w ........ DH-l 8 89.1 57.1 53.9 1.38 X 10-6 .00042 13.57 1.68w ........ DH-l 13A 84.1 56.2 49.1 2.21 X 10-6 .00062 14.19 1.59w ........ DH-l l5A 69.1 54.4 54.0 2.00 X 10-6 .0006 11.00 1.59w ........ DH-l 16A 64.3 50.3 53.2 2.18 X 10-6 .00062 10.64 1.52w ........ DH-2 18A 99.0 62.5 48.2 8.76 X 10-6 .00056 11.61 1.66w ........ DH-2 l7A 94.1 47.4 55.0 7.76 X 10-7 .00076 14.47 1.45W •••••••• DH-2 19A 89.1 59.0 53.8 1.40 X 10-6 .0006 14.17 1.65W •••••••• DH-2 20A 84.1 51. 7 53.0 2.28 X 10-6 .001 20.00 1.52w ........ DH-2 SA 79.1 49.9 51.6 4.67 X 10-6 .001 11.00 1.47W •••••••• DH-2 6A 74.1 51. 1 53.1 5.59 X 10-6 .0014 11.43 1.58W •••••••• DH-2 7A 69.1 51. 9 52.8 2.42 X 10-6 .0011 12.73 1.53w ........ DH-2 8A 64.1 52.3 46.8 2.48 X 10-6 .001 12.00 1.59w ........ DH-2 9A 59.1 54.5 53.2 2.90 X 10-6 .00105 11.90 1.54B ........ DH-1 1 99.0 45.6 46.4 2.97 X 10-4 .0016 40.62 1.48B ........ DH-1 2 95.1 44.3 47.2 2.49 X 10-5 .0026 57.69 1.50B ........ DH-1 3 90.1 48.9 47.8 6.53 X 10-6 .004 45.00 1.46B ........ DH-1 4 75.1 24.2 61.0 2.06 X 10-4 .04 8.50 1.85B ........ DH-1 5 70.1 21.3 56.8 3.05 X 10-4 .069 8.55 1.56B .... DH-1 6 65.1 25.8 55.8 8.86 X 10-4 .088 6.14 1.64B3 ....... DH-2 3A 99.2 63.0 55.3 3.75 X 10-3 .0004 10.50 2.07B ........ DH-2 rOA 94.1 62.2 51. 0 9.18 X 10-7 .00086 7.32 1.74B ........ DH-2 llA 89.1 64.0 54.2 7.51 X 10-7 .00035 8.71 1.84B ........ DH-2 12A 84.2 59.6 50.9 1.76 X 10-" .'00045 7.11 1.84B ........ DH-2 A 79.1 57.7 51. 1 1.38 X 10-6 .0006 7.50 1.69B ..•••••. DH-2 1A 74.2 60.1 52.5 1.86 X 10-6 .00083 7.23 1.70B ........ DH-2 2A 69.2 57.7 52.8 4.12 X 10-6 .00041 9.02 1.66ISurface elevatIon at all drIll holes was assumed at 100 feet.2The size at which 10 percent is finer.3She1by tube 3A contained a large amount of vertical roots and holes.
11
The range of the grain-size distribution curves (fig. 10) for each drillhole shows a relatively well-graded material, quite similar within each drillhole, with the exception of BDH-1. BDH-1 was not homogeneous in respect tosize distribution and showed a much larger particle size in the deeper samples.This indicates that the discharge line was probably in a different location atsome earlier date and not as shown on figure' 1.
Specific gravity values shown in table 1 are relatively uniform for eachsite location. The low values of specific gravity indicate high coal content.The specific gravity of pure coal is in the range of 1.25 to 1.70 (£).
The importance of shear strength data dictated a rather extensive sheartest program. Two types of shear tests were performed on undisturbed Shelbytube samples: drained direct shear and unconsolidated triaxial shear.Results of the direct shear are shown in table 2. They indicate that there issome degree of strength and cohesion. However, these tests were allowed todrain and were run slowly enough to prevent pore pressure buildup. The angleof internal friction, ¢, was determined by using peak stresses.
TABLE 2. - Shelby tube shear data
Mean Drained direct shear in situ conditionsSite Drill Shelby e1eva- Moisture Placement Conso1i- Degree of Cohe-No. hole tube tion, content, density, dation satura- ¢, sion,
No. No. feet percent pcf density, tion, degrees psipcf percent
W •••• DH-1 14A 99.1 58.4 53.0 62.5 100.0 32 0.9w .... DH-1 8 89.1 50.2 58.4 66.0 100.0 29 4.7w .... DH-1 16A 64.2 49.7 56.5 62.9 100.0 32 4.0w .... DH-2 18A 99.0 66.0 54.4 66.0 100.0 26 3.0w .... DH-2 17A 94.1 61. 6 54.2 65.0 100.0 28 2.2w .... DH-2 9A 59.1 47.9 57.0 62.5 100.0 32 2.9B., .. DH-1 2 95.1 55.8 47.4 50.8 87.7 35 .4B .... DH-1 3 90.1 53.4 52.4 57.8 99.5 34 1.8B .... DH-1 4 75.1 21.8 63.7 69.0 66.8 35 1.3B .... DH-2 3A 99.2 59.9 61. 9 74.9 100.0 20 5.4B .... DH-2 11A 89.1 65.8 56.4 69.1 100.0 25 2.0B .... DH-2 2A 69.2 63. 7 52.7 57.2 100.0 34 1.2
The undrained, unconsolidated triaxial shear tests show no shear strengthor cohesion. This can be attributed to the high degree of saturation whichallowed the pore fluid pressure, ~, to attain the same pressure as the con-fining liquid or lateral pressure, 03' By using the effective maximum stressratio for failure, the results are zero.
