Behaviour of Compacted Filtered Iron Ore Tailings–Portland Cement Blends: New Brazilian Trend for Tailings Disposal by Stacking

Failures of tailings dams, primarily due to liquefaction, have occurred in Brazil in recent years. These events have prompted the Brazilian government to place restrictions on the construction of new dams, as iron ore tailings deposited behind upstream dams by spigotting have been shown to have low in situ densities and strengths and are prone to failure. This work proposes a new trend for tailings disposal: stacking compacted filtered ore tailings–Portland cement blends. As part of the proposal, it analyses the behaviour of compacted iron ore tailings–Portland cement blends, considering the use of small amounts of Portland cement under distinct compaction degrees. With the intention of evaluating the stress–strain–strength–durability behaviour of the blends, the following tests were carried out: unconfined compression tests; pulse velocity tests; wetting–drying tests; and standard drained triaxial compression tests with internal measurement of strains. This is the first study performed to determine the strength and initial shear stiffness evolution of iron ore tailings–Portland cement blends during their curing time, as well friction angle and cohesion intercept. This manuscript postulates an analysis of original experimental results centred on the porosity/cement index (η/Civ). This index can help select the cement quantity and density for important design parameters of compacted iron ore tailings–cement blends required in geotechnical engineering projects such as the proposed compacted filtered iron ore tailings–cement blends stacking.

Unsaturated mine tailings disposal

Filtered tailings is the disposal technology that is most likely to yield an unsaturated state of the tailings. Such state has important benefits. A dam to contain the mine wastes is no longer needed, the risk of polluting seepage is minimized, and liquefaction of tailings is prevented. Filtering also allows most of the water mixed with the tailings to be recovered and reused in the process. The resulting material can be handled with traditional soil moving equipment to form a stack, for instance. While the idea is simple, the multiple phenomena involved in the tailings unsaturated disposal make up a complex process. The present work is based on a case study, the Casposo Mine filtered tailings disposal facility, located in the central Andes of Argentina. Throughout ten years of operation, a series of field and laboratory studies have been carried out to characterize the phenomena that intervene in the disposal of filtered tailings. Two stages were studied in detail: air drying upon tailings discharge and tailings compression under the weight of the subsequent lifts of the stack. Flocculant agents were found to have an outstanding influence in the tailings behaviour. Because of the multiple influencing factors, the process outcome (namely, the tailings water content and their void ratio) is highly variable. To deal with such variability, projects must include enough redundancy. In this regard, the case study’s incorporation of waste rock layers interspersed between tailings layers was a successful experience.