MARBLE WASTE MINIMIZATION Introduction R. K. Bapna * Marble ranks the largest produced natural stone in the world and it accounts for 50% of the world's natural stone production. Around 90% of the world's production of marble comes from India and approx 85% of India's production is received from Rajasthan and almost all mining and processing activities are concentrated around Udaipur, where the proposed study is planned to undertake. The marble mining industry has come up significantly in recent past. Rajasthan has around 4000 marble mines and about 1100 marble gang saws (processing plants). The industry involves Mines, Processing plants, Cutters for the production of tiles for walls and floors, articles, waste reproduction and other ancillary works. The marble mining and the industry as a whole is different from other industries with the very fact that, the marble is a "Dimensional Stone", which means the stone is sold by size not by weight. (In other words in sqm not by tonnes) Since the selling price increases manifolds with size, all the operations involving mining & processing are aimed to get slabs as big as possible. Waste generation The very fact of being dimensional stone marble has contributed to the development of grave environmental problems in the region due to waste generation at different stages of mining and processing operations. The technical, operational and management practices in the industry are less developed and they have also contributed significantly to greater waste generation. The industry is causing two serious problems, which are creating havoc in the region: * B.E. (Mining), F.C.C., Consultant Mining Engineer. (a) Problems owing to slurry produced in different operations, and (b) Dumping of small boulders which are not economic to cut into slabs. The magnitude of the problem can be seen in the following table: Finished marble produced (Saleable product) Marble waste generated - Mining waste (including small blocks of lower revenue, boulders, cutting slurry) - Processing waste (including broken tiles, dressing waste, cutting slurry) - Polishing and transportation Waste Total Waste Total excavated marble 30% 50% 15% 05% 70% 100% From the above table it can be adjudged that recovery is only 30%, while 70% of excavated marble go as wastage. Environmental problems due to waste The production of waste shown in the above table are causing following environmental problems: (a) Conservational The valuable national wealth is getting wasted mainly due to lack of management and lack of technology. This waste, if recovered as useful, can change perhaps the entire scenario of the industry. Since it is not impacting directly on the environment the non-conversion of useful mining product is a more grave problem in longer term than other direct problems. (b) Air pollution This is the most direct and hazardous impact of the industry. As it is clear from the table, slurry is produced at almost every operation and its dumping is a great problem. When it gets dried and airborne, it causes air pollution and related problems. (c) Water pollution Like any industry, the marble industry needs water in its different operations for cooling and flushing different discharge. In these operations water gets contaminated. This contamination is considerable and it can be said that water pollution of the region is caused by discharging slurry. (d) Vegetation related problems Due to opencast nature of the mining, devegetation