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International Journal of Mining Science and Technology 26 (2016) 511516

Contents lists available at ScienceDirect

International Journal of Mining Science and Technology


journal homepage: www.elsevier.com/locate/ijmst

Valorization of mining waste and tailings through paste backfilling


solution, Imiter operation, Morocco
Khaldoun Abdelhadi , Ouadif Latifa, Baba Khadija, Bahi Lahcen
Mohammadia Engineering School, Mohammed V University, Rabat 10106, Morocco

a r t i c l e

i n f o

Article history:
Received 9 September 2015
Received in revised form 12 December 2015
Accepted 8 January 2016
Available online 16 March 2016
Keywords:
Mining waste
Process tailings
Valorization
Paste backfill
Uni-axial compressive strength

a b s t r a c t
Mine waste and process tailings storage is one of important challenge for which mining operations are
increasingly confronted. Treatment discharges of plants and main part of waste rock development are
generally stored on surface areas. The volume and chemical characteristics of these materials generate
serious problem for required storage spaces and mainly environmental degradation. Paste backfill
(PBF) is one of ingenious solutions to minimize the quantity of tailings to store. PBF is basically defined
as a combination of mine processing tailings, binder, and water mixing. The purpose of this paper is to
present backfilling components characterization and formula verification for a waste valorization solution through paste backfilling technology in Imiter operation. Obtained results and realized analysis
demonstrate PBF conformity and adequacy with assigned underground functions. However the studied
recipe can be more ameliorated to obtain an optimal mixture ensuring the required mechanical strength.
2016 Published by Elsevier B.V. on behalf of China University of Mining & Technology.

1. Introduction
More than 20 years ago, concentrator treatment discharges of
mining plants were wholly stored on tailings parks on surface
areas. The quantity and chemical characteristics of these tailings,
often rich of sulfurs, generate serious problem for storage requiring
spaces and mainly environmental degradation due to acid mine
drainage.
Moroccan mining operations use different kinds of backfill
depending on the extraction method. The most used backfills are
mechanical backfill (only waste material) and hydraulic backfill
(cemented backfill).
The environmental legislation, increasingly requiring, leads
mining societies to minimize as possible, the volume of tailings
stored on the surface. Morocco is one of countries which are going
to make the environment preservation as the first preoccupation
during and at the end of mining activities.
Cemented paste backfill has become increasingly widespread,
mainly because it reduces by 50%60% the quantity of sulphidic
tailings deposited on surface, increases ore recovery, and minimizes stoping sequences [1]. Its a mixture of total mill tailings
generated during mineral processing, Portland cement or blended
cement with supplementary cementitious material (lime,
pulverized fly ash, and ground granulated blast furnace slag), and
Corresponding author. Tel.: +212 662111920.
E-mail address: abdelhadikhaldoun@gmail.com (A. Khaldoun).

water (tap water, lake water or recycled and/or treated mine


process water) [2].
The purpose of this paper is to present testing results and
analysis done to assess Imiter PBF mixture as a waste and tailings
valorization solution against underground defined functions.

2. Paste backfill technology


2.1. PBF advantages
Since their introduction in 1990, PBF technology has demonstrated advantages regarding economics factors, environment,
geo-mechanics and safety [3,4].
This success of PBF is explained first by the engineered character of the product which allows high quality in comparison with
old backfill methods.
Actually, the economic and environment benefits of PBF have
not to be approved. Costs due to tailings management in the storage areas and closing budget can significantly be reduced.
PBF technology is suitable for most mining methods because of
its versatile characteristic which has allowed the increasing of
resource extraction.
In term of safety, PBF is used as local and regional ground support and also help to reduce the number and exposure time of
operators by fast filling rates. The fast filling increases, in addition,
mine productivity with shorter stop cycle times.

http://dx.doi.org/10.1016/j.ijmst.2016.02.021
2095-2686/ 2016 Published by Elsevier B.V. on behalf of China University of Mining & Technology.

A. Khaldoun et al. / International Journal of Mining Science and Technology 26 (2016) 511516

Binding agents
(SiO2+Al2O3)/
(CaO+MgO)
CaSO4 %

Tailings
Sulfides %
Grain size
distribution density,
specific gravity

Mixing water
SO42- content
soluble lime

Additives

2000
1050
460
2.8

Solids %, Cw
(78%-85%)
Binder %
(3%-7%)(by weight)

UCS28-jourw
(kPa)

512

4.8

6.8 7.0

% ciment
Water content
(expected slump)

8.7 9.3 30
W/C

55

70 3.38

% fine (20 m )

3.45 3.50
t (g/cm3)

Fig. 2. Example of component impact simulation curves [8].

