FROM LABORATORY TO INDUSTRIAL SCALE
Authors: Janne Kauppi, Vladimir Zhukov, Metso Outotec
Millions of tonnes of tailings with no commercial use are produced every year in Europe. Instead, tailings are typically used in various earthworks applications, such as to backfill mines and as a covering material for surface landfills. Geocomposite materials are technological innovations that have particular appeal in industrial sectors where sustainable development is important. Products made using geopolymer technology represent future product families and are characterized by cheap local raw material, high structural integrity, low carbon footprint and multiple uses in the same location. The novelty of the material also increases its potential as part of the design of tomorrow’s built environments; it brings new dimensions to the readiness to use free design, advanced manufacturing automation and robotics.
INNOVATIVE CONSTRUCTION MATERIAL WITH ECOLOGICAL AND ECONOMIC POTENTIAL The UIR project succeeded in identifying commercial opportunities related to tailings, which can be enriched in this context by means of geopolymer chemistry. In the future,
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tailings could completely replace natural sand as the fine aggregate used in construction-grade geopolymer materials. Unused tailings have excellent potential in reducing CO2 emissions compared to existing building materials. The mineralogy of each mining concession is different, and each operator therefore needs to develop a recipe that works for them. Research has also shown that some mineralogical systems require very few commercial chemicals and are therefore highly competitive and environmentally friendly compared to, for example, steel-reinforced concrete. New kinds of industrially designed instrument systems have promising potential for 3D printing, eliminating sharp edges, creating optimal geometry for industrial processes and providing excellent compressive strength and earthquake resistance. 3D printing achieves these properties at a lower overall cost compared to steel structures and Portland steel-cement concrete foundations. However, it should be noted that geocomposite printing is still in its infancy and the scale is small for industrial applications. Industry’s need for large-scale
structural models capable of convincing decision-makers must also be taken into account. From the industry perspective, it appears that geopolymers and manufacturing based on 3D printing have a brighter future in the mining sector than even in the construction industry. It is very important to correctly understand the roles of research and product development in the process of ramping additive manufacturing up to an innovative industrial scale. Geocomposites are extremely well placed to break through in miningrelated construction.
UIR AS A VEHICLE OF VERSATILE INNOVATION AND BUSINESS DEVELOPMENT Metso Outotec was involved in the project since its inception. Cooperation with LUT University and other partners enabled the implementation of a well-run development project of a high standard.