of the area is imminent. Also dried slurry deposited over plants and vegetation hamper their growth. (e) Visual impacts Running mines, abandoned mines, dumping sites, slurry waste sites, deposition of dried slurry over almost every structure in surrounding aeas are a very bad sight. Hills having been excavated and dumps over them are very unaesthetic. (f) Scarcity of the dump sites The production of a large amount of waste needs additional land for its dumping and handling. (g) Accidents due to unscientific dumping There are a number of accidents due to unscientific dumping of mine wast on road and quarry sites. (h) Loss to flora & fauna Already grown trees and bushes have died out and new ones do not grow. Animals have also been deprived of their food and shelter. Measure to remedy problems related to waste Reaching general evaluation of the industry, it is observed that the problems related to waste production in the marble mining and processing and its disposal and reutilization can be circumvented by technical assistance and improved management practices. For this purpose the most useful step can be : (a) Reduction of waste production If waste is reduced a crucial part of the problem is solved; and hence, the methods have to be developed to reduce the waste production in conjunction with its reutilization and rehabilitation. This following are some measures to reduce waste production: Inputs to be made cheaper: The diamond based tools have industrial diamonds in them. There are two types of diamond insertion (Bit, Segment and Beads), Electroplated or Impregnated. The Electroplated type is the most suitable for sawing soft stones and requires less water spray and Impregnated type is suitable for all types of stone with fairly abundant spraying. Therefore, if the selection is made according to the need the cost will be reduced. Improvement in performance: Some of the factors which affect the performance of sawing are (i) Mode of sawing, (ii) blade peripheral speed, (iii) sawing rate, (iv) machine parameter, (v) operator skill, (vi) flushing medium (type & rate), (vii) thrust and (viii) diamond type, size & concentration. For improvement of performance the following aspects of cutting operations are inferred in most of the studies: (i) Optimising the application for particular stone, (ii) Improvement of performance of diamond segments, (iii) Finding substitute of costly segments, (iv) By adding surfactant into coolants and (v) Reducing diamond dropouts. Reduction in production of slurry: For the reduction of the production of slurry, till date sharp and perfect cutting edges were the only measures. Now thin blade technology has been introduced in Italy. Its results are very good and can be used to reduce the production of slurry. (b) Suppression / disposal of waste All efforts should be made to minimize waste. But it is also a fact that some of the waste will be produced. Hence proper suppression and disposal techniques are essential. Not much work has been done yet, apart from giving site for slurry disposal. Yet a moderate advancement has taken place. In other words interfaculty application from Mineral Dressing, has suggested the making of cake of slurry using Filter Press. It has been suggested because 5000,000 tonnes slurry generated annually contains 4000,000 tonnes of water. Hence an effort should be made to get the maximum possible water out of it and slurry be converted in the form of cakes. This can far