Search Results (60)

This study presents an innovative solution to improve the mechanical performance of traditional cemented tailings backfill (CTB) by incorporating 3D-printed polymer lattice (3DPPL) reinforcements. We systematically investigated three distinct 3DPPL configurations (four-column FC, six-column SC, and cross-shaped CO) through comprehensive experimental methods including Brazilian splitting tests, digital image correlation (DIC), and scanning electron microscopy (SEM). The results show that the 3DPPL reinforcement significantly enhances the CTB’s tensile properties, with the CO structure demonstrating the most substantial improvement—increasing the tensile strength by 85.6% (to 0.386 MPa) at a cement-to-tailings ratio of 1:8. The 3DPPL-modified CTB exhibited superior ductility and progressive failure characteristics, as evidenced by multi-stage load-deflection behavior and a significantly higher strain capacity (41.698–51.765%) compared to unreinforced specimens (2.504–4.841%). The reinforcement mechanism involved synergistic effects of macroscopic truss behavior and microscopic interfacial bonding, which effectively redistributed the stress and dissipated energy. This multi-scale approach successfully transforms CTB’s failure mode from brittle to progressive while optimizing both strength and toughness, providing a promising advancement for mine backfill material design. Full article

This study investigates the coupled effects of waste rock-to-tailings ratio (WTR) and curing temperature on the pore structure and mechanical performance of cemented tailings waste rock backfill (CTRB). Four WTRs (6:4, 7:3, 8:2, 9:1) and curing temperatures (20–50 °C) were tested. Low-field nuclear magnetic resonance (NMR) was used to characterize pore size distributions and derive fractal dimensions ($D_a$, $D_b$, $D_c$) at micropore, mesopore, and macropore scales. Uniaxial compressive strength (UCS) and elastic modulus (E) were also measured. The results reveal that (1) the micropore structure complexity was found to be a key indicator of structural refinement, while excessive temperature led to pore coarsening and strength reduction. $D_a$ = 2.01 reaches its peak at WTR = 7:3 and curing temperature = 40 °C; (2) at this condition, the UCS and E achieved 20.5 MPa and 1260 MPa, increasing by 45% and 38% over the baseline (WTR = 6:4, 20 °C); (3) when the temperature exceeded 40 °C, $D_a$ dropped significantly (e.g., to 1.51 at 50 °C for WTR = 7:3), indicating thermal over-curing and micropore coarsening; (4) correlation analysis showed strong negative relationships between total pore volume and mechanical strength ($R$ = −0.87 for ${\mathsf{\delta }}_a\mathrm{v}\mathrm{s}.\mathrm{U}\mathrm{C}\mathrm{S}),$ and a positive correlation between $D_a$ and UCS (R = 0.43). (5) multivariate regression models incorporating pore volume fractions, $T_2$ relaxation times, and fractal dimensions predicted $\mathrm{U}\mathrm{C}\mathrm{S}$ and E with R² > 0.98; (6) the hierarchical sensitivity of fractal dimensions follows the order micro-, meso-, macropores. This study provides new insights into the microstructure–mechanical performance relationship in CTRB and offers a theoretical and practical basis for the design of high-performance backfill materials in deep mining environments. Full article

Cemented paste backfill with mine tailings provides a desirable solution for maximally utilizing mine tailings. Ordinary Portland cement (OPC) is the most widely used binder for cemented tailings backfills; however, the serious environmental problems resulting from OPC production and the drawbacks of OPC in cementing fine tailings motivate the investigation of novel binders characterized by environmental friendliness, cost-effectiveness, and efficiency. We previously synthesized solid-waste-based cementitious materials (SWCMs) for cementing fine tailings. In this study, CaCl₂ was added as an accelerator to further enhance the cementing performance of SWCMs for fine tailings. Adding a small amount of CaCl₂ accelerated the hydration of raw materials and prompted the formation of larger amounts of hydration products. As a result, the cementing performance of SWCMs for fine tailings was significantly enhanced through the combined effect of C-S-H gel and ettringite. The cemented fine tailings backfill can be hardened only after curing for ~36 h, with a 50% decrease in hardening duration compared to the control sample without CaCl₂. The optimal amount of CaCl₂ was controlled at 1.5 wt.%, and the sample strength reached 0.21 MPa at 36 h, even at a low binder-to-tailings ratio of 1:8, meeting the requirement of early strength of common cemented tailings backfills. The rapid hardening of cemented fine tailings backfills has significant implications for accelerating ore mining speed, improving mining production capacity, ensuring the safe environment of underground mining sites, and preventing the movement of surface masses in the terrain where mining production takes place. Full article

