Recovering Iron from Iron Ore Tailings and Preparing Concrete Composite Admixtures

An improved balanced replicated sampling design for preliminary screening of the tailings ponds aiming at zero-waste valorization. A Romanian case study

The scope of this study consists of setting up of an integrated cost-effective sampling & laboratory analyses procedure which delineates sampling, sub-sampling and analytical uncertainties in case of fine-grained extractive waste deposits. This procedure is designed to support the decision makers towards fine-grained waste deposits upcycling and land reclamation. This procedure consists of a balanced replicated sampling design (BRSD) coupled with a three split levels ANOVA data processing. The paper provides the readership with the mathematical backgrounds of the three split level ANOVA analysis (3L-ANOVA) and an Excel algorithm for its implementation. Also, the paper presents an example of implementation of the developed methods in the case of a Romanian iron ore tailings (IOT) old pond. The findings of the paper consist of: a) argues, based on OM, SEM-EDS, XRFS and XRD observations, that classical TOS is ineffective for fine-grained waste deposits; b) BRSD in conjunction with 3L-ANOVA analysis is the only approach fit for reliable characterization of the fine-grained stockpiles; c) sampling uncertainty is the critical factor of the uncertainty budget of the analyte concentration; d) Lilliefors approach is adequate for the hypothesis testing where or not the measurand is normal distributed; e) The outcomes of the BRDSD&3L-ANOVA investigations carried on Teliuc tailings, estimated at circa 5.5* 106 m3, consist mainly of mineral quantification at lot level i.e. quartz ∼54% (±7%), hematite ∼15% (±3%), calcite ∼11% (±3%), MgO 3% (±1%), Al2O3 9% (±2%). The concentrations of some CRMs like Ti, V, Ba, Y, W were found at ACE limits and their associated relative expanded uncertainties overpass 50%. Thus, the expanded uncertainties clearly depict the reliability of acquired data for the decision makers regarding waste valorization. f) The IOT into Teliuc can be upcycled as minerals for cement and ceramic industries as well as for geopolymer manufacture. Also, IOT can be downcycles as filler in road construction and mine closure. Finally, the Teliuc yard can be rehabilitated with zero-waste left behind. The data exactness provided by this procedure can be increased to any desirable level through increasing the number of collected items, but the cost of sampling and analyses increases proportionally. In such circumstances, the posted approach can be tailored at the stakeholder request as to safely underpin the decision to turn finegrained by-products into valuable secondary resources, facilitating a greater circularity of the mining industry.

Mechanical Behaviour Evaluation of Full Iron Tailings Concrete Columns under Large Eccentric Short-Term Loading

In this study, full iron tailings concrete (FITC) was created using iron tailings from a tailings pond in Qian'an, China. Iron tailings account for 86.8% of the total mass of solid raw materials in the FITC. To enable large-scale use of FITC, a comprehensive investigation of the structural behaviour of full-iron tailing-reinforced concrete (FITRC) specimens is warranted. Therefore, eight rectangular reinforced concrete (RC) columns with conventional reinforced concrete (CRC) as a control were tested to investigate the effects of section dimensions, initial eccentricities, and concrete strengths, on the structural behaviour of FITRC columns under large eccentric short-term loading. The experimental and analytical results indicated that the sectional strain of the FITRC columns satisfied the plane-section assumption under short-term loading, and the lateral deflection curve agreed well with the half-sinusoidal curve. In addition, the FITRC columns exhibited a slightly lower cracking load and lower ultimate load capacity than the CRC columns, and the crack widths were larger than those of the CRC columns. The reduction in the load capacity observed in the FITRC was within the permissible range stated in the design code, thereby satisfying the code requirements. The deformation coefficients of the FITRC and CRC columns were identical, and the cracking and ultimate loads calculated according to the current code and theories were in good agreement with the measured results.

Concrete Made with Iron Ore Tailings as a Fine Aggregate: A Step towards Sustainable Concrete

The need for low-cost raw materials is driven by the fact that iron ore tailings, a prevalent kind of hazardous solid waste, have created major environmental issues. Although many studies have focused on using iron ore tailing (IOT) in concrete and have reported positive results, readers may find it difficult to accurately assess the behaviors of IOT in concrete due to the scattered nature of the information. Therefore, a comprehensive assessment of IOT in concrete is necessary. This paper thoroughly reviews the characteristics of concrete that contains IOT such as fresh properties, mechanical properties and durability at different age of curing. The outcome of this review indicates that by using IOT, concrete's mechanical properties and durability improved, but its flowability decreased. Compressive strength of concrete with 20% substitution of IOT is 14% more than reference concrete. Furthermore, up to 40% substitution of IOT produces concrete that has sufficient flowability and compactability. Scan electronic microscopy results indicate a weak interfacial transition zone (ITZ). The optimum IOT dosage is important since a greater dose may decrease the strength properties and durability owing to a lack of fluidity. Depending on the physical and chemical composition of IOT, the average value of optimum percentages ranges from 30 to 40%. The assessment also recommends areas of unsolved research for future investigations.