Paste
backfill

Fig. 1. Schematic diagram illustrating the different components of paste backfill


[3].

2.2. Influencing parameters


As showed in Fig. 1, the percentage and characteristics of each
PBF component (tailings, binder, and water) affect directly the
mechanical strength of hardened backfill.
(1) Chemical composition of tailings
The sulfurs content is the most important parameter to
verify the chemical composition of tailings because of its
direct influence on increasing the tailings density. The
pulp density is a critical determining factor in the
strength of cemented backfill. Increase in its value significantly increases the backfill strength [5].
(2) Morphology of grain and size distribution
Generally a well-graded material can help to minimize the
hardening time of PBF. The morphology of tailings particles
can also affect the quality of the final product mainly with
phyllo-silicate material.

2.4. PBF mixture optimization


At this stage, each proportion of tailings, binder (one or several
cementation agents) and mixing water has to be defined in an optimized recipe.
The backfilling cost represents 2%20% from the total mining
operation cost. Knowing that 75% of backfilling cost corresponds
to binder acquisition, its important to optimize recipes to product
backfill with a minimum cost [9].
The recipe optimization takes into consideration the mechanical and delivery exigencies thought a pertinent selection of type
and binder proportion.
2.5. Flow sheet production
Generally, the PBF plant is located on the surface nearby the
processing plant to facilitate the recovery of tailings at the end of
the processing line.
The following presents the classic procedure of PBF fabrication:
thickening of tailings slurry to about Cw = 55% (solid weight percentage); filtration of tailings with disk filtersor pressfilters to Cw
between 70% and 82%; binder addition with a proportion between
3% and 7% from the total mass of dry tailings; water addition (processing or fresh water) to generate an optimal slump comprised
between 150 and 250 mm; recipe mixing in a screw mixer with
high power during 45 s to 1 min; and underground implementation of PBF through delivery network [9].
2.6. Transportation

(3) Binder and water chemistry


Its inefficient to choose paste backfill mixtures without
testing first the binder and mixing-water chemistry.
The binder chemistry combined with the mixing-water
chemistry affects the formation of primary and
secondary hydrates during paste backfill strengthening.
The cohesion of the paste backfill matrix is directly
dependent on the nature of the precipitated hydrates
[6]. Presence of sulphide-rich compounds can causes
deterioration in the hardened paste matrix due to
sulfate attack [7].
Fig. 2 shows the composition impact of each component of
mixture on the backfill strength expressed with uniaxial
compressive strength (UCS).

Several works focused on the problematic of backfill transportation since their introduction PBF product must be delivered from
surface to underground via boreholes and pipes at the highest
practical density (Fig. 3) [1013]. Practically, it is not easy to have
real proprieties of PBF rheology because of experimental dispositive complexity.
It makes difficult or even impossible determination or prediction of paste viscosity which depends on several factors [3].
Generally, the slump test and flow-loop test are used to evaluate the paste consistence and pressures drop along the transporting network.

Backfill plant
Mixer

2.3. PBF limit strength


The first step of PBF design is to calculate critical strength
ensuring both stability of PBF and filled stope. The value of critical
strength to reach depends on the function of the PBF in the mining
method.
PBF can be used to support voids roof and then its design will be
focused on rigidity and mechanical cohesion. In case where one
side of PBF has to be exposed, the shear strength is the main
parameter conditioning the backfill stability.

Gravity/pump
system

Pump/gravity
system

Pump
Gravity
system

Pump ?

Paste
backfill
Open stope

Fig. 3. Basic configurations for paste backfill distribution systems [14].

