Staged drainage system of large ore storage yard and construction and dynamic maintenance method of staged drainage system

Abstract

The invention discloses a staged drainage system of a large ore storage yard and a construction and dynamic maintenance method of the staged drainage system, and belongs to the technical field of large bulk cargo storage yard foundation treatment and dynamic drainage engineering. The system comprises a peripheral closure system, an internal seepage and drainage transition system, an under-road communication system and a permanent drainage system. The core of the construction and dynamic maintenance method is as follows: a flexible gravel ditch is adopted to adapt to differential settlement in the initial stage; monitoring in the settlement period, and dynamically backfilling and maintaining the settlement area by adopting a graded material; and after stabilization, the gravel ditch is reconstructed into a reinforced concrete ditch in situ. According to the method, foundation settlement is effectively dealt with through the strategy of'firstly softening and then rigidness, dynamic monitoring and timely upgrading ', drainage failure caused by foundation settlement in a traditional method is avoided, efficient and reliable operation of a drainage system in the whole life cycle is achieved, and safety and economical efficiency are remarkably improved. The method is suitable for drainage of large material piles such as ore and coal under the rainstorm working condition, and has remarkable safety and economic benefits.

Description

Technical Field

[0001] The present invention relates to the technical field of foundation treatment and dynamic drainage engineering of large bulk material stockpiles, and in particular to a staged drainage system of a large ore stockpile and a construction and dynamic maintenance method thereof. Background Art

[0002] Large ore stockpiles are key facilities in industries such as metallurgy, coal, and ports. They are characterized by large storage volumes, high load intensity, uneven material particle size, and high permeability. These stockpiles are often built on coastal landfills or in areas with poor geological conditions. The foundations experience significant and persistent uneven settlement under the action of the load. Under extreme conditions such as heavy rain, large amounts of rainwater can easily accumulate within the stockpile. If drainage is not timely, the accumulated water will seep into the stockpile, increasing its deadweight and reducing its shear strength. This can easily lead to landslides or collapses, threatening operational safety and causing significant material losses and equipment damage. Furthermore, leachate containing minerals can pollute the surrounding soil and groundwater. Therefore, establishing an efficient and reliable drainage system is key to ensuring the safe, environmentally friendly, and efficient operation of the stockpile.

[0003] Drainage systems in large ore stockpiles must simultaneously cope with the impact of falling ore, adaptability to dynamic stockpile changes, and the impact of foundation settlement. Traditional fixed drainage structures often fail under complex operating conditions. Chinese invention patent CN101435220A (published May 20, 2009) discloses a ditch-based, graded sedimentation drainage system for bulk cargo yards. This system employs drainage ditches installed on the sidewalls of track beams, with sedimentation tanks at the ends. The longitudinal and transverse slopes of the ditches guide rainwater to the end sedimentation tanks, combining drainage with primary sedimentation. The ditches also double as fire escapes, saving space. However, the system's ditches are fixed to the sidewalls of the track beams, making them unable to adapt to the dynamic changes in the stockpile shape. This creates blind spots and reduces drainage efficiency. Furthermore, the stockpile contains a large amount of coarse slag, which can easily cause rapid siltation in the sedimentation tanks, increasing the frequency and cost of cleaning.

[0004] Chinese utility model patent CN207794248U (publication date August 31, 2018) discloses a drainage ditch and system for bulk storage yard, which realizes the functions of drainage and sedimentation by setting first and second drainage ditches and using the combined structure of infiltration ditch and groove. The first drainage ditch includes adjacent first groove and first infiltration ditch, and the water flow is guided through the water-permeable holes on the water wall. The cover plate design can reduce the bulk material falling into the groove. The rubble filled in the infiltration ditch is easily displaced by large-diameter bulk material, causing the infiltration channel to be blocked. In the face of post-construction settlement of several meters, the rigid ditch body and cover plate are prone to breakage due to uneven settlement. In addition, the water-permeable holes of the water wall are prone to misalignment and blockage during the settlement process, resulting in loss of drainage function. Furthermore, when large mobile machinery is operating in the yard, its load will directly act on the cover plate, which is prone to deformation and damage over time, further increasing the risk of ditch blockage.