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and 11 the pore fluid pressure.
(1)
The presence of water does not affect the angle of internal friction of asoil, but as these test results indicate, it can dramatically affect the shearstrength of the soil. The value of shear strength that should be used in anal-ysis can vary considerably, depending on whether a slow "creep" type of fail-ure or a sudden "quick" condition exists. The slow permeability rates in coalsludge would indicate the possibility of pore water pressures and reducedstrength.
One-dimensional compression tests were performed on four compositedsamples (one for each drill hole). After the previous tests were performed,all Shelby tubes from each drill hole were composited and water was mixed witheach to attain the average in situ water content. The sample was then placedin the test chamber near the average inplace density. The test resultsyielded earth pressure at rest values, ~, approaching 1.0 (table 3). Thetest chamber was not completely sealed, allowing some water to drain duringthe test; this may account for the results that show 8 l~ value less than 1.However, the pore water pressure monitored during the test shows the readingto be the same as the vertical applied stress. These test results also indi-cate either no shear strength and the material being in a quick condition orzero effective stress. The Poisson's ratio and Young's modulus can beobtained from this test (table 3).
The maximum and minimum densities shown in table 3 are average numbersfor the two drill holes. Although it is not considered practical to compactthe entire sludge deposit, it is worth noting that the average field densitiesfor the two holes are less than 80 percent of maximum. Using the Proctor den-sity as the maximum and the usual minimum laboratory density as a base, therelative density of the most dense field sample is only 54 percent, which putsit in the critical range of potential liquefaction. Any sudden reduction invoid ratio due to a shock or shifting of the pond could easily set up a "quick"condition resulting in zero shear strength.
As noted in table 1, some of the field densities observed are lower thanthe laboratory minimum density. This is probably due to the excessive waterin the sludge deposit which separates the soil particles and increases thevoid ratio. The laboratory minimum tests are performed on dry material.
TA
BL
E3.
-C
omp
osit
esa
mp
les
rroc
tor
Den
sitv
Det
erm
inat
ion
On
e-D
imen
sion
alC
omor
essi
onT
ests
Op
tim
um
Gra
inS
ize
Per
cen
tV
erti
cal
Drill
Max
imu
mm
oist
ure
Min
imu
mEffective
Coefficient
Dry
Wat
erof
applied
Con
stra
ined
Earth
You
ng
ts
Atrerbere
Lim
its
Site
hole
den
sity
,co
nte
nt,
den
sity
,si
ze,
ofSpecific
den
sity
,co
nte
nt,
nat
ura
lsrress'
modulus,2
pre
ssu
reP
oiss
on's
lmodu1us,5Liquid
Plasticity
No.
No.
pcf
per
cen
tpcf
Du
nif
orm
ity
grav
ity
pcf
per
cen
tdry
psi
psi
atre
st3
rae-to''
psi
limit
index
10d
ensi
ty
WDH-1
66.4
27.8
44.8
.00048
11.67
1.61
53.0
55.4
101.3
00.0
00
0.0
41.7
8.7
54.5
104.2
25898.2
1.00
.500
.055.6
106.3
501,066.1
1.00
.500
.056.8
108.6
751,131.8
1.00
.500
.058.1
111.1
100
1,167.3
.992
.498
13.1
WDH-2
--
-.00078
10.26
1.60
49.9
53.4
96.1
0.0
00
.038.0
2.7
53.6
103.3
25353.0
.96
.490
21.0
55.3
106.6
50493.9
.98
.495
14.8
57.0
109.8
75580.2
.973
.493
23.1
59.4
114.4
100
606.6
.937
.484
56.2
BDH-1
70.4
18.0
50.0
.006
58.33
1.58
61.5
35.0
117.1
0.0
00
.034.3
064.0
121.9
25678.7
1.00
.5.0
64.4
122.7
501,183.9
1.00
.5.0
64.6
123.0
751,621.0
.997
.499
8.1
65.0
123.8
100
1,960.8
.990
.497
29.4
BDH-2
--
-.000349
9.17
1.87
51.1
60.6
97.3
0.0
00
.051.1
13.1
53.4
101.7
25566.0
.980
.495
16.9
54.1
103.0
50863.6
.990
.497
12.9
54.9
104.6
801,115.8
.994
.498
10.4
55.0
104.8
100
1,357.5
.990
.497
20.3
°""v
erti
cal
app
lied
stre
ss.
ii=
con
stra
ined
mod
ulu
s:::
0v/v
erti
cal
def
orm
atio
n(E
v)·
Ko=
eart
hp
ress
ure
atre
st=
late
ral
hor
izon
tal
stre
ss(o
h)
lov.
v=Poisson's
ratio
=K/(1+K).