A. Khaldoun et al. / International Journal of Mining Science and Technology 26 (2016) 511516

The prepared PBF should be pumped through pipelines reticulation network without causing any plugging. The pumpability of
PBF is measured by the slump height. The fresh PBF behaves as a
non-Newtonian fluid. That is, applied pressure is required to initiate flow [2].
2.7. In-situ behavior
Once the PBF is deposed in underground voids, it undergoes
various transformations and interactions.
The PBF interactions with rock mass depend mainly on void
dimension but also on pressure at the bottom and over the stope
barricade. Barricade should be designed with appropriate strength
and permeability or drainage by taking into account the backfill
total pressure, pore water pressure, and loads from blast, liquefaction and piping [15].
Like the case of conventional concrete, hydration reactions is
the main phenomena that give PBF solidification. Researches and
tests made by demonstrate that the use of sulphated water contributed to the refinement of the porosity and the increase of
UCS [16]. This has been explained by a combination of the behavior
of the binder and a potential precipitation of sulphated minerals in
the pores which decrease bigger pore proportion.
In addition to hydration reactions which give the mechanical
strength of hardened backfill, other processes occur during the curing time of PBF, mainly drainage of excess water. Settlement and
consolidation, and settlement of saturated fresh mine backfill
depend on the materials coefficient of consolidation cv, which
combines permeability coefficient (or saturated hydraulic conductivity: ksat) and stiffness, and on the filling rate [17].
The strength of pastefill in the filled stope is related to the water
flow which is a function of the paste properties [18]. Transformations and interactions of PBF have to be monitored in the short,
middle and long term. This monitoring will show the impact of
selected recipe and material characteristics on the mechanical
strength of PBF. Adjustment can then be made to find the most
appropriate recipe.
The stress components in backfilled openings are affected not
only by the weight of the fill, but also by interaction between the
fill and the opening walls. Some of the stress in the backfill is thus
transferred to the adjacent walls through shearing forces between
the fill and walls. This leads to a decrease of stress in the fill compared to the overburden stress. This phenomenon is known as the
arching effect [19]. The interaction between backfill and adjacent
rock mass can be quite complex, especially when one of the supporting walls is removed [4].
3. Imiter Mine operation
Imiter Mine is an operation situated in Ouarzazate region,
southern of Morocco, 30 km from Tinghir locality and 150 km from
Ouarzazate city. The exploitation concerns a rich silver ore body.
3.1. Geological overview
Imiter Mine is located in NE edge of the Ouarzazate Basin (Eastern Saghro, Anti-Atlas). The deposit is hosted in the volcanosedimentary series of the Precambrian II and secondarily in
volcano-clastic formations of the Precambrian III. Fig. 4 presents
regional geological and metallogenic context of Imiter deposit.

513

underground exploitation using two principal extraction methods:


cut-and-fill and sublevel stopping (Fig. 5).
Cut-and-fill method extracts ore in horizontal tranches, starting
from the bottom and advancing upward. Voids are backfilled with
hydraulic fill or waste rock when the stope has been worked-out.
Backfilling serves both to support walls and provide a working
platform for equipment for the next tranche.
In sublevel stoping method ore is extracted in open stope (keep
out for worker circulation). Ore body is generally large enough
with an important vertical extension.
Pillars are normally shaped as vertical beams across the ore
body. A specific extraction sequence is followed with primary
and secondary stopes. Primary stopes are progressively filled to
allow the extraction in secondary left ore parts.
In Imiter Mine, the cut-and-fill or sublevel stoping method is
used depending on ore body extension and geometry. The sublevel
stoping can also be longitudinal or transversal according to rock
mass quality and geometry.
Fig. 5 presents an adapted satellite image showing the main
installations of Imiter Mine area. Several tailing storage facility
(TSF) has been built since the operation beginning. Its more and
more difficult to find adequate storage areas near the processing
plant. This shows the important interest of reusing and integration
of this waste material in PBF formulation to reduce required storage area and environmental impacts.
4. Imiter paste backfill
4.1. PBF components characteristics
Imiter operation uses a PBF recipe which combines crashed
waste material (Gravel and sand), tailings and cement. Mixing
water comes from local drilling pumping.
The following presents Imiter PBF characteristics from conducted laboratory testing. All tests were made according to Moroccan standards (NM) or French standards (NF) in case of need.
4.1.1. Gravel and tailings
Table 1 presents results of laboratory testing generally realized
for conventional concrete aggregates. These results confirm
acceptable characteristics according to Moroccan standards.
I appears that gravel and sand used for Imiter PBF mixture presents good conformity according to concrete standards. Although
PBF materials are not at the same requirement level of conventional concrete, this results show the quality of used materials
which will eventually improve quality of final product.
Table 2 presents fine particles proportions for tailing obtained
by sedimentation techniques. Fig. 6 shows the particle size distribution for gravel, sand and tailings mixture.
The general grain size distribution obtained is relatively spread
and can also have a positive impact on the final PBF strength.
Table 3 presents chemical composition of tailing obtained by XR
technics.
Processing of XR results gives mineralogical composition presented in Table 4.
4.1.2. Binder
Tables 5 and 6 present, respectively, physical and mechanical
testing realized on cement (CPJ45 type) sampled from site stock.
Results are presented in comparison with Moroccan standard NM
10-1-004 for hydraulic binder.