[0005] Chinese invention patent CN118241636A (publication date June 25, 2024) discloses a soft soil foundation drainage method based on in-plate pressurized plastic drainage board. The method sets a pressurizing pipe in the main structure of the plastic drainage board, and cooperates with the shoe, vacuumizing device and pressurizing device to use high-pressure gas to drive the water in the soft soil foundation to drain into the drainage channel, thereby shortening the drainage consolidation time. This patent focuses on accelerating foundation consolidation and cannot effectively solve the problem of rapid collection and removal of surface water under extreme conditions such as heavy rain. At the same time, the plastic drainage board is prone to breakage, and the connection between the pressurizing pipe and the shoe is also prone to breakage under external force, thereby losing the pressurized drainage function.

[0006] In summary, large-scale ore storage yards have complex geological conditions and special working conditions, which pose high requirements on the safety, adaptability and long-term effectiveness of the drainage system. In the existing technology, the drainage system with fixed structure cannot adapt to the dynamic changes of the heap and the continuous settlement of the foundation, and is prone to problems such as drainage blind area, ditch breakage and channel blockage, resulting in decreased drainage efficiency or even functional failure. Not only can it not meet the drainage needs under extreme conditions such as heavy rain, but also poses safety hazards and environmental risks. The drainage method that focuses on foundation consolidation cannot solve the core problem of rapid removal of surface water. Therefore, for the complex working conditions of large-scale ore storage yards, it is an urgent need in the current industry to develop a drainage system that can adapt to foundation settlement, dynamically adjust the structure form, and consider efficient drainage and long-term reliability, as well as a construction and maintenance method. SUMMARY

[0007] In light of this, the present invention has designed a phased drainage system for large ore stockpiles, along with its construction and dynamic maintenance methods. This system addresses the risks of water accumulation and collapse in large ore stockpiles during heavy rains, as well as the significant post-construction settlement that makes traditional fixed drainage ditches susceptible to failure and inability to withstand the loads of large mobile machinery. This invention utilizes a proactive management strategy of "monitoring - dynamic maintenance - stable upgrades" to ensure the functional integrity and reliability of the drainage system throughout the stockpile's lifecycle. The technical solution is as follows: The phased drainage system for large ore stockpiles includes an external interception system, an internal seepage and drainage transition system, an under-road connection system, and a permanent drainage system.

[0008] The peripheral interception system includes uncovered drainage ditches arranged around the stockpile and beside the main roads, which are used to intercept and drain the water collected around the stockpile.

[0009] The internal seepage and drainage transition system includes a trapezoidal gravel drainage ditch arranged at the edge of the internal road of the yard, which is used to perform the core functions of internal drainage, filtration and adaptation to uneven settlement before the settlement of the yard stabilizes.

[0010] The under-road connection system includes drainage pipes buried under the road and covered with reinforced concrete, which are used to bear pressure and seamlessly connect the peripheral interception system and the internal infiltration and drainage transition system.

[0011] The permanent drainage system includes a reinforced concrete drainage ditch that is rebuilt in situ from the gravel drainage ditch after the post-construction settlement of the yard is stabilized, which is used to provide long-term, stable, and load-bearing drainage capacity.

[0012] Furthermore, the cross-section of the gravel drainage ditch is trapezoidal, the upper bottom width is 5~6m, the lower bottom width is 0.5~1m, the depth is 1.5~2m, the slope coefficient is 1.25~1.5, and the gravel particle size is 20~50mm.

[0013] Furthermore, the drainage pipe is a steel pipe with a diameter of DN1000-DN1500. The outer wall of the pipe is enclosed by a reinforced concrete structure, and the burial depth is determined according to the road design load to ensure the safety of large mobile machinery when passing through.

[0014] Furthermore, the reinforced concrete drainage ditch has a rectangular cross-section, a width of 1.0-2.0 m, a depth of 1.0-2.5 m, and a concrete strength grade of not less than C30.