E=Young'smodulus
=M~1-v-2e2)/(1-v).
Das
hes
ind
icat
ete
stw
asn
otru
n.
18
Because of the apparent substantial percentages of coal in the wastematerials, regular coal proximate and ultimate analyses were performed, andthe results are tabulated in table 4. The ash, volatile matter, and fixedcarbon percentages obtained by the proximate analysis define the amount ofcombustible material in the refuse, while the calorific value defines th~ rankof the coal. The ultimate analysis describes the elemental composition of thecoal portion and the percent ash.
TABLE 4. - Standard coal analyses
SamoleBDH-l1 WDH-ll Average Average
red dog2 3coarseProximate analysis:
In situ moisture ........... percent .. 35.0 55.4 7.1 7.4Moisture free:
Volatile matter ............ do ..... 22.1 22.1 6.8 15.8Fixed carbon ............... do ..... 52.4 45.6 3.4 29.0Ash ........... " ........... do ..... 25.5 32.3 89.8 55.2Heat content .............. Btu/lb .. 10,690.0 9,600.0 597.0 5,944.0
Moisture and ash free:Volatile matter .......... percent .. 29.7 32.6 70.0 36.6Fixed carbon ............... do ..... 70.3 67.4 30.0 63.4Heat content. ............. Btu/lb .. 14,340.0 14,180.0 4,856.0 13,102.0
Ultimate analysis, percent:Moisture free:
Hydrogen .......................... 3.6 3.3 .5 2.2Carbon ............................ 62.3 56.1 4.7 35.2Nitrogen .......................... 1.0 .8 .1 .6Oxygen ............................ 6.8 7.0 3.4 5.7Sulfur ............................ .8 .5 1.5 1.1Ash ............................... 25.5 32.3 89.8 55.2
Moisture and ash free:Hydrogen .......................... 4.9 4.8 5.1 5.1Carbon ............................ 83.6 82.8 58.4 77.7Nitrogen .......................... 1.3 1.2 .9 1.3Oxygen ............................ 9.2 10.5 25.6 13.3Sulfur ............................ 1.0 .7 10.0 2.6
lComposite of sludge from drill hole.2Composite of burned coarse coal waste from prior sampling program.3Composite of coarse coal waste from prior sampling program.
A chemical analysis was run on the ash left after burning the refuse. Bystudying the composition of the ash, any significant high percentages of com-pounds can be easily identified. This analysis was made to determine if thereare any useful recoverable elements in such an abundant source of "rawmaterial." Table 5 lists the composition of the various samples.
19
TABLE 5. - Chemical composition of ash
Sample SiO:a FeaOs rro, Al:aOs CaO NaaO SOs K:aO MgO Lost onfusion
BDH-l ............ 56.8 7.9 1.2 25.2 1.4 0.2 1.2 3.7 1.3 0.6WDH-l ............ 53.2 5.4 1.0 26.6 3.2 .5 2.8 4.3 1.9 .6Average red dog .. 60.9 8.1 1.3 22.9 .6 .3 .7 3.7 1.0 .3AveraQ:e coarse ... 59.2 7.2 1.2 22.6 2.2 .4 1.8 4.0 1.3 .8
X-ray diffraction of the refuse identifies major, minor, and trace miner-als. These data point out the dominant characteristics of the refuse materialand are listed in table 6.
TABLE 6. - X-ray diffraction analysis of coal refuse
Sample Quartz Illite Kaolin- Cal- Feld- Gyp- Hetalite Mul- Cristo-ite cite soar sum lite balite
BDH-ll ........... M m m - - - - - -WDH-l1
.....••.•.. M t m t t - - - -Average red dot· M - - - - m m m tAveraQ:e coarse .. M m m t t - - - -M = major mineral, mlComposite of sludge:aComposite of burned3Composite of coarse
minor mineral, t = trace mineral, - = undetected.from drill hole.coarse coal waste from prior sampling program.coal waste from prior sampling program.
In addition to X-ray diffraction, the ash wasgraphic analysis to identify the elements present.table 7, can be correlated with the results of thediffraction of the ash.
also examined by spectro-These data, listed in
chemical analysis and X-ray
TABLE 7. - Spectrographic analysis of coal ash
Site AQ: Al Be Ca Co Cr 'Cu Fe Ga K Mg Mn Na Ni Pb Sc Si Ti V y ZrBDH-l1 .••..... F A F C E E E B E B B D C D D E A C D E EWDH-l1 .••....• - A F B E E E B E B B D C D D E A C D E E1CompositeNOTE.--A
BCDEF
of sludge from drill hole.Probably >10 percent.Probably 1-10 percent.Probably 0.1-1 percent.Probably 0.01-0.1 percent.Probably 0.001-0.01 percent.Probably 0.0001-0.001 percent.Undetected.