3.2. Ore extraction


In an old stage of the mine, the open pit was the principal
extraction method. Actually the main extracted ore is coming from

4.1.3. Mixing water


Mixing water comes from local drilling pumping. Table 7 presents chemical composition obtained by laboratory analysis.

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A. Khaldoun et al. / International Journal of Mining Science and Technology 26 (2016) 511516

Sidi flah
Ag

West African
Cration

Tafrent
Au

Zgounder
Ag

Atlas
Central

Igherm
Anti

Kerdous
A
tla
nt
ic
O
ce
an

SAF

Agadir
E

Ougnat
ro

Sagh

Sirwa

N
W

Tamlelt
Au

South
Ouarzazate

High

Abidjan

Fault

Atlas

Atlas

15

500 km

Bou Maadine
Cu-Pb-Zn-Au-Ag

Imiter
Ag-Hg

Ifni

as Fault

Tagmout
Cu-Ag

Bou azzer
Co-Ni-As-Ag-Au

Akka

Tiouit
Au-Cu

Anti-Atl

Zenaga
Au

100 km

Ordovician
Late Ediacaran to
Cambrian

Bleida
Cu-Au

Ediacaran
Cryogenian and
Paleoproterozoic

Iourirn
Au

Fig. 4. Location of the main ore deposits in the Anti-Atlas belt [20].

Plant
O

TSF-7

TSF-5

TSF-9

TSF-6

TSF-4

TSF-8

TSF-3
TSF-2

Principal ore body


underground extraction

Old open pit


extraction

200 m

Fig. 5. Satellite image showing main installation of Imiter operations area, TSF = tailing storage facility (Adapted from Google Maps).

Table 1
Laboratory characterization of Imiter paste backfill gravel (%).
Laboratory testing

Flatness coefficient

Superficial cleanliness

Los angeles hardness

Sand equivalent

Testing result
Standard NM10.1.27

23
625

0.3
63

15
630

56
P60

Table 2
Tailing fine particle distribution.
Particle size (PS) (l)

Proportion (%)

PS < 2
2 < PS < 20
20 < PS < 80

18
38
20

Results are also presented in comparison with Moroccan standards


NM 10-1-008.
Table 8 presents PBF mixture actually used in Imiter Mine and
combining the above characterized materials. A cement percentage
of 2% is applied.
4.2. Prediction of PBF strength
Typically stopes of 4 m width and 4 m height are mined with
fill-and-cut instead 15 m height for sublevel stopping method.

The most significant design parameters when evaluating the


cemented paste backfill stability are the mechanical properties
(i.e., uniaxial compressive strength UCS and the modulus of elasticity E) obtained from the compression tests [21]. The following presents an estimation of required PBF UCS according to the assigned
function.
The long term (>90 days) UCS of filling backfill can be predicted
by Eq. (1), which considers a null friction angle: / = 0 [22].




H
UCSdesign SF  cb H 1
L

where FS is the safety factor, cb the PBF bulk unit weight, kN/m3; H
the PBF height, m; and L the stope width, m.
The required UCS was calculated for different safety factors
based on Imiter ore geometry in case of each mining method. A

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A. Khaldoun et al. / International Journal of Mining Science and Technology 26 (2016) 511516
100
90
80

Passing (%)

70
60
50
40
30
20
10
0
31.50

16.00

8.00

4.00

2.00

1.00

0.50

0.25

Sieving analysis

0.13
63.00
Sieve bores

31.50

16.00

8.00

3.15

1.60

1.00

0.40

Sedimentation analysis

Fig. 6. Imiter PBF particle size distribution.