[0015] Furthermore, the width of the uncovered drainage ditch is 2-2.5 m, and the depth is 1.5-3 m.

[0016] Furthermore, when uneven settlement occurs in the yard, materials with properties similar to those of the original yard materials are selected as backfill materials to promptly backfill and repair the settled area to prevent water accumulation due to rainfall.

[0017] The present invention provides a method for constructing and maintaining the above-mentioned staged drainage system, the method comprising the following steps: S1: Initial system construction stage During or after the yard is formed, the outer uncovered drainage ditch and the internal trapezoidal gravel drainage ditch are constructed simultaneously according to the design drawings; where the drainage ditch needs to cross the internal road, the trench is excavated in advance, the drainage pipes are installed, and they are reinforced by reinforced concrete encapsulation. After backfilling and compaction, the road surface is restored to form an initial drainage network that allows deformation.

[0018] S2: Dynamic monitoring and maintenance stage during the settlement period During the yard's operational loading period, a systematic inspection and monitoring system was established. The elevation, linearity, and water accumulation of the drainage ditches were regularly measured and recorded. If uneven settlement caused ditch misalignment, fractures, or localized water accumulation, maintenance procedures were immediately initiated. The settled areas were backfilled in layers using graded materials similar in properties to the original yard material. Compactors were used to compact the layers, and levels were used to calibrate the layers to accurately restore the designed drainage slope.

[0019] S3: Stable system upgrade stage After long-term monitoring through buried settlement observation points and determining that the settlement of the yard foundation has reached the stability standard, a system upgrade was organized and implemented: mechanical equipment was used to dig out the filling materials in all the internal gravel drainage ditches, and then the ditches were excavated to the design elevation according to the final design dimensions. Rebars were tied in situ, formwork was set up, and concrete with a strength of not less than C30 was poured on site, converting it into a permanent reinforced concrete drainage ditch in one go.

[0020] S4: Long-term regular maintenance phase Compared with the prior art, the present invention has the following significant advantages: 1. This invention breaks away from the traditional "one-time construction" mentality and creatively proposes a "phased adaptation" approach. By initially employing flexible, variable gravel trenches to accommodate settlement, and later upgrading to rigid, permanent concrete trenches, this solution perfectly resolves the fundamental contradiction in constructing a large-scale storage yard drainage system on a weak foundation. The technical concept is ingenious and not obvious.

[0021] 2. This invention views the drainage system as a dynamically evolving organism, providing a comprehensive methodology covering construction, monitoring, maintenance, and upgrades. Through real-time monitoring and dynamic backfill maintenance, problems are eliminated before they occur, transforming passive repairs into proactive maintenance, significantly improving system reliability and service life.

[0022] 3. This invention offers low initial construction costs: gravel trenches are much cheaper than concrete trenches. Maintenance costs during the settlement period are low: dynamic backfilling costs are far lower than the cost of repeatedly rebuilding concrete trenches. Ultimately, this creates a permanent, high-quality facility. This results in optimal overall cost-per-cycle costs and a high return on investment.

[0023] 4. The present invention can effectively ensure that the accumulated water in the storage yard is quickly discharged under extreme working conditions such as heavy rain, greatly reducing the risk of landslide and collapse of the storage yard, ensuring the safety of personnel and equipment, and significantly reducing the incidence of material loss and equipment failure. At the same time, the filtering effect of the gravel layer reduces the discharge of pollutants with rainwater, which has positive environmental significance.

[0024] 5. This invention optimizes the drainage ditch layout to avoid the core areas of material storage and equipment operation. While ensuring drainage function, it minimizes the impact on the process flow. Dynamic maintenance operations are flexible and fast, and the interference with normal operations in the yard is far less than the maintenance and construction of large concrete structures.

[0025] The above description is only an overview of the technical solution of the present application. In order to more clearly understand the technical means of the present application so that it can be implemented in accordance with the contents of the specification, and to make the above and other purposes, features and advantages of the present application more obvious and easy to understand, the following is a detailed description of the preferred embodiment of the present application in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, the following will briefly introduce the drawings required for the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present application. For those of ordinary skill in the art, other drawings can also be obtained based on these drawings without inventive work. In all drawings, similar elements or parts are generally identified by similar reference numerals. In the drawings, the elements or parts are not necessarily drawn according to the actual scale.