CONCLUSIONS AND RECOMMENDATIONS
The physical properties and field conditions of coal sludge combine tomake deposits of this material unstable. The extremely fine size of the mate-rial plus the rather well graded grain sizes make the permeability very slow.
20
Consequently, the material acts as a barrier, impounding water, and if satu-rated, it is extremely difficult to drain. This characteristic of coal sludgeallows waste piles to become dangerous. It is generally accepted that if afine-grained saturated sand has a relative density less than 60 percent, itmay liquefy when subjected to sudden shock or reorientation of particles.Since most sludge is transported as a slurry from spigots, deposits occurwhich could be on the verge of liquefaction. The slow settling characteris-tics of the low-specific-gravity particles are conducive to loose or honey-combed structures of high void ratio with high degree of saturation.
The shear strength of sludge as determined by drained direct shear wasvery similar to the coarse coal waste, as could be expected. The results ofsaturated undrained triaxial shear tests indicate that in this condition,which may be more representative of field conditions, the sludge has verylittle strength. It is quite apparent that if a sudden failure due to a slideor shock were to occur, the sludge would not contribute anything to theresisting forces.
Coal sludge comprises approximately 25 to 30 percent ash when dried, butstill yields about 10,000 Btu per pound, which places it in the subbituminouscoal range. Since this material is a prime liability in waste embankments,utilization as a fuel would solve a hazard problem. Even if it were amarginalproduct, elimination of legal disposal problems may make utilization econom-ically feasible. Some companies are currently reclaiming coal from sludgeponds by minidredge machines. Recovery is about 40 tons of coal per hour.
The objection to high-ash coal is based upon fouling problems, erosion,decreased heat conduction, and corrosion of furnaces.s New developments infurnace design have resulted in units that can handle 30-percent ash materialwith little trouble, and projections are that furnaces will soon take coalsapproaching 50 percent ash.
The ash itself could very well be a valuable byproduct with its high alu-mina content. It has been reported that in Britain, 1 ton of alumina wasobtained from 10 to 12 tons of ash.7 8 A comparison of bauxite, the principalalumina ore, and coal waste ash follows:
Bauxite.(percent)
Alz03.... 50 to 60SiOz' . . . . 2 to 20FeZ03• • • • 1 to 25'TiOz. . . . . 1 to 3Other.... e)1Not determined.
Coal waste ash(approx. percent)
2560
7e)
6Reference 4, pp. 820-891.7Reference 4, p. 1098."Coal ash produced from burning U.S. coal waste average about the same percent
Alz03
as ash from British coal and, therefore, should contain the sameamount of alumina.
21
Coal Age magazine has quoted Alcoa as privately estimating that aluminafrom coal wastes could be produced on a commercial scale cheaper than thedelivered cost of alumina produced from high-grade bauxite from outside theUnited States (1). It was also stated that current technology makes thisrecovery ''matter of fact."
It appears that refuse materials could possibly be used as a supply ofheat for the production of alumina, and the ash from this burning would be asource of feed ore for alumina. Once the alumina was extracted, the new mate-rial would be high in Si02 and would very likely be a suitable constructionmaterial.
22
REFERENCES
1. Busch, R. A., R. R. Backer, and L. A. Atkins. Physical Property Data onCoal Waste Embankment Materials. BuMines RI 7964, 1974, 142 pp.
2. Coal Age. March 1974, p. 146.
3. Lambe, W. T. Soil Testing for Engineers. John Wiley & Sons, Inc., NewYork, 1967, p. 88.
4. Lowry, H. H. Chemistry of Coal Utilization, Supplementary Volume. JohnWiley & Sons, Inc., New York, 1963, 1142 pp.
5. Nicholson, D. E., and R. A. Busch. Earth Pressure at Rest and One-Dimensional Compression in Mine Hydraulic Backfills. BuMines RI 7198,1968, 40 pp.
6. Tieman, John W. Chemistry of Coal, Elements of Practical Coal Mining.Port City Press, Inc., Baltimore, Md., 1973, p. 40.
7. U.S. Bureau of Mines. Methods of Analyzing and Testing Coal and Coke.BuMines Bull. 638, 1967, 82 pp.
APPE
NDIX
.--D
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MS FORT~AN (4.2) / MSOSPROGRAM DIRSHFAR
CC
COMMON PI:F.K(2C:;),PLOAD (?S) 'IlLT (25) .I'LOAD (215) 'HIl.J~ (2) 'T~J1IM~(2) ,
1 TEST(3),KNTP,KNTUr)JI>1EN~ION A(1},75), TEsTER1(5), TI':C:;TFR2(5), TTMI:(7S)
c
CINTEGER TESTERl, TESTEP2, TfST
cR~AL MOIST, MOISTURE, ~IORMtNIT, MOIc:;TA
ccCCCCCCCCCCCCCC
KNTU= NUMBER OF DATA SETS Uc:;tl\lGULTIMATE FOR PLOTTING.KNTp= NUMBER OF DATA SETS UStNG PEAK FOR PLOTTING.