more easily be disposed. For the purpose a special filter press is designed and plant owners are encouraged to install one. This helps in utilization of water, proper disposal of slurry and lowering the damage to eco-system. Added to this, is the fact that by help of filter press, the solid concentration can be increased from 15 to 18% in slurry and 83 to 87% in cake. (c) Reutilization of marble waste Even by taking measures for minimum waste production the problem is partially solved. Therefore it is -the need of the hour to develop modes of reutilization of waste. The marble slurry is generating in substantial quantity and creating environmental havoc in the region. Thus many scientists and agencies are working on it. Efforts are being made to reutilize slurry for different civil works, since other applications cannot consume such a bulk amount of slurry. (d) Reutilization of marble waste other than slurry There are a number of possibilities for the secondary use of marble lumps. Some of them are: - Value added products: Articles, idols, stairs, monuments etc. are being prepared. Mr. Bhagirath Joshi from Jodhpur has shown a remarkable potential of the segment of the industry. - Marketable Chemicals: There are some of the areas of applications in chemical production by marble waste like: synthetic Calcium Sulphate and Magnesium Sulphate from dolomite waste. - Defluorination of water: Rajeev Gandhi Mission for Water has suggested that serpentine can be used for Defluorination of water. Conclusion In the beginning it has been explained that the marble mining and processing industry in Rajsamand district has assumed a great dimension. But, to our great dismay it is also alarming that as big as 70% of the marble resource goes waste which is not only unprofitable but is also immensely harmful to the environment. Later in the article environmental problems have been discussed and some useful suggestions made with a hope that if they are carried out the problem will be solved to some extent. Acknowledgement I express my deep regards and sincere thanks to Shri B.L. Paliwal, Retd. Vice Principal, Kendriya Vidyalaya, Pratap Nagar, Udaipur for his guidance and help in writing this article. I am also highly grateful to Shri M.S. Paliwal, Mining Engineer, DMG, Amet for his technical guidance and valuable suggestion in writing this article. Refrences Agarwal R.K. ; 'Modern marble processing techniques and their suitability for Indian condition"; A company report by Rajasthan Udyog, Jodhpur. Anon; "Technological evaluation & norms study in marble & granite industry'" Report of Ministry of Science & Technology, GOI; July 1993. Battacharya B.C.; "Possible utilization of waste marble powder / slurry - a case study". Seminar on gainful utilization of marble slurry in various construction activities; UCCI, Udaipur; Sept. 18,2002. Bhatnagar A.; "Scientific and modern mining of marble - Development of large block extraction with minimum of waste". Global seminar for golden jubilee of I.I.T. Kharagpur, TMMPE-2000; Dec. 1-3-2000. {ks= fjä ?kksf"kr djus ckcr~ vf/klwpuk,¡ ^^v** [kku ¼xzqi&1½ foHkkx t;iqj] tykbZ 24] 2002 la[;k i-5¼27½ [kku@xzqi1@97 % loZlk/kkj.k dks lwfpr fd;k tkrk gS fd [kfut fj;k;r fu;e] 1960 ds fu;e 75 ds }kjk iznÙk 'kfä;ksa dk iz;ksx djrs gq, jkT; ljdkj }kjk [kfut cslesVy ,oa ukscy esVy ds fy;s fudV xzke [ksjok] m.Moky] ftyk&ck¡lokM+k esa 73-00 oxZ fdyksehVj {ks= dks 'kklu dh vf/klwpuk Øekad i&5¼27½ [kku@xzqi&1@97 t;iqj