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Open pit mine waste dump area design based on stability principles

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Open Pit Mine Waste Dump Area Design based on Stability
Principles

Istanbul Technical University, Mining Engineering Department, Istanbul

M. Zengin, D. Arslan, Y. Tuncel, Z. Baz

ÖZET
deki
. lan
,

. Sahada henüz döküm faaliyetleri

etkileyen jeoteknik parametrelerin
büyüklükleri, geri-ana Bu uygulama,
–
tayin

Anahtar Kelimeler: -denge

yöntemi

ABSTRACT The main purpose of this study is to design waste dump area for an open pit
copper mine owned by Asya Maden Inc. located in Hanonu, Kastamonu. Design studies can
be carried out based on slope stability principles as per the design works of open pit bench and
overall slope angle. Therefore, geotechnical properties of dump material as well as ground
must be primarily determined. Hydrogeology as well as seismicity which have important
effect on the stability should be also part of stability works. The values of geotechnical
parameters for dump material controlled the stability of dump site determined from the back
analysis method from different designs, because of the unavailability of dump material since
dumping is not initiated at present. This application iterated for the other designs having
different overall slope angles. As a result of the stability analyses based on limit equilibrium
methods, the values of geotechnical parameters making the design stabile are determined.
After this stage, relations among geotechnical properties and overall slope angle of the dump
site as well as dump site capacity are presented.

Keywords: Slope stability analysis, waste dump, geotechnical properties, limit equilibrium
method

570
1 INTRODUCTION Geology of the area is reported in Okay et
External waste dump area design is an al. (2006). A geological cross-section of the
important design issue of open pit mine study area is given in Figure 2, while a cross-
design and planning concept. The aim of this section prepared by the Asya Maden
study is to design the waste dump area for an Geological Department is also given in
open pit mine located in the Hanönü village Figure 3 to show the main geological
of Kastamonu town. The copper mine will be formations in open pit mine and dump site.
operated by open-pit mining method, and the
overburden material will be dumped to the 3 GEOTECHNICAL PROPERTIES OF
site called as Corakoglu. The mine will be DUMP AND BASE GROUND
operated by Asya Maden Inc. Dump site area Material properties are one of the important
borders, digital topographical map, and input for slope stability investigations.
information for the geology of the site were Cohesion (c), internal friction angle ( ), and
provided by the Company. Different designs unit volume weight ( ) are geotechnical
were carried out to determine the relations parameters used in limit equilibrium analyses
between overall slope angle of the dump site of slope stability researches. In this case
and dump site capacity. Overall slope angle study, mainly two distinct material are
is an output of the stability analyses carried defined. The first one is the dump material
out for the dump site. Stability analyses, for while the other one is called as base ground.
this case study, were determined based on
limit equilibrium methods. The required
main geotechnical data for limit equilibrium
stability analysis are cohesion, internal
friction angle, and unit volume weight for
each material at the site. During the design
stage in this engineering project, it is not
possible to obtain the actual values for
geotechnical properties for dump material
due to the unavailability of material at site.
However, it needs to design the area of dump
site according to the engineering point of
view. In this situation, back analyses for
stability investigations can be usable to
understand the required values for
geotechnical properties of dump material
based on a certain limit of factor of safety Figure 1. Location map and satellite image
(FoS). The details of these investigations as from Google Earth for the study area (IMC
well as presenting a procedure for the design Technical Report, 2013).
studies of dump site during the planning
phase of a mining project are the main
outputs of this research. The results proposed
in this study are a part of a project completed
by ITU Mining Engineering Department in
2014 (ITU Technical Report, 2014).

2 STUDY AREA AND GEOLOGY OF Figure 2. Cross-section for the site (Okay
THE SITE et.al., 2006).
The copper mine deposit is located in
northern Turkey close to the Hanönü town in
the Kastamonu province (Fig.1).
571

Figure 3. Geological cross-section of open
pit and dump site.
3.1 Dump Material
The required geotechnical data should be
determined by laboratory experiments on the
samples taken from the site as well as in-situ
tests. In this study, the excavation for
overburden material has not been started,
therefore it is not possible to obtain dump
samples from the site. The unavailability of
dump samples led to use the previous rock
mechanics studies for open pit mine planning
(ITU Technical Report, 2013). Waste dump
material will be produced from the
excavation of overburden material during the
open pit mining activities. The original rock
is mostly consist of mixed schist (MSCH),
green schist (GSCH), and schist (SCH) based
on the lithology of the open pit site geology.
The values of geotechnical parameters for
dump material are predicted from in-situ
rock due to the unavailability of material at
site. Triaxial compressive strength tests as
well as direct shear strength tests were
carried out in the existing rock mechanics
project. The values of cohesion and friction
angles are listed in Table 1. In order to make
the most possible safe design, minimum
values for geotechnical parameters are
selected as design parameters which are 50
kPa for cohesion and 23.310 for friction
angle.