This study utilizes machine learning (ML) techniques to predict the performance of slag-based cemented tailings backfill (CTB) activated by soda residue (SR) and calcium carbide slag (CS). An experimental database consisting of 240 test results is utilized to thoroughly evaluate the accuracy of seven ML techniques in predicting the properties of filling materials. These techniques include support vector machine (SVM), random forest (RF), backpropagation (BP), genetic algorithm optimization of BP (GABP), radial basis function (RBF) neural network, convolutional neural network (CNN), and long short-term memory (LSTM) network. The findings reveal that the RBF and SVM models demonstrate significant advantages, achieving a coefficient of determination (R²) of approximately 0.99, while the R² for other models ranges from 0.86 to 0.98. Additionally, a dynamic growth model to predict strength is developed using ML techniques. The RBF model accurately predicts the time required for filling materials to reach a specified strength. In contrast, the BP, SVM, and CNN models show delays in predicting this curing age, and the RF, GABP, and LSTM models tend to overestimate the strength of the filling material when it approaches or fails to reach 2 MPa. Finally, the RBF model is employed to perform coupling analysis on filling materials with various mix ratios and curing ages. This analysis effectively predicts the changes in filling strength over different curing ages and raw material contents, offering valuable scientific support for the design of filling materials. Full article

The presence of free muscovite in tailings can negatively affect the mechanical strength and rheological properties of cemented paste backfill, as has been observed for several cementitious materials. The aim of this study is to evaluate the influence of free muscovite content in tailings on the consistency and rheology of cemented paste backfill. For this purpose, cemented paste backfill mixtures were prepared from two different tailings. The mixtures were prepared at solids contents between 70% and 74% and with the addition of 5% GU (general use Portland cement)/slag binder. In addition, the influence of muscovite was studied by varying the muscovite content of the tailings from about 14% to 25%. Abrams cone slump tests and rheological analyses were carried out for each recipe. The results show a decrease in slump height and an increase in yield stress, Herschel–Bulkley flow index, and infinite shear rate Cross viscosity with increasing muscovite content for a given solids content. Therefore, water should be added to maintain the required flowability of cemented paste backfill, which increases the water/binder ratio and may affect the mechanical strength. A method is presented for determining the amount of binder to be incorporated to maintain the water/binder ratio of the original cemented paste backfill recipe. Full article

Understanding the mechanical and physical behavior of aged CPB under cyclic loading is a significant area of research. Many parameters such as cementation (hydration) and the microstructure, which dictate the arrangement of particles and permeability, affect the mechanical features of cemented paste backfill (CPB). The impact of a wide range of external energy sources within the mining environment, such as cyclic loading resulting from long-term blasting, can significantly alter the applied stresses on the backfill mass. This paper aims to delve into this crucial area of research. A series of uniaxial cyclic tests were conducted on CPB, utilizing samples made from tailing materials sourced from a copper mine in South Australia. Different loading levels were applied at various curing times. All samples exhibited cyclic loading hardening behavior for cyclic loading levels between 80% and 93% of monotonic unconfined compressive strength (UCS), and a cyclic loading damage behavior was observed for 96% of UCS loading level for both 14- and 28-day curing periods. To further investigate these findings, scanning electron microscope analysis as well as sonic velocity tests were conducted for capturing microstructural changes in the samples before and after tests. These findings can be used to indicate a safe firing distance to a filled mass. Full article