Table 3
Chemical composition of tailings.
Chemical element

AL2O3

CaO

Fe2O3

K2O

MgO

MnO

Na2O

P2O5

SiO2

TiO2

LOI

Total

Element percentage (%)

13.86

2.81

6.33

3.59

3.96

0.18

1.61

0.19

57.37

0.72

8.47

99.12

Table 4
Semi-quantitative mineralogical composition of tailings.
Mineral

Composition in tailings (%)

Dolomite
Quartz
Muscovite
Albite

35
24
16
14

PBF bulk unit weight of 18 kN/m3 was considered. Table 9 presents


the obtained results for UCS design prediction.
These results show difference between the required UCS for
each method. This difference is due to the exposed PBF height face
which depends on utilized method. This can be materialized by
adopting two PBF recipes.
5. Uniaxial compressive strength results
PBF mixtures presented in chapter 4 was reconstituted in laboratory and crafted as cylindrical specimens of 10 cm diameter and
20 cm length. Mechanical performance of the analyzed PBF was
evaluated by UCS testing. Tests were realized for different ages of
specimens: 7, 14, 21 and 28 days after confection. UCS test is
widely used as principal parameter for PBF backfilling system
design because of its low cost and possibility to make correlation
with other mechanical parameter.
Table 10 presents UCS results for actual PBF mixture.
6. Results discussion
Several laboratory testing and analysis have been realized to
identify and evaluate each component of Imiter PBF and the resulting backfilling mixture. Results show generally comply physical
and chemical characteristics for development waste, tailing, binder
and water. The conformity of used material was, at a first time,
evaluated according to conventional concrete standards.

Table 6
Mechanical testing-cement CPJ45.
Item

Uniaxial compressive strength (MPa)

Testing result
Standards NM 10-1-004

After 2 days

After 7 days

After 28 days

18.7

27.3
P20

39.5
P32.5

Table 7
Chemical analysis of mixing water.
Chemical
parameter

Ph

Material in
suspension
(mg/L)

Testing
6.60 0.5
result
Standards P4 62000
NM 101-008

Dissolved
salt (mg/
L)

Sulfates
(mg/L)

Chlorides
(mg/L)

Organic
material
(mg/L)

617

153.60

194.70

65000

62000

6500

6200

Table 8
Imiter PBF mixture.
Component

Quantity

Gravel (kg)
Sand (kg)
Tailings (kg)
Water (L)
Cement (kg)
Total weight (kg)

600
1000
340
500
40
2480

The mechanical performance of the formulated PBF was evaluated by the uniaxial compressive strength test and analytical prediction model. Table 11 presents values of analytical prediction of
the long term uniaxial compressive strength made in chapter 4

Table 5
Physical testingcement CPJ45.
Physical parameter

Setting time

Expansion (mm)

Specific surface (Blaine fineness) (cm2/g)

Testing result
Standards NM 10-1-004

2 h 00 min
P1 h 30 min

1.7
610

2470
P2200

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A. Khaldoun et al. / International Journal of Mining Science and Technology 26 (2016) 511516

Table 9
UCS design calculation according to safety factor.
Item

UCS design (kPa)

Safety factor
Cut-and fill
Sublevel stoping

1.0
36.0
56.8

1.1
39.6
62.5

1.2
43.2
68.2

1.3
46.8
73.8

1.4
50.4
79.5

Table 10
UCS results for Imiter PBF.
Age (day)

Mean unit weight (kN/m3)

Mean UCS (MPa)

7
14
21
28

17.9
17.2
17.0
16.9

0.40
0.72
1.08
1.33

Table 11
Predicted UCS design instead experimental values.
PBF function

Predicted UCS (kPa)


Curing time >90 days

Experimental result (kPa)


Curing time = 28 days

Cut and fill


Sublevel stoping

54
85

1330
1330

considering a safety factor of 1.5, and corresponding experimental


laboratory testing after 28 days of curing time.
Table 11 shows that the PBF recipe can be more optimized; laboratory testing gives a high UCS value at 28 days of curing time
compared to predicted values. This high experimental value can
be explained by the mixture characteristics of Imiter PBF which
combines in addition to plant tailing, crashed waste rock from
mine development against an ordinary PBF combining only plant
tailings, binder and mixing water.
7. Conclusion and prospects
Analytical results show difference between the required UCS for
each extraction method. This difference between the cut-and-fill
and sublevel stoping method is due to the exposed PBF height face.
This can be materialized by adopting two PBF recipes.
Obtained result confirms that utilized recipe is adequate with
the assigned functions of PBF. However, PBF recipe can be ameliorated to obtain an optimal mixture ensuring required mechanical
strength.
The future works related to this topics will be focused on the
recipe composition to define the optimal binder proportion ensuring required mechanical properties, and evaluate the possibility to
reduce or eliminate waste mine gravel from the PBF mixture. The
final objective is to determinate an optimal recipe combining low
possible cost and strength requirements.
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