Table 1. Material strength parameters for rock fill (ITU Technical Report, 2013).
Triaxial Compression Direct Shear Test -
Tests Residual
Material Stat.
Cohesion Friction Cohesion Friction
(kPa) Angle (0) (kPa) Angle (0)
Avg 2,270 53 220 23.31
Mixed Schist MSCH
Min. 850 42 - -
Avg 1,750 62 50 30.67
Green Schist GSCH
Min. 730 60 - -
Schist SCH Avg 410 48 100 25.55
Design Parameters 50 23.31

3.2 Base Ground Corakoglu dump area consists of sandstone,

Strength properties of the ground which
waste will be dumped on, are also required
for the stability investigations. The study
carried out to determine geological and
geotechnical properties for the site by DMT
Corporation is used to obtain ground strength
data (DMT Technical Report, 2013). The
geology of the study area show that
mudstone, and sediments as well as volcanic
members. Table 2 is prepared from DMT
technical report to predict the strength
parameters for the base ground. It should be
noted that prior to dumping, the required
strength tests must be carried out for the
justification of the predictions for the ground
geotechnical properties, as well.

572
 Table 2. Natural ground geotechnical properties (DMT Technical Report, 2013).
Sr # Material Cohesion (kPa)
1 Sandstone
2 Mudstone
3 Limestone
Design Parameters
4 BENCH DESIGN
Initial study for the design of waste dump
area is to decide the geometry of individual
benches. A bench can be designed by
selecting the value for height, width, and the
slope angle (Fig. 4). First, the angle of the
slope must be decided according to the type
of the dump material, if there is no available
site application. Common approaches can be
used to decide the slope angle based on
literature. Added to that, basic friction angle
from site experiments or friction angle values
from shear strength parameters can be also
used to select the most proper slope angle.
Figure 4. Slope geometry.
According to the classification proposed by
Levy (2011), slope ratio between height and
length can be taken as ¼:1 to ½:1 for dump
material defined as mostly rock. In this
study, several bench designs were considered
and height is 10 m, angle is 600 is selected as
bench design parameters for a safe and
reliable design. The width of the slope is the
only parameter to obtain alternative angles
for overall slopes. In order to obtain different
combinations of overall slope angle, different
values for width are used for the design of
dump site. The alternatives for slope width
that make the designs for a safe overall slope
angle are searched in the next section for the
design of waste dump based on stability
principles.
Friction Angle (0)
300-400 35-45
200-300 25-35
200-300 25-35
200 25
5 DUMP AREA DESIGNS
The size of the licensed area as dump site is
nearly 135 hectares, while projection of the
size is equal nearly 120 hectares. The
elevation of the dump site ranges between
440 m and 630 m. The design of the waste
dump area is carried out by considering slope
stability principles. Limit equilibrium
methods are used to decide the suitability of
the design. Simplified Bishop multiple
analyses are used during stability
investigations due to the characteristic of the
dump material. It is assumed that failure
surface is circular.
As a result of slope stability analysis, a
safety factor (FoS) value is calculated which
is an indicator of stability consists of the
ratio of forces resist the slippage to forces
that cause slippage. When the safety factor
value is 1 (FoS=1), the slope under
investigation is in the limit of stable and
unstable condition, and this condition is
known as “Limit Equilibrium Condition”.
Back analysis is also used to determine
valuable information regarding shear
strength parameters such as cohesion and
internal friction angle along a sliding surface
as well as underground water conditions. The
information of slope geometry before sliding,
location of sliding surface, and underground
water table level (UGWT) is important to
increase the sensibility of back analysis. Unit
volume weights of the material for the
unstable condition shall be also known for
the analyses.
There are numerous researches to define
factor of safety in open pit mining as well as
waste dump deposit. Huang (1983) proposed
selection of safety factor in open pit mining.
In this study, FoS takes as 1.30 without the
effect of earthquake as the table from
D’Appolonia Cons. Engnrs. Inc.
573
 Due to the absence of the actual
geotechnical data for natural ground and
waste dump material, different alternatives
for waste dump have been investigated based
on different overall slope angle. The purpose
of this study is to design the dump in a way
that the amount of dumped material is not