[0027] Figure 1 This is a schematic diagram of the plan layout of the staged drainage system of the present invention.

[0028] Figure 2 This is a schematic diagram of the cross-sectional structure of a drainage ditch without a cover plate in the staged drainage system of the present invention.

[0029] Figure 3 This is a schematic diagram of the cross-sectional structure of a gravel drainage ditch of the staged drainage system of the present invention.

[0030] Figure 4 This is a cross-sectional view of a drainage pipe in a road section of a staged drainage system according to the present invention; Figure 5 The figure is a flow chart of the construction and dynamic maintenance method of the staged drainage system of the present invention.

[0031] Figure numerals: 1. Uncovered drainage ditch; 2. Gravel drainage ditch; 3. Drainage pipe; 4. Reinforced concrete drainage ditch. DETAILED DESCRIPTION

[0032] In order to make the purpose, technical solutions and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be clearly and completely described below in conjunction with the drawings in the embodiments of the present application. Obviously, the described embodiments are part of the embodiments of the present application, rather than all of the embodiments. In the following description, specific details such as specific configurations and components are provided only to help fully understand the embodiments of the present application. Therefore, it should be clear to those skilled in the art that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present application. In addition, for clarity and brevity, the description of known functions and structures has been omitted in the embodiments.

[0033] It should be understood that references throughout this specification to "one embodiment" or "this embodiment" mean that a particular feature, structure, or characteristic associated with the embodiment is included in at least one embodiment of the present application. Therefore, the appearance of "one embodiment" or "this embodiment" throughout this specification does not necessarily refer to the same embodiment. Furthermore, these particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

[0034] In addition, the present application may repeat reference numerals and / or letters in different examples. This repetition is for the purpose of simplicity and clarity and does not in itself indicate the relationship between the various embodiments and / or settings discussed.

[0035] The term "and / or" in this article is only a description of the association relationship of associated objects, indicating that there can be three relationships. For example, A and / or B can mean: A exists alone, B exists alone, and A and B exist at the same time. The term " / and" in this article describes another type of association object relationship, indicating that there can be two relationships. For example, A / and B can mean: A exists alone, and A and B exist alone. In addition, the character " / " in this article generally indicates that the related objects before and after are in an "or" relationship.

[0036] The term "at least one" in this article is merely a description of the association relationship between associated objects, indicating that three relationships may exist. For example, at least one of A and B can mean: A exists alone, A and B exist at the same time, and B exists alone.

[0037] It should also be noted that, in this document, relational terms such as first and second are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "include," "comprises," or any other variations thereof are intended to cover non-exclusive inclusion.

[0038] Example 1 In order to make the technical means, objectives and effects achieved by the present invention easier to understand, the present invention is further described below with reference to specific illustrations.

[0039] This embodiment introduces a staged drainage system for a large ore yard, including an external interception system, an internal seepage and drainage transition system, an under-road connection system, and a permanent drainage system. Figure 1 .

[0040] The peripheral interception system is composed of uncovered drainage ditches 1 arranged around the pile and beside the main road. Figure 2 .

[0041] The internal seepage and drainage transition system is composed of a trapezoidal gravel drainage ditch 2 arranged at the edge of the internal road of the storage yard. Figure 3 .

[0042] The roadside connection system consists of a drainage pipe 3 buried under the road and covered with reinforced concrete. Figure 4 .

[0043] The permanent drainage system is composed of a reinforced concrete drainage ditch 4 that is rebuilt in situ from the gravel drainage ditch after the settlement of the yard is stabilized.

[0044] Preferably, the uncovered drainage ditch 1 is set up around the large storage yard and on the main road, adopts C30 concrete structure, and has a designed section with a top width of 2.5m, a bottom width of 1.8m, and a depth of 3.0m.