Preparation of Mineral Admixture from Iron Tailings with Steel Slag-Desulfurization Ash and Its Application to Concrete

Iron tailing solid waste not only has a high annual output but also has a low comprehensive utilization rate. Low utilization rate of iron tailings seriously restricts the development of comprehensive utilization of solid waste. In order to prepare an iron tailings-based ternary solid waste admixture and to verify its application to concrete, first, the effect of solid waste synergy on the strength of an iron tailings-steel slag-desulfurization ash admixture (ISD) system was investigated. Second, the effect of chemical activator dosing on the strength of an ISD system was studied and the mechanism of chemical activator action on the ISD system was investigated by thermogravimetric analysis (TG-DTA) Then, the effect of this admixture on the strength of concrete was studied. Finally, the mechanism of the effect of this admixture on the strength of concrete was clarified by mercury intrusion porosimetry (MIP) and backscattering electron tests (BSE). The results showed that the 7 d and 28 d compressive strengths of the ISD admixture were significantly higher than those of iron tailings single admixture. The 7 d and 28 d compressive strengths of the ISD system reached 24.9 MPa and 36.1 Mpa, respectively, when the ratio of iron tailings:steel slag:desulfurization ash = 1:1:1. Na₂SiO₃ is suitable for the early strength agent of the ISD admixture, but the amount of admixture should not exceed 0.6% of the admixture. TG-DTA shows that Na₂SiO₃ is enhancing the early strength of the ISD system by promoting the consumption of Ca(OH)₂ in the ISD system to produce C-S-H. However, in the late reaction of the ISD system, Na₂SiO₃ inhibits the late strength development of the ISD system by suppressing Ca(OH)₂ production. Concrete with ISD dosing of 30% or less meets the C40 requirement. MIP and BSE show that ISD provides a filling effect to concrete, but also causes a reduction in the active reactants of concrete and the combined effect of microfilling and active effects affects the strength development of ISD concrete. This study provides a theoretical and scientific basis for the preparation of iron tailings-based ternary solid waste dopants, and, in addition, the study promotes the consumption of iron tailings solid waste and the development of multiple solid waste dopants.

A review on the industrial solid waste application in pelletizing additives: Composition, mechanism and process characteristics

Reducing the cost of pellet additives as a substitute for reducing bentonite binder is an important research direction of new pellet additives. There are some industrial solid wastes that have the similar physical and chemical properties to bentonite, and SiO₂ content of them may be much lower than bentonite, but also contains a lot of Fe₂O₃, Al₂O₃, MgO, B₂O₃ and other components beneficial to the quality of pellets, which have been paid more attention by many pellet workers. In this review, the effect mechanism of Fe₂O₃, Na₂O/K₂O, Al₂O₃, SiO₂, CaO, MgO and B₂O₃ in the industrial solid wastes on the fired strength and reduction expansion of pellets were systematically summarized. At the same time, the influences of five representative large scale modified industrial solid waste additives including iron tailings, bauxite tailings, fly ash, red mud and boron sludge on the properties of green pellets and finished pellets were described in detail. It can be seen that the applications of industrial solid waste in pellet additives can partially or completely replace bentonite binder, especially fly ash, red mud and boron sludge, which can not only improve the quality of pellets, but also decrease the cost, save energy and reduce pollution, with significant economic benefits.

Preparation of a newly synthesized biopolymer binder and its application to reduce the erosion of tailings

A new type of binder was developed by grafting casein and β-glucan to investigate its effect on tailings erosion and plant growth. 6% casein and 2% β-glucan were recommended as the best ratio of the new biopolymer binder, which had the best effect on the soil utilization of iron tailings. The infrared analysis of the new binder demonstrated that casein and β-glucan reacted adequately as raw materials. The results of physichemical properties and loss prevention of iron tailings showed that the binder-treated soils demonstrated lower erodibility compared with untreated iron tailings. The particle size of the tailings was increased after the addition of the binder. In treated soil, the content of soil organic matter increased significantly, which provided sufficient nutrients for the plants growing. Compared with natural tailings without binder, plant height, fresh weight, chlorophyll content, and enzyme activity (POD and SOD) were also significantly increased. This study overcame the current defects of biopolymer in soil improvement and provided an environmentally friendly method to prevent the loss of iron tailings and promote its soil utilization efficiency.