N = NUMBER OF POINTe:; IN EACH SETTEST(ll=
1 ..• PL~f ENTIRE GRApHo - PLO AXIS AND POINTS ONLYTEST(2)=
1 ... DROP PEAK vAllIE:o - KEEP PEAK VALUE
TE5T(3)=1 "'_DROP ULTIMATE VALUEo - KEEP ULTIMATE VALUE
2 CONTINUEKl\JTU = 0KNTP=ONJUMP = 0
ccc
READ HEADING AND INITIAL NOQMAL DIAL REAotNG1 REAO(60'600) TEST'TNUM'OATE'TESTERl'TESTER2'RINGN'MCAP
IF (f-DFCKF (60) .EQ. 1) GO TO 999REAO(60,602) MOIST,WETWT,T~ICK.AREA,PSI,GRAV, MOISTA
CCC
SAVE FIRST TEST NUMBER FOR PLOT LABEL.
c
IF ( NJUMP .EQ. 1 ) GO TO 4TNUMF(l) = TNUM(I)TNUMF(2) = TNUM(Z)NJUMP = 1
4 READ(60,604) A(I,I), A(I,2), NORMINITN=t)
5 "'=N+lccc
READ DATAREAO(60'604) TIME(N),IF ( ITRIG .EQ. 4H
A(2'N)' 1\(4.N)' 1\(6.N)' !TRIG) GO TO '5
c
27
28
MS FORTRAN 14.2) 1 MSOS 09/24174 PAGE: 002
CC
ccC
CONSOL = 0.0IF I NORMINIT .EQ. 0.0 ) GO TO toCONSOl = NORMINIT-A(4,,)
CALCULATE INITIAL VALUES10 ACCUM = 0.0
APPLOAD = AREA ~ PSIRADIUS:SQRTIAREA/3.141;9)ARIA = CONTACTIACCUM,RAOIUS)SAMVOl = AREA ~ THICK I 1728.wETWT = wETWT * .0022DENwET = wETWTI SAMVOlOENDRY=OENWET/ll +MOIST)DRYWT = DENDRY * SAMVOlCONOEN = DRyWT 1 I lT~ICK - CONSOLI * AREA)CONDEN = CONDEN * 1728•MOISTURE = MOIST*tOoVOLCC = SAMVOl * 1728.* 16.387064vs = DRYWT * 453.6 1 GRAVVOIO=IVOlCC·VS)/VSPOR = VOIDI II. + VOID) * 100.NCAp=1000IF I MCAP .EQ. 4H500 ) NCAP = soo~~~~gt~:~~::~~g~o)lN~~~p==l~gooSATURATE = I (MOISTA * GRAV)I VOID) * 100·IF I SATURATE ,GT. 100. ) SATURATe: = 100•MOISTA = MOISTA * 100.IF l MOISTA tEQ. 0·0 ) SATURATE = 0.0
CCC
WRITE HEADINGWRITEI61'700) TNUM'DATE'TESTERl'TESTER2WRITEI61,702) AREA,DRYWT,DENDRYWRITEI61,704) THICK,wETWT,OENWETWRITEI61'706) SAMVOl'GRAV'MOISTURF.WRITEI61,70B) CONSOL,RrNGN. CONoENWRITE 161, 710) POR, MCApWRITE 161'712) VOID' APPLOAD' SATURATEWRITEl61,713) MOISTA
SET FIRST ROW OF OUTPUT IN TARLESUBTRACT INITI~L CONSOLIDATION TO GET ACTUAL THICKNESS AT TIMFOF DATA READINGS.
CCCCCC THICK = THICK - CONSOl
THICKA = THICKAI3,1l=0.OAlS,l)=CONSOlA(7,1)=STRESSlAI6,1).NCAPI
29
09/24/74 PAGE 003
~C~'11=ACA'11/AP~LOiDC til = C7tlll RIAC10'I) = C APEA * THIrK ~ 16'3R7"64 - VSll VSACll,11 = AC10,111 (1. + AC10,1) I •• 100.c
CC
CALCULATE DATA IN TABLE
00 50 K = 2'NAC3,,0 = A(2'K) - A(2'K-llACCUM = 'CCUM + A(3,K)AC"5,K) = AC4,Kl - A(4'K-1)A(7'K) = STRESSCAC6'K), NeAp)ACg,K) = AC7,K) / APPLoADAPIA = CONTACT CACCUM. RADIUSAc9'Kl = AC7'K) I AfnlT~ICK = THICK + ACS,K)AC10,Kl = C APEA ~ THTrK * 16.3A7n64 - VS)I VSAC11,K) = AC10,K) / (1. + AI10,K» * 100.