[0045] Preferably, the gravel drainage ditch 2 is excavated and arranged along the edges of both sides of the internal road of the yard, with a trapezoidal cross-section, an upper bottom width of 6m, a lower bottom width of 1m, a depth of 2m, and a slope coefficient of 1.5, which matches the natural repose angle of the ore, and is filled with graded gravel with a particle size of 20-50mm.

[0046] Preferably, the drainage pipe 3 uses a DN1200×12mm Q235B steel pipe, is installed at all road intersections, and is encapsulated and reinforced by pouring 300mm thick C30 plain concrete outside the steel pipe. The minimum soil cover depth of the pipe top is 1.2m, and it is designed to withstand a ground load of 300 kPa.

[0047] Preferably, the reinforced concrete drainage ditch 4 is rebuilt from the gravel drainage ditch 2 and is implemented after the settlement is stable. The reinforced concrete drainage ditch adopts a rectangular cross-section, a width of 1.8m, a depth of 2m, a wall thickness of 300mm, a concrete strength of C30, and a reinforcement of HRB400.

[0048] By adopting this staged drainage system, water accumulated in the stockpile can be quickly drained from the large ore stockpile under extreme conditions such as heavy rain, effectively preventing stockpile collapse accidents, reducing material loss and equipment damage, and improving the stockpile's operational efficiency and safety. Therefore, the staged drainage system for large ore stockpiles formed by the present invention has significant advantages in improving stockpile safety and stability, and has high application value.

[0049] Example 2 This embodiment introduces the construction and dynamic maintenance method of a staged drainage system for a large ore yard. Figure 5 Flowchart of this method.

[0050] S1: When the stockpile is first formed, lay out the lines according to the design drawings and simultaneously excavate all peripheral uncovered drainage ditches 1 and gravel drainage ditches 2. As the internal roads are formed, the construction of the underpass drainage pipes 3 is simultaneously promoted to ensure that the drainage system is put into use at the same time as the stockpile construction.

[0051] S2: A professional maintenance team was formed to conduct dynamic maintenance, with monthly inspections. During one inspection, a section of the gravel trench, approximately 50 meters long, in Area B was found to have sunk 0.4 meters in the centerline, resulting in accumulated water. Tailings with a particle size of 0-40 mm, screened from the stockpile, were immediately used as backfill material. The backfill was layered and statically compacted twice with an 18-ton roller, controlled by a level gauge, restoring the designed longitudinal slope of 0.4%.

[0052] S3: Data from buried settlement observation piles showed that the monthly settlement rate of the foundation had been less than 2mm / month for three consecutive months, indicating that the settlement had entered a stable phase. Following this decision, a system upgrade was initiated. Excavators were used to remove the gravel from all internal gravel drainage ditches. The gravel was cleaned and reused. Excavation was then carried out to the designed elevation, rebar was tied, and composite steel formwork was installed. C30 concrete was poured continuously in one go to form the final reinforced concrete drainage ditch 4.

[0053] S4: Throughout the life cycle of the system, a long-term maintenance plan for the entire plant infrastructure will be implemented, with all ditches desilted and structural inspections conducted quarterly to ensure the continued effectiveness of the system.

[0054] The drainage system construction and maintenance method described in Example 1 utilizes the coordinated design of external uncovered drains and internal gravel drains, combined with the upgrading and renovation of reinforced concrete drains after settlement stabilization, to form a hierarchical drainage system tailored to the specific characteristics of the stockpile. Therefore, the resulting large-scale ore stockpile drainage system and its complete technical system for construction and maintenance have high application value.

[0055] The foregoing is intended to be merely exemplary embodiments of the present invention, and not exhaustive. Those skilled in the art will appreciate that various modifications and variations may be made to the exemplary embodiments of the present invention without departing substantially from the spirit and scope of the present disclosure, and that all such modifications and variations are intended to be within the scope of the present disclosure as defined by the appended claims. The scope of the present disclosure is defined by the appended claims, and their equivalents are intended to be encompassed therein.