Cemented tailings backfill (CTB), composed of tailings, binder, and water, is widely used for filling underground goaves in mining operations. Unmanaged tailings can occupy extensive land and pose significant environmental risks. Microwave technology offers a promising approach to enhance the utilization of tailings, reducing dependency on natural resources. However, limited research on microwave heating parameters has impeded its broader adoption. This study uses the orthogonal experimental method to study the influence of various factors on the strength of the CTB and to determine the impact capacity of each factor. Additionally, this study conducted a visual analysis of the microwave heating time (MHT), microwave delay time (MDT), cement-tailings ratio, slurry concentration and microwave power (MP) to verify the experimental results. The results show that microwave heating can enhance or diminish the mechanical properties of CTB samples at different curing ages, depending on the specific microwave parameter settings. Research indicates that microwave technology can be effectively applied to mine backfill materials to improve their early strength and the modulus of elasticity. Full article

The backfill binder material is the key to the cost and performance of cemented paste backfill. This study aims to understand the current situation of metal ore backfill binders, identify industry challenges, inspire research ideas, and explore development directions. Current research investigates trends and developments of backfill binders through literature review, experience summary, field research, statistical analysis, and other methods. Firstly, the main backfill binder types are summarized, including cement, metallurgical slag, thermal slag, chemical slag, and tailings binders. Secondly, the research progress regarding reactivity activation, hydration mechanism, harmful ion solidification, energy conservation, and carbon reduction is summarized. Thirdly, three industrial applications of new backfill binders are introduced and summarized. Cement is still the most common, followed by slag powder binder. The cases of steel slag binder and semi-hydrated phosphogypsum backfill have shown significant effects. Solid waste-based backfill binder materials are gradually replacing cement, which is a trend. Finally, further research is discussed, including hydration modeling and simulation, material properties under extreme environments, hardening process control, and technical standards for backfill binders. This work provides a reference and basis for promoting green and efficient paste backfill and sustainable industry development. Full article

Ensuring the mechanical performance of backfill materials while reducing cementation costs is a key challenge in mine backfill research. To address this, fiber materials such as polypropylene (PP) fiber and rice straw (RS) fiber have been incorporated into cement-based mixtures for mine backfilling. This study investigates the effects of PP and RS fibers on the mechanical properties, flow characteristics, and microstructure of Tailings and Wasted Stone Mixed Backfill (TWSMB). A series of orthogonal experiments were designed to evaluate the influence of variables, including the cement–sand ratio, solid mass concentration, wasted stone mass concentration, fiber content, and fiber length on the TWSMB properties. The results indicate that the influence of cement–sand ratio and solid mass concentration have a more significant impact on strength than fibers, though the fibers show a stronger effect than the wasted stone mass concentration. Both fiber types enhanced the strength of the specimens, with PP fiber exhibiting a stronger reinforcing effect than RS fiber. Furthermore, the effect of PP fiber content was more pronounced than that of fiber length, whereas the opposite trend was observed for RS fiber. The optimum fiber parameter levels were determined for each type: PP fiber performed best at a mass concentration of 1.5% and a length of 6 mm, while RS fiber showed optimal performance at a mass concentration of 1.0% and a length of 5–10 mm. Macroscopic damage analysis indicated that the structural integrity and residual compressive strength of the TWSMB specimens were preserved even after surpassing the ultimate compressive strength, due to the crack-bridging effect of the fibers. Microstructural analysis showed that PP fiber-reinforced specimens exhibited a dense structure formed through reactions with other hydration products. In contrast, the surface of RS fibers was nearly fully encapsulated by hydration products, resulting in the formation of a physical skeleton structure. This study provides new insights into minimizing cement consumption and reducing backfilling costs in mining operations. Full article