50 CONTINUECCC
WRITE OUT RESULTS IN TARLE FORM
Kl = 1K2 = '0
60 IF CK2 .GT. N) K2 = NWqITE 161,714)WRITE 161,716)WRITE 161'718)Wi:lITEI61,714)I!\ST = IH*WqITEI61,720) IIAST, I = 1,131)WRITE C61,714)
C*"***WRITE 161, 722) C TIMEIJ), IAII,J), T = 2,11), J = I,N)wRITE 161,722) (TIMECJ),(AII,J)tI=2'111,J=Kl,K2)IF (K2 .EQ. N) GO TO 6~Kl = Kl' + 1K2 = K1 + 49WRITE C61,701)
701 FORMAT (lHI)GO TO 60
65 CONTINUE
M-OA1974M-OA1974M-OA1974
M-OA1974M-OA1974M_OA1974M-OA1974M·O~1974M-OA1974M-OA1974M_OA1974
CCC
CALCULATE PEAK = STRESS/AREA -- AT HIGHEST STRESS FORCE/LOAn RATTO.
MIIX = "pE:AK = 0.0DO 7S J = 1, NIF( ACA,J) .LE. PEAK) GO TO 75pE:AK = AI8,J)MIIX = J
75 COt-.jTINUEPEAK = A(7' MAX)NEND = N _ MAx
C
30
MS FORTRAN 14.2) I MSOS 09/24174 PAGE 004P~AKSAT = ( (MOIST * GRAVJ I A/lO,MAX) ) * 100.IF ( PEAKSAT .GT. 100. ) PEAKSAT = Ino.
CCC
CALCULATE ULTIMATE RASED O~ PEAK TERMIF 1 NEND ) 76' 76' 78
76 ULTIMATE = PEAKGO TO 110
78 GO TO /80,80,80,85), N~NDaO ULTIMATE = A(7,N )
GO TO 11085 LN = 0
DO 90 J = 1,NENDM = N" JIF 1 AI7,M) 1 A(7'N ) .GT•• oc;) GO TO 95
90 LN = LN • 195 IF ( LN .Ea. 0 ) GO TO 80SUM = 0.0M = 0DO 100 J = M'LNNZ = N.. M
100 SUM = SUM' A(7,NZ)ULTIMATE = SUM I ILN • 1)
DIVIDE PEAK AND ULTIMATE BY AREA AND SAVE FOR PLOTTINGALSO SET LOAD EQUAL TO PSt READING AND SAVE FOR PLOTTING
110 PK = PEAK 1 AREAIF ( TEST(Z) .EQ, 1 ) GO TO lISKNTP = KNTP • 1PEEK(I<NTP) = PKPLoADIKNTP) = PSIIIIRtTEI61,7Z6) PKGO TO 120115 WRITEI61.724) PK
120 WRITEC61,731) pEAKSATUT = ULTIMATE 1 AREAIF ( TEST (3) .EQ. 1 ) GO TO iasKNTU = KNTU • 1U!,.TCKNTU)= UTULOADIKNTU) = PSIWRtTE(6lt730) UTGO TO 130
125 WRITEC61,728) UT
CCCC
c130 IFIITRIG .Ea. 4HAA ) GO TO 1
CCALL GRAPHGO TO 2 M·OR1974999 CONTINUE M·OR1974
CC 600 5 ARE INPUT FORMATSC 600 FORMATI3rt' 3A8' 10A4' A7' 2X' 44)
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33
MS fORT~AN (4.2) 1 MSOSFONCTION STRESS ( B,N)IF ( N .EQ. 5"0 ) GO TO So~~ :NN·:~~.l~g~OG~ ~g ~go15o
09/24174 PAGi=:001
CC COMPUTATIONS FOR 1000-POUND RtNGC
STRESS = 5.368421 + 25562.348 * 8RF.TURN
CC COMPUTATION FOR 500-POUND RINGCC 50 STRESS = 8920.0 * B
SO STRESS = 9010.0 * BRETURN
CHANGED TO FOLLOWING CARD ON 18 JAN 72
cC COMPUTATION fOR 100-POUND RINGC
100 STRESS = 26638.302*8**3 + 185.42126*8**2 + 1469.1632*8 + 2.0601RETURN
ccC
COMPUTATION FOR 2500-POUND RING.150 STRESS = 63000. * B
RI!:TURNEND
STATEMENT NUMSERS
So 00060
6JUN72
100 00064 150 00105EXTERNAL REFERENCESSYSTEM EXTERNALS ONLY
FORTRAN DIAGNOSTIC RESULTS FOR STRESSCOMpILED LENGTHS OF STRESS
NO ERRORS - p 00147 C 00000 D 0000"
34
MS FORTRAN 14.2) 1 MSOS 09/24174 PAGF: 001
FUNCrtON CONTACT lD,R)S!NTERM = 2 0 R 0 R 0 ASINe O/12.*R) )SQTERM = 0/2. * SQRT e 4. 0 R 0 R • n * 0 )CONTACT = 3.14159 * R * R • e SQTrRM • SINTERMRnURNEND
PROGRAM VARIABLES00004 R SINTERM 00011 R
EXTERNAL REFERENCESASIN SQRT
FORTRAN DIAGNOSTIC RESULTS FOR cONTACT
COMPILED LENGTHS OF CONTACT • PNO F:RRORS
00130 c 00000 D 00000
MS FORTRAN 14.2) 1 MSOS 09/24174 PAGE 001
FUNCTION ASINlX)C ••••• THIS PROGRAM COMPUTES THE ARCSIN FUNCTION USING THE ALGORYTHEMC ••••• ON PAGE 163 OF APPROXI~ATIONS FOR DIGJTAL COMPUTERS BY HASTINGSC ••••• 1q55 PRINSTON UNIVERSITY PRESS.