fnukad 258-93 ftldk jktLFkku jkt&i= esa izdk'ku fnukad 28-8-93 dks gqvk ds }kjk foHkkxh; iwosZ{k.k ,oa vUos{k.k dk;Z gsrq fnukad 28-01-93 ls nks o"kZ ds fy;s vjf{kr fd;k x;k Fkk A mijksä of.kZr {ks= dks [kfut fj;k;r fu;e] 1960 ds fu;e 59 ds iz;kstukFkZ bl vf/klwpuk ds izdk'ku dh frfFk dks NksM+dj 30 fnu i'pkr~ fjä ?kksf"kr fd;k tkrk gS A {ks= dk fooj.k Vksiks'khV ua-&46&vkbZ@5] 6] 9 ,oa10 ls rd fc;fjax nwjh 0 ,Q- vkj- ih- 430 , 29 00* 1400 eh0 , ch 335 00* 13 fd- eh0 ch lh 650 00* 07 fd- eh0 lh Mh 155 00* 07 fd- eh0 Mh bZ 245 00* 03 fd- eh0 bZ ,Q 155 05* 06 fd- eh0 ,Q , 245 00* 04 fd- ehdqy {ks= ,] ch] lh] Mh] bZ] ,Q] ,]&73-00 oxZ fd-eh- mijksä of.kZr {ks= esa iwosZ{k.k vuqKk i=@i= [kuu iV~Vk dks Lohd`r djrs le; 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ij funsZ'k tkjh fd;s tkus ds ckotwn Hkh ;s ns[kk x;k gS fd izLrko viw.kZ ik;s tkus ls funs'kky; Lrj ij fu.kZ; fy;k tkuk lEHko ugha gksus ds dkj.k vuko';d foyEc gksrk gSa A ;g Hkh ns[kk x;k gS fd vkosnu &i=ksa esa ikbZ xbZ dfe;ksa dh iwfrZ;k¡ iw.kZ :i ls ugha djkbZ tkrh gS tks uksfVl tkjh fd;s tkrs gSa muesa Hkh dbZ ckj vuk'o;d dfe;k¡ Hkh vafdr dj nh tkrh gS ftlls funs'kky; Lrj ls vHkh fcUnqvksa dks 'kkfey djrs gq, iqu% uksfVl tkjh djuk iM+rk gS A vr% funs'kky; Lrj ij fu.kZ; fy;k x;k gS fd vkosnu&i= izkIr gksrs gh vkosfnr {ks= dh fjärk ckcr~ fLFkfr ekywe dj ysoas] ;fn vkosfnr {ks= dk dqN Hkkx /kkfjr@vkosfnr {ks=ksa ls fojksf/kr gksrk gS vFkok ftuds fuLrkj.k ds ckn Hkh {ks= Lohd`r djuk lEHko gks rks ,slh fLFkfr esa vkosnd dks {ks= fjärk dh lEiw.kZ fLFkfr ¼la;qä Iyku lfgr½ ls voxr djkrs gq, ;fn os 'ks"k cpk gqvk {ks= ysus gsrq lger gS rks mudh lgefr dks v.Mj Vsfdax lfgr fuEu dfe;ksa dh vkSipkfjdrkvksa dks n'kkZrs gq, fu;ekuqlkj 30@60 fnol dk uksfVl tkjh fd;k tkos %& 1- ou jfgr iqf"V iwjs vkosfnr {ks= dk jktLo jsdkMZ dh tekcUnh udysa ,oa [kljk esi is'k gksus ij ou foHkkx dks Hkstuk gksrk gS A uohuhdj.k ds ekeyksa esa Hkkjr ljdkj ls MkbZo'kZu djkuk A 2- pkjkxkg gsrq iqf"V [kuu iêksa ds ekeyksa esa vkosfnr {ks= dks tekcUnh dh udysa ,oa [kljk esi ds vk/kkj ij pkjkxkg dh iqf"V dh tkrh gSa tgk¡ 4-00 gsDVj rd pkjkxkg Hkwfe gS mlds fy, ftyk dysDVj ls] 4-00 gsDVj ls vf/kd Hkwfe pkjkxkg gS rks jktLo foHkkx ls vuqefr yh tkrh gSa A ;fn pkjkxkg Hkwfe vkosfnr {ks= dh 5% ls vf/kd ugha gS rks vkosnd ls bl vk'k; dk 'kiFk i= izkIr fd;k tkos fd og blesa [kuu vkjEHk djus ls iwoZ ftyk dysDVj vFkok l{ke jktLo vf/kdkjh ls vukifÙk izek.k i= izsf"kr djsxk A 3- i;kZoj.k Dyh;jsUl ,e-vks-bZ-,Q- dh vf/klwpuk fnukad 27-194 o 10-4-97 ds vuqlkj ,e-,y- esa 5-00 gsDVj esa o ih-,y- esa 5-00 gsDVj ls vf/kd {ks= nsus gsrq lquokbZ djus ds mijkUr bUok;jesUVy@lkbZM Dyh;jsUl fy;k tkuk vko';d gS] ftlds fy;s vkosnd ls vf/klwpuk fnukad 10-4-1997 ds rgr ifjf'k"B IV vuqlkj 22 lsV esa vkosnu funs'kky; ds ek/;e ls izsf"kr djsxk A 4- cdk;k ugha gksus dk izek.k&i= tgk¡ vkosndksa i{k esa ,e-,y-@ih,y- /kkfjr gS muls lEcfU/kr dk;kZy;ksa dk cdk;k ugha dk izek.k&i= vko';d gS A ,d ckj cdk;k ugha dk izek.k&i= izkIr gksus ij nwljh ckj lafonk fu"iknu ls iwoZ ekaxk tkrk gS A 5- rdfudh HkwoSKkfud fjiksVZ /kkjk 5¼2½ ds rgr [kfut miyC/krk izekf.kr gksus ds mijkUr gh [kuu iêk nsus dk izko/kku gSa] ftlds fy, foHkkx ds HkwoSKkfud ls izekf.kr rdfudh HkwoSKkfud fjiksVZ yh tkrh gS A 6- ekbZu Iyku uohuhdj.k @u;s [kuu iêk Lohd`fr ls iwoZ vuqeksfnr ekbZu Iyku gksuk vko';d gSa A 7- izFke ifjf'k"B ds [kfut o tks [kfut izFke ifjf'k"B esa vkrs gSa mudh fo'ks"k 'krZ ds ekeys Lohd`fr gsrq iwoZ esa Hkkjr ljdkj ls vuqeksnu ysuk vko';d gksrk