less than waste which will be excavated from
open pit.
For the first design of the dump site, all
waste material is considered to be dumped at
the site and resulting overall slope angle is
found. After determining the overall slope
angle, the required strength parameters for
dump material were calculated by using
slope stability back analysis techniques.
Back analyses can also be performed to
obtain critical material strength parameters
from known or assumed failure surface.
Hence, it is possible to determine required
cohesion and friction angle of waste dump
material for the 1st design that is used to
dump all waste material to the waste dump
area.
Second, the reliable overall slope angle is
determined where FoS is 1.30 after stability
analyses. The predicted strength parameters
for dump material given in Table 1 are used
Figure 5. Design procedures based on stability principles in this project.
to for the 2nd design. Hence, it is possible to
determine the slope width as well as the
geometry of the waste dump. After design
studies, the volume of total waste material
could be dumped for the 2nd design is
calculated.
When the overall slope angles for 1st and
nd
2 designs are determined, those are
maximum and minimum values successively,
3 more designs were carried out to determine
the relation between overall slope angle and
total dump volume. The following figure
shows the design procedures for the study.
The studies for the waste dump area
design as outlined in Figure 5 were carried
out by using an integrated mining and slope
stability software. Micromine is used as
integrated mining software to model existing
topography and to draw the border of the
dump. The designs numbered from 1st to 5th
were also modeled by using Micromine.
Cross-sections from these designs are taken
from the software. Galena as a slope stability
software is used to obtain the results of the
stability analyses. Factor of safety for
designed slopes as well as back analyses for
material strength parameters determination
can be handled by using Galena.
574
In order to avoid the mass presentation of
figures, graphs and cross-sections used in the
design studies, only 1st design outputs are
presented in this study including the results
of the each design in the following table.
In the 1st design, the value of bench width
is selected as 5 m while the other parameters
of the slope geometry is already fixed as 600
for slope angle and 10 m. for slope height.
The design of the dump site is given in
Figure 6 as plan and views. Maximum
Figure 6. 1st - Design, plan and isometric view.
Figure 7. Cross-sections of the dump area.
The outputs of the back analyses studies are
combined in a single graph given in Figure 9
for 4 designs performed as back analyses.
The data obtained from this graph is used to
set up a multiple linear regression model
between cohesion, friction angle, and overall
overall slope angle is calculated as 420 in the
1st design with 143.5 million m3 capacity.
Cross-sections of the dump site can be seen
in Figure 7.
Back analyses were carried out to find the
material strength properties required for
stability of this design. The output of the
back analysis is given in Figure 8.
slope angle (OSA) for FoS=1.30. The
equation determined from the multiple linear
regression analysis is given below has 0.94
correlation coefficient and 1.34 standard
error (Eq.1). This equation may be used to
define overall slope angel after testing dump
material and determining cohesion and
friction angle values.
Figure 8. Back analyses results for 1st -
Design.
OSA = 0.02xc + 0.44x +19.51 (1)
575
 50 5 different designs are constructed for the
40
dump site. The results for the geometry of
dump sites as well as the individual slopes
30 OSA: 42 including the capacities of the damp areas
20 OSA: 38 are outlined in Table 3
10 OSA: 34
OSA: 28
0 .
0 500 1000 1500
Cohesion (kPa)

Figure 9. Results of back analyses from

stability studies.

Table 3. Summary of the design studies.

1st - 2nd - 3rd - 4th -
Sr # Description 5th - Design
Design Design Design Design
1 Overall Slope Angle (0) 42 23 28 38 34
2 Slope Angle (0) 60 60 60 60 60
3 Slope Height (m) 10 10 10 10 10
4 Slope Width (m) 5 17.5 13 7 9
5 Maximum Elevation (m) 890 670 730 830 780
6 Total Damp Volume (million m3) 143.5 37.5 61.5 112.5 88.5

A relationship between overall slope angle correlation coefficient, claims a relation

and total dump volume that can be seen in between overall slope angle and dump
Figure 10 is proposed as a result of these capacity. The following arguments can be
design works. The graph with a very high made from the graph.
160
140
120
100
80
60
40
20 TDV = 5.43xOSA - 90.5 (Mm3)
0
15 20 25 30 35 40 45
0
Overall Slope Angle ( )