DIMENSION A(8)OATAlA= •• 0012624911,.0066100901, •• 0170881256,.0308918B10,1 ··0501743046,·08891B9874,··2145988016,1·5101963050)ASIN = 0.0D0 25 J = 1, 8ASIN = ASIN * X • AeJ)
25 CONTINUEASIN = 1.570796326 • SQRT(l.X) * ASINRETURNEND
PROGRAM VARIABLES
00002 R A 00024 I J
STATEMENT NUMBERS25 00056
EXTERNAL REFERENCESSQRT
FORTRAN DIAGNOSTIC RESULTS FOR ASIN
COMPILED LENGTHS OF ASIN - P 00130 C 00000 0NO ERRORS
00000
MS FORTRAN 14.2) / MSOSSU8ROUTINE GRApH
cc COMMON ypI2S)'YPLlZS)'YUlZS)'YULI2S)'TNUMI2)'TNUMFI2)'TESTI3)'
1 KNTP,KNTUC
cINTEGER TESTDIMENSION XI2S)'YlZS),IBUFlSO),IWORDI6)
cccccccCCCCCCCCCC
YP = PEAK STRESSESYPL = CORRESPONOING LOADS
KNTP = NUMBER OF PEAKS TO PLOTTEDYU = ULTIMATE STRESSES
YUL = CORRESPONDINr, LOADSKNTU = NUMBER OF ULTIMATES TO BE PLOTTED
TEST I1) =1 • DRAW ENTIRE PLOT.o - PLOT AXyS AND POINTS ONLY.
KOUNT = 0 IMPLIES PEAKSKOUNT = I IMPLIES ULTIMATES
GET X' Y MAXIMUM FOR PLOTKOUNT = 0MN = YPLlt<NTP) / 10•• 1.XMAX = ~N * 10yMAX = 0 0[')0 10 K=I,KNTPIFlYPll<) .LE. YMAX) GO TO 10YMAX :I: YPlK)
10 CONTINUEMN = yMAX / 10•• 1.yMAX = MN * 10
CC SCL = SCALE FACTOR -- INCHES/USERS UNITCC*****yMAX=SO.C*****SCL = 9./ YMAX
XSC :I: 12.86/XMAXYSC = q.O/YMAXIF IIYMAXOXSC) .GT. 9.0) GO TO 12SCL = XSCyMAX = 9.0/XSC • 0·5MN = YMAX/10•OYMAX = MN*10GO TO 15
12 SCL = YSCXMAX = 12.86/ySC • 0.5MN = XMAX/I0·0XMAX = MN*1015 CONTINUE
35
PAGF: 001
M-OA1974M-OA1974M-Oq1974M"'OAl'h4M-OA1974M_OA1974M_OA,974M"Ol:l1974M ••OA1974M_OA,974M-OA1974M_OPICl74M_OAlcH4
36
MS FORTRAN 14.?1 1 r-1S0S
ctlll PLOTS l If:lUF,50, 7CAll PLOTC3·0.-12·0'-31CALL PLOTlc.a.9.5,-3)CALL FACTORl.70)
09/24174 PAGF 002 1974
cC THPU 2~0 -- PLoTS V AXTS AN~ NUMBERS IT.C
250
FPN = 0.0ChLL NUM8EPco.a,.75,.2],FPN.270 •• 01CALL PLOTCO·O,·14,3)CALL PLOTlo.a,0.0,2)MN = VMAXLTK = °STEP = 0.01)0 260 K = 1,MNI.T K = L T t< + 1STEP = STEP + 1 * SCLCALL PLOTCSTfP,0.0,21IF l LTt< .EQ. 51 GO TO 250IF l LTK .EO' 10 ) GO TO 2~5CALL PLOTlSTEP,.07,2)CALL PLOTlSTEp,O.o,Z)GO TO 260COPlJTINUECALL PLOTCSTEP •• 14,Z)CALL PLOTlSTEp,0.O,2)GO TO 260FPN = FPN + 10.C/.ILLNIJM8ERCSTEP,. 75,.2ltFP~I,270 •• 01CALL PLOTlSTEP"14,3)CALL PLOTlSTEP,O.O,Z)tTK = I)C()NTIN11EFPN = 0.0
255
?60CCC
THRU 2~O DRAWS X AXIS AND NUMBERS IT.