Claims

1. A staged drainage system for a large ore yard, characterized by: It includes the peripheral interception system, internal seepage and drainage transition system, under-road connection system and permanent drainage system; The peripheral interception system includes uncovered drainage ditches (1) arranged around the stockpile and along the main roads, which are used to intercept and collect surface runoff outside the site; The internal seepage and drainage transition system includes a trapezoidal gravel drainage ditch (2) arranged at the edge of the road inside the yard, which is used to collect the seepage water inside the yard before the settlement is stabilized and to adapt to the foundation settlement of the yard; The under-road connection system includes a drainage pipe (3) buried under the road, with both ends of the pipe being connected to the uncovered drainage ditch (1) and the trapezoidal gravel drainage ditch (2) respectively, for conveying the internal water collection to the peripheral drainage ditch; The permanent drainage system includes a reinforced concrete drainage ditch (4) that is rebuilt in situ from the gravel drainage ditch (2) after the post-construction settlement of the yard is stabilized, in order to provide a structurally strong permanent drainage channel during the stabilization period; The peripheral interception system is connected to the internal infiltration and drainage transition or permanent drainage system through an under-road connecting system, together forming a complete drainage channel network.

2. The staged drainage system for a large ore stockpile according to claim 1, characterized in that: The cross section of the gravel drainage ditch (2) is trapezoidal, with an upper bottom width of 5-6m, a lower bottom width of 0.5-1m, a depth of 1.5-2m, a slope coefficient of 1.25-1.5, a gravel particle size of 20-50mm, and the slope coefficient matches the natural repose angle of the yard materials.

3. The staged drainage system for a large ore stockpile according to claim 1, characterized in that: The drainage pipe (3) is a steel pipe with a diameter of DN1000~DN1500. The outer wall of the pipe is enclosed by a reinforced concrete structure. The buried depth is determined according to the design load of the road, while ensuring that it does not affect the passage of large mobile machinery.

4. The staged drainage system for a large ore stockpile according to claim 1, characterized in that: The reinforced concrete drainage ditch (4) has a rectangular cross-section, a width of 1.0-2.0 m, a depth of 1.0-2.5 m, and a concrete strength grade not less than C30.

5. The staged drainage system for a large ore stockpile according to claim 1, characterized in that: The uncovered drainage ditch (1) has a width of 2 to 2.5 m and a depth of 1.5 to 3 m.

6. A method for constructing and dynamically maintaining a phased drainage system for a large ore yard, characterized in that: The following steps are involved: Step S1: During or after the formation of the storage yard, a peripheral uncovered drainage ditch (1) and an internal trapezoidal gravel drainage ditch (2) are simultaneously constructed, and drainage pipes (3) are pre-buried and installed at the locations where the drainage ditch needs to cross the road, thereby forming an initial drainage network; Step S2: During the yard operation period, the drainage system is monitored. When ditch misalignment, fractures, or waterlogging occurs due to uneven settlement, the settled area is backfilled and compacted in layers using graded materials similar in properties to the original yard material, and the designed drainage slope is restored. Step S3: After the monitoring data indicates that the settlement of the storage yard foundation has reached the stability standard, the internal gravel drainage ditch (2) is excavated to the design elevation, and a reinforced concrete structure is constructed in situ to transform it into a permanent reinforced concrete drainage ditch (4); Step S4: Establish a regular maintenance mechanism, clean up debris in all types of open ditches, check the structural integrity of the drainage ditch, and promptly repair any cracks or damaged parts with concrete of the same grade.

7. The method according to claim 6, characterized in that During the construction of the drainage pipe (3) in step S1, a waterproof layer is provided around it. The waterproof layer is made of a polymer waterproof material and has a thickness of not less than 2 mm.

8. The method according to claim 6, characterized in that The monitoring in step S2 includes regular inspection and measurement of the elevation, linearity and water accumulation of the drainage ditch.

9. The method according to claim 6, characterized in that The settlement stability standard in step S3 is: the monthly average settlement rate for three consecutive months is less than 2 mm / month.

10. The method according to claim 6, characterized in that The periodic maintenance mechanism described in step S4 is performed at least once a quarter, and the frequency of maintenance is increased after extreme weather such as heavy rain to ensure the normal operation of the drainage system.

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