Backfill Binder System

The backfilling provides ground support and regional stability, thus facilitating ore removal from nearby regions.

The large underground voids created by the ore removal are backfilled with the waste tailings in the form of paste fills, hydraulic fills, and others. The tailings are placed in the form of slurry that undergoes self-weight consolidation. A small dosage of binder is added to paste fill and cemented hydraulic fill to enhance strength. Considering the high cement cost, mines are using fly ash and slag to partially replace cement with blended cements.

  • Enabling a more complete extraction of the ore body.
  • Environmental constraints.
  • Management of surface subsidence.
  • Minimising waste-rock dilution.
  • Promotion of mine stability.
  • Reducing the volume of waste hauled to surface.
  • Recovery of remnant ore pillars.
  • Surface disposal limitations.

Rock Fill:

  • Placement of waste rock into the mining void. Generally undertaken using trucks and gravity, but sometimes placed or pushed up using LHDs.
  • Development or run-of-mine waste (sometimes imported waste).
  • Load Haul Dump (LHD) loaders, haul truck or conveyor.
  • Suitable as a working platform or for secondary stopes. Cannot be exposed vertically or under-cut.
  • Little quality control, highly variable particle size.
  • Relative cost: Low.

Cemented Rock Fill:

  • Cementitious slurry applied to waste rock. Systems vary but slurry is added to the waste rock, is mixed and then placed into the stope using a truck or LHD.
  • Ideally crushed and screened rock, development, or run-of-mine waste (sometimes imported waste). Particle size optimisation required to maximise particle-packing density.
  • LHD or haul truck. Cementitious slurry via agitator truck or slickline from surface.
  • Possible to achieve strengths >4 MPa depending on mix. Vertical exposure.
  • Size manipulation, mixing systems and deposition method greatly affects the final product quality.
  • Relative cost: Low to High. Trade-off between capital and operating costs.
  • Excellent for: Filling voids which will be exposed during future mining.

Hydraulic Fill:

  • Hydraulic disposal of tails into stope, with or without Solids will settle and require topping up to full on several occasions. Fill fence or weep-bags designed to allow water to escape.
  • Coarser than paste fill. Often requires hydro-cyclone (or similar) to modify Particle Size Distribution (PSD).
  • Reticulated from surface. Contained behind fill fence or in weep-bags.
  • The backfill dewaters during placement so increases demand on mine dewatering system. Requires topping up as backfill dewaters. Water cannot be allowed to accumulate in the stope as this poses a risk of failure or inundation to the mining operation.
  • Good quality control possible, susceptible to binder segregation during dewatering.
  • Relative cost: Low cost for a hydraulically delivered product but cement cost is high when required.
  • Excellent for: Establishing working platforms and vertical exposure where mine water is not considered a problem.

Paste Fill/ Cemented Aggregate Fill:

  • Binder added to whole-stream tailings, with or without aggregate and reticulated into the mine void.
  • Minimum 15% passing 20 µm.
  • Reticulated from surface. Contained behind fill fence or weep-bag.
  • High quality control, homogenous product.
  • Relative cost: Capital cost generally higher but operating costs lower than for hydraulic fill. Costs must be traded off vs backfill quality.
  • Excellent for: Stabilising voids and backfilling workings and filling voids which will be exposed during future mining exposures.
  • Conventional backfill binders bleed at a rate between 29 to 36%. Ec0star is currently at 18% to 22%. Based on the 18% to 22% bleed, that is approximately 15% more gained backfill volume underground.
  • Efficiency % per ton of backfill placed is currently 80%.
  • Phase 2 of the product will have a 100% efficiency of backfill placed.
  • 100% locally manufactured product.
  • Flow rate is approximately 6.9 seconds.
  • Higher compressive and flexural strengths.
  • Better flow rate.
  • More economical.
  • Superior chemical resistance.
  • Lowers hydration tempratures.
  • Reduction of pump-line pressures.
  • Quicker mixing per batch.
  • Reduced production times.
  • Removal of toxic pollutants.
  • Removal of chemical burns within cementitious systems.
  • This system requires any type of cement based on strength requirements mixed with ecofill to give the desired results.

View the product brochure to learn more about Backfill Binder System.

View some applications of Backfill Binder System below.

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