gS A blh rjg ftu [kuu iêksa esa fo'ks"k 'krZ yxkbZ tkrh gSa muesa Hkh Hkkjr ljdkj dk vuqeksnu vko';d gSa] ftlds fy, izLrko ds lkFk Hkkjr ljdkj dks Hksts tkus okys izi= ¼6 izfr;ksa esa ½ rFkk Lohd`r fd;s tkus okys {ks= ds ekufp= dh 6 izfr;k¡ layXu djuk vko';d gSa A 8- fu/kkZfjr lhek ls vf/kd {ks= nsus fuxeksa dks o cMs+ lhesUV IykUV gsrq rFkk vU; m|fe;ksa dks fu/kkZfjr lhek ls vf/kd {ks= nsus ckcr~ /kkjk 6 esa Hkkjr ljdkj ls NwV ysuk gksrk gS ftlds fy;s iw.kZ vkSfpR; ds lkFk izLrko fHktkuk vko';d gSa A 9- [kfut miyC/krk ckcr~ iwosZ{k.k vuqKk&i= ds ekeys esa fo'ks"k :i ls DokVZ~t] QsYLikj] ek;dk] Dyst] flyhdkls.M vkfn esa ;fn lEcfU/kr HkwoSKkfud [kfut miyC/krk izekf.kr dj nsrs gSa rks vkosnu dks [kuu iêk gsrq lykg nsosa A bl ckcr~ iwoZ esa Hkh funsZ'k fn;s tk pqds gSa A mä vof/k ds i'pkr~ mä fcUnqvksa dh iwfrZ vkosnd }kjk ugha dh xbZ rks mudk o.kZu djrs gq, vko';d izLrko Hksts rkfd muds fy, funs'kky; Lrj ls 'kkW dkt uksfVl tkjh fd;k tkdj vkosnu&i=ksa dk fuLrkj.k fd;k tk lds A mä funsZ'kksa dh dBksjrk ls ikyuk dh tkos A g-@& vfrfjä funs'kd ¼[kku½ eq- la'kksf/kr vf/klwpuk,¡ ^^v*** t;iqj] tuojh] 31] 2002 la[;k i- 16¼19½ [kku@xzqi&1@93 % bl foHkkx dh le la[;d vf/klwpuk fnukad 3-11-2001 esa vafdr {ks= ds fooj.k dh fc;fjax esa fuEukuqlkj la'kks/ku fd;k tkrk gS A ls {ks= dk C;kSjk ¼Vksiks'khV ua- 45@,e@5½ rd fc;fjax nwjh ¼ehVj Vh- okbZ- 835 v v c c l l n n v dqy {ks= v] c] l] n]&16 oxZ fd-eh- 0 340 00* 27030* 117030* 207030* 297030* esa ½ 300 8000 2000 8000 2000 *iwoZ esa bl {ks= ls lEcfU/kr vf/klwpuk jktLFkku [kfut cqysfVu ds lEiqV 22 vda 3&4 ds i`"V la[;k 51 ij izdkf'kr dh xbZ A ^^c** [kku ¼xzqi&1½ foHkkx t;iqj] vxLr 01] 2002 la[;k i- 16¼19½ [kku@xzqi&1@93 % bl foHkkx dh le la[;d la'kksf/kr vf/klwpuk fnukad 31-1-2002 esa {ks= dk C;kSjk ¼Vksiks 'khV ua- 45@,y@5½ ,oa ftldk jktLFkku jkt&i= esa ¼Vksiks 'khV ua45@,e@5½ fnukad 5-2-2002 dks izdk'ku gqvk gS ds LFkku ij Vksiks 'khV ua- 45@,p@5 i<s+ tkus dk la'kks/kd ,rr~}kjk fd;k tkrk gS A vkj- ,l- vxzoky 'kklu mi lfpo {ks= vkjf{kr djus ckcr~ vf/klwpuk t;iqj] Qjojh 02] 2002 la[;k ,Q 14¼5½ [kku@xzqi&2@2001 % loZlk/kkj.k dks lwfpr fd;k tkrk gS fd jktLFkku viz/kku [kfut fj;k;r fu;e] 1986 ds fu;e 73 ds iz;kstukFkZ [kfut ls.MLVksu ds fy;s fudV xzke tkyksM+k] rglhy Qyksnh] ftyk&tks/kiqj esa ¼iwoZ esa Lohd`r rFkk vosfnr [kuu iêk o iqosZ{k.k vuqKki= vYikof/k Lohd`r vuqKki= ds {ks=ksa dks NksM+dj½ foHkkxh; iwosZ{k.k ,oa vUos"k.k dk;Z gsrq 18-00 oxZ fd-eh- dk {ks=] ftldk bUnzkt dk;kZy; lgk;d [kfu vfHk;Urk] ckyslj] ftyk&tks/kiqj dh ekud iaftdk esa ,e- ,y- &5@2001 ij fnukad 21-7-2001 dks vkjf{kr vafdr fd;k x;k gS] dks fnukad 21-7-2001 ls nks o"kZ dh vof/k gsrq vkjf{kr fd;k x;k gSa A vr% mijksä {ks= esa jktLFkku viz/kku [kfut fj;k;r fu;e] 1986 esa iznÙk 'kfä;ksa ds rgr mä of.kZr [kfut ,oa vU; [kfutksa ds fy;s fnukad 21-7-2001 vFkok blds i'pkr~ izkIr fdlh Hkh iwosZ{k.k vuqKki= vFkok [kuu iês ds vkonsu i=ksa ij fopkj ugha fd;k tkosxk] tc rd fd mä of.kZr {ks= dks jktLFkku jkt&i= esa izdkf'kr vf/klwpuk }kjk fjä ?kksf"kr ugha dj fn;k x;k gks A {ks= dk fooj.k ¼Vksiks'khV ua- 45 ch@5½ ls rd fc;fjax th- Vh, 250000* LVs'ku&327 , ch 360000* ch lh 90000* lh Mh 180000* Mh , 270000* dqy {ks= ,] ch] lh] Mh] ,]&18 oxZ fd-eh- nwjh ¼ehVj esa½ 1000 4000 4500 4000 4500 mijksä of.kZr {ks= ds ekufp= ,oa fooj.k lwph dk;kZy; v/kh{k.k HkwoSKkfud] tks/kiqj ] dk;kZy; lgk;d [kfu vfHk;Urk ckyslj ,oa funs'kky;] [kku ,oa HkwfoKku foHkkx] mn;iqj esa fujh{k.k gsrq miyC/k gSa A jkT;iky ds vkns'k ls vkj- ,l- vxzoky 'kklu mi lfpo