Effects of HPMC on Workability and Mechanical Properties of Concrete Using Iron Tailings as Aggregates

Iron ore tailings (IOTs) are gradually used as building materials to solve the severe ecological and environmental problems caused by their massive accumulation. However, the bulk density of IOT as aggregate is too large, which seriously affects the concrete properties. Therefore, in this paper, the effect of hydroxypropyl methylcellulose (HPMC) on the workability, mechanical properties, and durability of concrete prepared from IOT recycled aggregate was studied. The action mechanism of HPMC on the workability and the mechanical properties of the IOT concrete was analyzed by mercury intrusion porosimetry (MIP) and scanning electron microscope (SEM). The results show that HPMC can effectively improve the segregation problem caused by the sinking and air entrainment of IOT aggregate and improve the crack resistance of concrete with little effect on its compressive strength and electric flux. These results are due to the air-entraining thickening effect of HPMC, which improves the slurry viscosity, hinders the sinking of aggregate, and improves the workability. At the same time, HPMC film, after concrete hardening, will bridge the slurry and aggregate through physical and chemical effects, hinder the propagation of microcracks, and improve the crack resistance.

Extraction of Value-Added Minerals from Various Agricultural, Industrial and Domestic Wastes

Environmental pollution is one of the major concerns throughout the world. The rise of industrialization has increased the generation of waste materials, causing environmental degradation and threat to the health of living beings. To overcome this problem and effectively handle waste materials, proper management skills are required. Waste as a whole is not only waste, but it also holds various valuable materials that can be used again. Such useful materials or elements need to be segregated and recovered using sustainable recovery methods. Agricultural waste, industrial waste, and household waste have the potential to generate different value-added products. More specifically, the industrial waste like fly ash, gypsum waste, and red mud can be used for the recovery of alumina, silica, and zeolites. While agricultural waste like rice husks, sugarcane bagasse, and coconut shells can be used for recovery of silica, calcium, and carbon materials. In addition, domestic waste like incense stick ash and eggshell waste that is rich in calcium can be used for the recovery of calcium-related products. In agricultural, industrial, and domestic sectors, several raw materials are used; therefore, it is of high economic interest to recover valuable minerals and to process them and convert them into merchandisable products. This will not only decrease environmental pollution, it will also provide an environmentally friendly and cost-effective approach for materials synthesis. These value-added materials can be used for medicine, cosmetics, electronics, catalysis, and environmental cleanup.

Effects of Elevated Temperatures on the Properties of Cement Mortars with the Iron Oxides Concentrate

Using the waste materials in the production of the building materials limits the storage of the wastes, burdensome for the environment and landscape, and makes possible to manufacture the materials and products with the use of the less volume of the raw materials. Cement concretes and mortars as the basic building materials offer the broad prospects of utilization of the recyclable or waste materials. The wastes from the iron ore processing are the solid wastes resulting from the process of enrichment of the ore concentrate. The paper presents the results of testing three mortars, in which a part of fine aggregate was replaced with the iron oxide concentrate (IOC) resulting from such a process. IOC has been used as a substitute of 10%, 20% and 30% (by mass) of the fine aggregate. The effect of the concentrate on the mechanical performance of the mortars at the high temperature (up to 600 °C) was also investigated. The IOC is a neutral material, not affecting chemically the process of cement hydration. The addition of IOC slightly improves the strength of the cement mortars (by 5% to 10%). In the case of the larger amount (20–30%) of the addition, the use of superplasticizer is necessary. The IOC significantly improves the high temperature resistance of the cement mortars (300 °C). The cement mortars containing 30% of the IOC addition keep 80% of the initial flexural and compressive strength when exposed to the temperature 450 °C.

Efficient activation of peroxymonosulfate by composites containing iron mining waste and graphitic carbon nitride for the degradation of acetaminophen

In this work, the potential to use an iron mining waste (IW), rich in α-Fe₂O₃ and α-FeOOH, for the development of composites based on graphitic carbon nitride (CN) is demonstrated. These materials were synthesized through a simple thermal treatment at 550 °C of a mixture containing melamine and different IW mass percentages, giving rise to the catalysts xIWCN (where x is related to the initial mass percentage of IW). The iron phases of the precursor were partially transformed throughout the formation of the composites, in such a way that a mixture of α-Fe₂O₃ and γ-Fe₂O₃ was observed in their final composition. Furthermore, structural defects were produced in the carbonaceous matrix of the materials, causing the fragmentation of g-C₃N₄ and an increase of surface area. The catalytic activities of these composites were evaluated in reactions of peroxymonosulfate activation for the degradation of paracetamol. Among these materials, the composite 20IWCN showed the best catalytic activity, being able to degrade almost 90 % of the total paracetamol in only 20 min of reaction. This catalyst also demonstrated high chemical stability, being successfully utilized in five consecutive reaction cycles, with negligible iron leaching.