This study analyzed the influence of the mechanical properties of two-step backfill on the stability of mining sites. The study focused on the one-step adhesive backfill of segmented backfill mining in a mine in Shandong Province, where the front wall was exposed and the back wall was compressed. A three-dimensional mechanical model of the front wall exposed, back wall compressed cemented filling material considering the mechanical properties of the two-step weakly cemented filling material was established through theoretical analysis. On this basis, considering the influence of different mechanical properties (elastic modulus, internal friction angle, cohesion, and Poisson’s ratio) of two-step weakly cemented filling on one-step cemented filling, FLAC 3D 6.00.60 numerical simulation software was used to study the influence of various factors on the horizontal displacement distribution of cemented filling under single-sided exposure conditions using numerical simulation methods. The results show that the adhesive filling material exposed on one side is subjected to lateral pressure from adjacent weak adhesive filling materials, and its stability is affected by the contact area and mechanical properties of the weak adhesive filling material. Increasing the elastic modulus of the two-step weak adhesive filling material from 100 MPa to 500 MPa can reduce the maximum horizontal displacement of the one-step adhesive filling material from 116 mm to 32 mm, a decrease of about 72%. Similarly, increasing the cohesive force from 0.09 MPa to 0.21 MPa can reduce displacement from 96 mm to 33 mm, a decrease of 66%. Improving the mechanical properties of the two-step weakly cemented filling material can reduce the tendency of tailings to slide and collapse, and can reduce the lateral pressure applied by the cemented filling material. The horizontal displacement law of the two-step cemented filling material with front wall exposure and rear wall compression is basically similar under different mechanical properties of the one-step weakly cemented filling material. In the vertical direction, as the height of the filling material increases, the horizontal displacement first slowly increases to the maximum value and then slowly decreases. As the mechanical properties of the two-step weakly cemented filling increase, the horizontal displacement of the one-step cemented filling decreases. Full article

Yellow phosphorus slag has been considered as a potential cement substitute for mine filling material due to its cementing activity; however, its slow setting and low early strength have limited broader use. This study investigates the grading, compactness, and strength of yellow phosphorus slag combined with tailing sand. Using yellow phosphorus slag as an aggregate, cement as a binder, and mixing tailing sand in different ratios, this study evaluates its feasibility as a coarse aggregate in mine backfill. The key findings are as follows. (1) The grading index of tailing sand was 0.5, aligning with Fuller grading, but it required mixing with coarse aggregates to enhance strength and reduce cement consumption. Yellow phosphorus slag, with a grading index of 0.97, does not match Fuller’s curve and thus benefits from mixing with tailing sand. (2) For mixtures of waste rock and tailings, the 5:5 ratio aligned closely with Fuller’s theory, showing optimal packing density and strength. Mixtures of yellow phosphorus slag and tailings at ratios of 3:7, 4:6, and 5:5 had R² values of 0.73, 0.80, and 0.85, respectively, confirming reliable fit. The 5:5 mixture provided the best packing density and strength. (3) A new strength prediction model, accounting for aggregate, cement, and water effects, suggests that a 5:5 ratio with a 71% mass concentration and 1/7 ash–sand ratio meets industrial strength requirements. FLAC3D simulations indicated that cemented backfill reduces stress concentrations caused by excavation and supports stability during mining while also absorbing energy through compaction, creating favorable conditions for safe mining operations. Full article

To enhance the application of alkali-activated materials in mine filling, cemented tailings backfill was prepared using slag, fly ash, sodium silicate, and NaOH as primary constituents. The effects of the raw material type and dosage on the backfill were examined through a single-factor experiment. Additionally, response surface methodology (RSM) was utilized to optimize the mixing ratios of the backfill, with a focus on fluidity and compressive strength as key objectives. The evolution of backfill quality and compressive strength under the combined effects of dry–wet and freeze–thaw (DW-FT) cycles was analyzed. The hydration products, microstructure, and pore characteristics of the specimens were analyzed using X-ray diffraction (XRD), scanning electron microscopy with energy dispersive spectroscopy (SEM-EDS), and nitrogen adsorption tests (NATs) across varying cycles. The results demonstrate that the optimal backfill composition includes 47.8% fly ash, 6.10% alkali equivalent, and a 1.44 sodium silicate modulus. The macroscopic behavior of the backfill under DW-FT coupling followed this progression: pore initiation → pore expansion → crack formation → crack propagation → structural damage. After a minor initial increase, the backfill strength steadily decreased. Microscopic analysis revealed that the decline in internal cementation products and the deterioration of pore structure were the primary causes of this strength reduction. Thus, the DW-FT coupling can cause significant erosion of the backfill. The technical solutions presented in this paper offer a reference for solid waste utilization and provide valuable insights into the durability of backfill under DW-FT coupling. Full article