CALL NUM~ERl-.4'.21'.21'FPN'Z10.'11CALL PLOTlO.O,.14,3)CALL PlOTlO.O,O·O,ZIMN = XMAXLTK = (\STEP = 0.000 280 K = ltMNLTK = LTK + 1STEP = STEP - 1 * SCLCALL PLOTlO.O,STEP,Z)IF l LTK .EQ. 5) GO TO 270IF l LTK .EQ· 10) GO TO Z75CALL PLOTl-.07,STEP,Z)CALL PLOTlO.O,STEp,Z)GO TO 280CONTINUF.CALL PLOTl-.14.STEP,Z)
37
MS FORTPAN C4.2) 1 MSOS 09/24114 PAGr:: 003CALL PLOTCO.0·STEP'2)ria TO 280
?75 FPN = FPN + 10.8~CK = STEP + .21CALL NUMBERC-.40,RACK,,21,FPN.270.,0)CALL PLOTC-.14,STEP,3)CALL PLOTCO.O,STEP,2)LTK=O280 CONTINUE
CC PUT DATA POINTS ON GRAPHr
C
YSYMROL = 1100 40 KK = 1, KNTPypT = YPCKK) 0 SCLXPT = YPLCKK) 0 SCLXPT = XPT 0C-l)
40 CALL SYMBOLC ypT, XpT, '12, ISYMBOL,270., -1)IF C TF.:ST(1).E"Q. 1 ) GO TO 60
45 CALL PLOT CO.O, 0,0, 3)45 CONTINUE
WRITE C59,810)pAusE 1GO To 420
46 CIJNTINUEISYMBOl = 2DO So KK = 1, KNTUXpT = YULCKK) 0 SCLyPT = YUCKK) * SCL
50 CALL SYMBOLCXPT,YPT,.I?,ISYM80L,O.O,-I)TEST TO SEE IF REST OF GRAPH IS To BE PLOTTED
CCC IFCTESTCl) .NE. 1) 55'206
55 XPT = XMAx * SCL + 6.r,ALL PLOT CXPT,O.O,3)RETURf\J
cr.c
LABEL Y AXIS
C60 ENCODEC23,800.IWORD)
CALL SYMBOL C-l.5,1.25,.28.IWORD,QO.0,23)CALL SYMBOL Cl.25,1.5 ••2A,IWORO,0.0.23)
CCC
LAI:3ELX AXISENCODE C23'AOl.IWORO)CALL SYMBOL C1.5,-.98,.28,IWORO,O.0,?3)CALL SYMBOL C-.98.-3'5,·28,tWORD,210.,23)
c
CCC
SET LOADS AND STRESSES TN ARRAYS X AND Y FOR CURVf FITTINA.DO 205 K=I'KNTPYCK) = YPCK)
38
09/24/74 pAGE 004MS FORTRAN (4.21 I MSOS
ccc
220CCC
CCC
205 X (KI = YPL (KINPLTP = KNTPGO TO 209DO 207 K=1.KNTUY (10 = YU (K IXIKI = YUL(KINPLTP = KNTU
206207
DETERMINE STRAIGHT LINE EQUATION THRU DATA PTS.209 'lAVE = 0.0
yAVE = 0.0DO 210 K = 1,NPLTpXhvE = XAVE • X(KI/NPLTPyAVE = yAVE • y(KI/NPLTPXY = 0'0oENOM = 0.000 220 K = 1,NPLTPxy = Xy + X(KI * Y(KIOF.NOM = DENOM • ( X(KI ~ XAVE 1**2
210
A = Y INTERCEPT B = SLOPEB = ( XY - NPLTP * XAVE * YAVE II OENOMA = yAVE _ 8 * XAVE
THRU 290 PLOT STRAIGHT LINE EQUATION DETERMINED FOR PTS.MN = XMAXyPT = A * SCLCALL PLOT(YPT.O.O,31XPT • 0.0DO 290 K = 1,MNXPT = XPT - 1 * SCLYpT = YpT • 8 * 5CL
C*****IF ( YPT .GT. YMAX I GO TO 295IF (YPT .GT. YMAX*SCLI GO TO 295
290 CALL PLOT(YpT,XPT.21CCC
LABEL PHI ANGLE ANn COHESION AND PUT ON RIGHT EDGE OF GRAPH295 XPT = XMAX * SCL • .5
yPOINT = 9.0IF(KOlJNT .EQ. 1) GO To 415F.NCOOE(2B,804,IWORO) TNUMFCALL SYM OL(9.0,-1.S,.28,IWORD,270.,28)ENCOOE(4,805,IWORD)CALL SYMBOL(S.5,-1.S,.28,IWORO,270.,41ENCODE(19,806,IWORDI TNUMCALL SYMBOL(8.0,-1·5"2A,IWORO,270.,191ENcOOE(8,807,IWORDICALL SYMROL(7.5,-1.5,.2S,IWORD,270.,AIGO TO 402yPOINT • YPOINT - 3.5415
MSFO
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/MS
OS09
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74
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267
c