Comprehensive reutilization of iron in iron ore tailings: preparation and characterization of magnetic flocculants

A large number of iron ore tailings (IOTs) are produced in steel industry, posing threat to the environment during its storage and disposal. To effectively reutilize Fe in IOTs, we propose a comprehensive utilization scheme: (1) most Fe in IOTs is extracted by concentrated hydrochloric acid to form FeCl₃ flocculants; (2) after separation from the FeCl₃ flocculants, a small amount of Fe is absorbed on the residue solids, which is further washed out to synthesize micron Fe₃O₄ as magnetic seeds. Results show that the as-synthetic FeCl₃ flocculants meet the product standard for FeCl₃ flocculants in China (GB/T 4482-2018) after a series of treatments including rotary evaporation, neutralization, and dilution and have comparable performance with commercial polyaluminum chloride (PAC) and polyaluminum ferric chloride (PAFC). Moreover, the addition of synthetic superparamagnetic Fe₃O₄ (as magnetic seeds) doubled the flocculation rate compared with as-synthetic FeCl₃ flocculants alone. Finally, the reutilization of Fe in IOTs can create a direct economic value of ¥ 1.27/kg IOTs, and produce 745 g high-silicon residues for further reutilization, which indicates that our comprehensive utilization scheme is of great application potential.

Retention of Contaminants Elements from Tailings from Lead Mine Washing Plants in Ceramics for Bricks

Mining activity is essential for the social welfare of the population. However, this activity produces a series of mining waste. These mining wastes, if not properly treated, can produce significant environmental pollution. This study develops the incorporation of tailings from washing plants in ceramic materials for bricks in order to retain the contaminating elements in the ceramic matrix. To this end, firstly, a physical and chemical characterisation of the mining waste is carried out and different groups of samples are conformed with clay and mining waste. These conformed samples with mining waste are evaluated through different physical and mechanical tests typical in the ceramic industry, studying the variation of properties by the incorporation of the waste. In turn, the leachates from the groups of conformed samples are analyzed, confirming the retention of the contaminating elements of the mining waste in the ceramic matrix. The results of these tests showed that ceramics can be made for bricks with up to 90% mining waste, obtaining physical and mechanical properties acceptable regarding the regulations and retaining the contaminating elements in the ceramic matrix, as confirmed by the leachate tests.

Editorial for Special Issue “Towards a Sustainable Management of Mine Wastes: Reprocessing, Reuse, Revalorization, and Repository”

The mining industry continues to face many challenges due to its potential environmental impacts [...]

A Holistic Approach in Re-Mining Old Tailings Deposits for the Supply of Critical-Metals: A Portuguese Case Study

Demand growth for metallic minerals has been faced with the need for new techniques and improving technologies for all mining life-cycle operations. Nowadays, the exploitation of old tailings and mine-waste facilities could be a solution to this demand, with economic and environmental advantages. The Panasqueira Mine has been operating for more than a century, extracting tungsten and tin ore. Its first processing plant, “Rio”, was located near the Zêrere river, where mineral-processing residues were deposited on the top hillside on the margin of this river in the Cabeço do Pião tailings dam. The lack of maintenance and monitoring of this enormous structure in the last twenty years represents a high risk to the environment and the population of the surrounding region. A field-sample campaign allowed the collection of data, and resulted from laboratory tests to use regression optimization. Re-mining the tailings by hydrometallurgical methods was considered to satisfy the two conditions of metal demand and environmental risk. The metal content in Cabeço do Pião was shown be enough for environmental restoration. The re-mining solution was studied, taking into account the technical, economic, social, and environmental aspects.

The Potential of Iron Ore Tailings as Secondary Deposits of Rare Earths

Rare earths have appeared in the market with new energy and Information Technology and Communications (ITC) applications. While their demand grows exponentially, their production is experiencing a bottleneck given that their deposits are concentrated in very few locations, mainly in China. This scarcity and dependence have turned them into strategic minerals, and the location of new sources has become vital. On the other hand, the inevitable trend towards sustainability favors the reuse of waste to avoid the degradation of new areas and the need for waste storage. One of the biggest generators of waste is iron mining. The tailings are stored in huge ponds with consequent environmental problems and risks. As tailings come from a concentration process, they incorporate different amounts of rare earths depending on their separation behavior. To evaluate the viability of these resources as potential repositories of rare earths, samples of different types of deposits and treatments were selected. The presence of different rare earths in them was determined through spectroscopy techniques to evaluate their use as a deposit. The results show an increase in the concentration of rare earths, especially high-density ones, which, although currently not economically feasible given the very wide geographical distribution of iron mining, represent a fundamental strategic reserve.