Figure 10. Correlation between OSA and total damp volume

After determining the actual material from stability analyses and total dump
strength properties for dump material and volume will be achieved can be easily
ground, overall slope angle can be calculated
576
computed from the equation in the graph
based on the actual overall slop angle values.
6 HYDROGEOLOGY AND
SEISMICITY
6.1 Effect of Water on Stability
The increasing level of underground water
has an adverse effect on the stability of
slopes. The stabilities of the designs
proposed in this study were investigated
under the dry condition of the slopes.
Observation well data is reported in
hydrogeology report for the open pit mine
prepared by Asya Maden Geological
Department. According to this data, there
exists an underground water table from the
ground level between 3.65 m and 79 m.
Average underground water table level is
observed as 29.5 m from the surface (Asya
Maden Technical Report, 2014).
Stability analyses by considering the
underground water table level for 1st -
Design is carried out to model the effect of
underground water on the stability.
In the first stability analysis, underground
water table elevates into the dump material.
The FoS value is calculated as 1.20 which is
below acceptable limit. In the second model,
the rising of the UGWT into dump is
prevented, and UGWT level is hold below
surface. FoS value is calculated as 1.30
which is acceptable for stability.
The results of stability analyses
considering water on stability show the
importance of decreasing the underground
water table level as well as controlling the
surface water. Constructing proper drainage
system to protect the dump against
increasing water table level is important.
6.2 Effect of Earthquake
The effect of earthquake for the stability of
dump slopes must be evaluated again by
using the stability principles due to the
importance of earthquake for Turkey. The
scale of seismicity for Kastamonu Hanönü
region is classified as 3rd degree according to
the map prepared by “Turkish Republic
Prime Ministry Disaster and Emergency
Management Presidency, Earthquake
Department Presidency”
Historical seismicity record map show that
the closest earthquake bigger than magnitude
of 5.0 happened in 1919, 20 km away from
the Hanönü region (Özmen, 2001).
Due to the seismicity degree, magnitude of
the historical earthquakes, and the distance
between the biggest earthquake to the mine
site, earthquake force is taken as 0.15g in this
study.
In order to understand the effect of
earthquake for 1st - Design and 2nd - Design,
stability analyses were performed under
earthquake condition. Cohesion is selected as
150 kPa while friction angle is selected as
400 from the result of back analyses. After
applying the stability analyses, the value of
FoS found as 1.03 that shows the suitability
of the design under the earthquake condition
for the 1st - Design. If FoS>=1.0 under
earthquake condition the design is
considered safe.
2nd - Design stability investigation under
earthquake condition was also performed and
FoS is calculated as 1.00 in this analysis that
is also acceptable under stability concerns.
7 CONCLUSION
Waste dump area design is main purpose of
this study. The most critical problem is
having no actual material strength data for
the dump material. Due to the absence of
material strength properties of dump
material, several different designs were
performed in order to obtain a relation
between overall slope angel and strength
properties of dump material. Back analysis
technique is used to understand value of
cohesion and internal friction angle for a safe
design, based on slope stability principles
having factor of safety value more than 1.30.
As a result of the designs, two valid
equations are determined as a main output of
this research. In the 1st equation overall slope
angle value can be determined from the
cohesion and internal friction angle of dump
material. In the 2nd equation, total dump
capacity of the site can be calculated from
the value of overall slope angle, so total
577
 dump capacity of waste dump deposit area
can be calculated, when the actual strength
parameters of dump material are determined.
The procedure applied in this study for the
design of waste dump deposit especially
during the planning stage of a mining project
can be applied for similar studies
successfully according to the results of this
study.

ACKNOWLEDGEMENTS
The Authors would like to appreciate the
contributions of Ilbak Group, Asya Maden
Inc. as well as the Managers and Engineers
for their support to the research.

REFERENCES
, 2014. Kastamonu

(in Turkish), 31 p.
DMT Technical Report, 2013. Technical Report -
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Bakacak Hill Mineral Exploration Project
Hanönü, Kastamonu, Turkey.
Huang, Y.H., 1983. Stability Analysis of Earth
Slopes. Van Nostrand Reinhold Comp, New
York.
International Mining Consultants (IMC), Technical
Report, 2013. Feasibility Study Report on the
Kastamonu-Hanönü-Gökirmak Copper Project,
, Report
No: 20634814.
Istanbul Technical University (ITU), Faculty of
Mines, Technical Report, 2014. Kastamonu
Hanönü Copper Mine Waste Dump Design (in
Turkish), 61 p.
Istanbul Technical University (ITU), Faculty of
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mechanical properties of rock materials for
Kastamonu Hanönü Copper Mine (in Turkish),
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