With the escalating demand for advanced and eco-friendly processing technologies in mining engineering, the potential applications of microwave heating technology in the treatment of cement tailings backfill (CTB) are expanding significantly. This research comprehensively investigates the mechanisms through which microwave irradiation duration and power influence the mechanical properties of CTB with varying concentrations and cement-to-sand ratios. The aim is to reveal the influencing patterns through experimental methods, providing scientific evidence for optimizing CTB treatment processes. This paper conducted microwave heating tests, uniaxial compression tests, and SEM-EDS tests on CTB. The research results indicate that heating time and power significantly enhance the early strength of CTB, with a more pronounced effect on CTB with higher concentrations and higher cement–sand ratios. When the heating time is 7 min and the heating power is 340 W, the cement hydration reaction is maximally promoted, thereby increasing the density and strength growth rate of CTB. However, excessively long heating time or overly high heating power may cause microcracks or thermal stress concentration within the CTB, adversely affecting the strength growth rate of CTB. Optimal thermal exposure duration and microwave power settings facilitate the activation of cementitious materials and the nucleation of calcium-silicate-hydrate (C-S-H) phases, thereby accelerating the compressive strength evolution of cemented tailings backfill (CTB). The outcomes of this research offer valuable insights into the deployment of microwave heating methodologies in underground mine backfilling, which are pivotal for augmenting the economic viability and environmental sustainability of mining operations. Full article

Cement production may involve excessive use of natural resources and have negative environmental impacts, as energy consumption and CO² emissions can cause air pollution and climate change. Cement kiln dust (CKD), a by-product waste material, is also a primary issue associated with cement production. Utilizing CKD in mining applications is a pathway to eco-sustainable solutions. Cemented paste backfill (CPB) made with mine tailings is an efficient method for void backfilling in underground mines. Therefore, this study investigated the eco-sustainable utilization of CKD as a co-binder material that can partially replace cement in CPB prepared with copper tailings. At 7, 14, 28, 56, and 90-day curing times, the experimental campaign measured the physical and mechanical parameters of the cured CPB samples, including density, UCS, and elastic modulus (stiffness). Additionally, the CPB-cured mixes were analyzed using XRF, X-ray XRD, SEM, and EDX techniques to link the mineral phases and microstructure to mechanical performance. Four proportions (5, 10, 15, and 20%) of CKD represented in 75 samples were prepared to replace ordinary Portland cement (OPC) in the CPB mixtures, in addition to the reference mix (control) with 0% CKD. As all combinations exceed the compressive strength of CPB required for achieving stability in underground mines, the results showed that CKD could be utilized advantageously as a partial substitute for OPC with a proportion of up to 20% in the CPB mixture. When tested after 90 days, the combination modified with 5% CKD exhibited comparatively higher compressive strength than the control mixture. Full article

Using metallurgical solid waste Titanium-extracted Residual Slag (TRS) as mine-filling cementitious material is crucial to reduce the filling cost and promote the utilization of solid waste resources. In this paper, taking the strength of the backfill at different curing ages as the response target, the Design-expert mixing design was used to optimize the proportioning experiment of titanium-extracted residual slag, titanium gypsum, silicate cement, and total tailings, to analyze the interactions and influences of the materials on the strength of the backfill, and to analyze the hydration mechanism of the titanium-extracted residual slag-based filling cementitious materials under the optimal proportioning. The results show that: (1) the order of the sensitivity of each component to the strength of backfill is: composite activator > cement > titanium gypsum > titanium-extracted residual slag, and there are different degrees of interaction between them; (2) the optimal ratio of titanium-extracted residual slag-based filling cementitious materials is TRS:titanium gypsum:cement:composite activator = 55:25:17:3; (3) early strength formation of backfill is mainly related to its hydration products ettringite and C-S-H, the rapid nucleation and cross-growth of ettringite in the early stage forms an effective physical filling effect, which is the main reason for the formation of high early strength, and the later strength of backfill benefited from the continuous accumulation of C-S-H encapsulation and bonding, which further densified its internal structure; (4) the use of titanium-extracted residual slag-based filling cementitious materials contributes to safe, green, and economic mining. Full article