Compacted Iron Research Articles

Conceptual and Applied Aspects of Water Retention Tests on Tailings Using Columns

The water retention capacity of porous materials is crucial in various geotechnical and environmental engineering applications such as slope stability analysis, landfill management, and mining operations. Filtered tailings stacks are considered an alternative to traditional tailings dams. Nevertheless, the mechanical behaviour and stability of the material under different water content conditions are of concern because these stacks can reach considerable heights. The water behaviour in these structures is poorly understood, particularly the effects of the water content on the stability and potential for liquefaction of the stacks. This study aims to investigate the water retention and flow characteristics of compacted iron ore tailings in high columns to better understand their hydromechanical behaviour. The research used 5 m high columns filled with iron ore tailings from the Quadrilátero Ferrífero region in Minas Gerais, Brazil. The columns were prepared in layers, compacted, and instrumented with moisture content sensors and suction sensors to monitor the water movement during various stages of saturation, drainage, infiltration, and evaporation. The sensors provided consistent data and revealed that the tailings exhibited high drainage capacity. The moisture content and suction profiles were effectively established over time and revealed the dynamic water retention behaviour. The comparison of the data with the theoretical soil water retention curve (SWRC) demonstrated a good correlation which indicates that there was no hysteresis in the material response. The study concludes that the column setup effectively captures the water retention and flow characteristics of compacted tailings and provides valuable insights for the hydromechanical analysis of filtered tailings stacks. These findings can significantly help improve numerical models, calibrate material parameters, and contribute to the safer and more efficient management of tailings storage facilities.

One-part alkali-activated GGBFS as a cement for enhancing compacted filtered iron ore tailings disposal by stacking

Brazil is one of the top world iron ore producers. However, it implies the generation of millions of tons of iron ore tailings (IOTs). Dewatering technologies now permit the obtainment of a compactable geomaterial rather than the slurry consistency tailings that were commonly stored in impoundments. Thus, this filtered compacted geomaterial can be stacked in piles. In this regard, the incorporation of small amounts of cement into the filtered tailings has the potential to strengthen the geomaterial. By using alkali-activated binders, strengthening the IOTs’ mechanical properties can be achieved with minimum environmental drawbacks. Accordingly, the present study evaluates the strength, mineralogy, and microstructure of compacted iron ore tailings-binder blends. A one-part alkali-activated cement (AAC) composed of ground granulated blast furnace slag (a residue of steel industry), sodium silicate, and sodium hydroxide was used, highlighting the circular economy appeal of this cement. A response surface approach was used in the definition of this cement’s composition. As well, tests using a commercially available high early-strength Portland cement were conducted. The optimized AAC outperformed the early strength Portland cement regardless of the test conditions, associated with the formation of a more developed cementitious matrix (C-S-H and C-A-S-H gel of amorphous structure).

Effect of Gentamicin Sulfate and Polymeric Polyethylene Glycol Coating on the Degradation and Cytotoxicity of Iron-Based Biomaterials.

The work is focused on the degradation, cytotoxicity, and antibacterial properties, of iron-based biomaterials with a bioactive coating layer. The foam and the compact iron samples were coated with a polyethylene glycol (PEG) polymer layer without and with gentamicin sulfate (PEG + Ge). The corrosion properties of coated and uncoated samples were studied using the degradation testing in Hanks' solution at 37 °C. The electrochemical and static immersion corrosion tests revealed that the PEG-coated samples corroded faster than samples with the bioactive PEG + Ge coating and uncoated samples. The foam samples corroded faster compared with the compact samples. To determine the cytotoxicity, cell viability was monitored in the presence of porous foam and compact iron samples. The antibacterial activity of the samples with PEG and PEG + Ge against Escherichia coli CCM 3954 and Staphylococcus aureus CCM 4223 strains was also tested. Tested PEG + Ge samples showed significant antibacterial activity against both bacterial strains. Therefore, the biodegradable iron-based materials with a bioactive coating could be a suitable successor to the metal materials studied thus far as well as the materials used in the field of medicine.

Triaxial testing response of compacted iron ore tailings considering a broad spectrum of confining pressures

The filtered tailings disposal (dry stacking) up to 300 m high is an alternative to overcome the drawbacks related to the slurry tailings storage in large impoundments as it is safer and demands smaller portions of the existing landform. Even so, the understanding of the denser and dewatered material response over a broad range of confining pressures is essential to safely design tall dry stacking tailings facilities. Accordingly, the present research assesses the mechanical behavior of compacted iron ore tailings through triaxial tests. A series of compression and extension drained and undrained triaxial tests were conducted over a wide spectrum of confinements (σ́3 ranging from 75 to 8,000 kPa) to check possible particle breakage occurrence and effects. The influence of the initial density due to compaction was, as well, evaluated since the tests were performed using specimens molded at distinct dry unit weight values. The results were analyzed in the light of the critical state soil mechanics and have indicated the existence of a curvilinear critical state line in the ν: log ṕ plane. Small particle breakage has occurred and can be associated with reduction in surface roughness, breakage of asperities, and reduction in particle angularity. Moreover, a tendency for static liquefaction was observed amongst the loosest specimens sheared under the lowest confining levels.

The effect of key parameters on the mechanical response of artificially cemented iron ore tailings for dry stacking purposes

Regulations prohibiting the construction of new tailings dams using the upstream method and requiring the closure of the existing ones have been recently introduced in Brazil. This scenario demands the sought for alternatives to manage both the previously disposed tailings as well as the upcoming generated mining residues. Fortunately, advances in dewatering technologies have enabled the tailings’ dried disposal in stacks having hundreds of meters rather than the traditional slurry deposition. Eventually, a cement material can be incorporated into the tailings before the stacking aiming to enhance the overall material’s performance, permitting the construction of higher and more inclined piles. In this regard,the present study evaluates the effect of key variables on the stiffness and strength of compacted iron ore tailings-cement blends. Specifically, the effect of the following variables was statistically evaluated through a full factorial design set: dry unit weight (17, 18, and 19 kN/m3), amount of cement (1, 3, and 5%), curing period (7, 28, and 90 days) and cement type (pozzolana Portland cement and high early strength Portland cement). The results have shown that all the main factors, and most of the second-order interactions, were significant in altering both the strength and stiffness of the studied mixtures, with a highlight to the amount of cement, curing time, and dry density. The type of cement, in turn, has exerted a marginal influence. As well, both responses could be successfully correlated to the adjusted porosity/cement index via power-type functions.

Effect of Powder Particle Surface Treatment on DC Magnetic Properties of Compacted Iron Cores

Effect of Powder Particle Surface Treatment on DC Magnetic Properties of Compacted Iron Cores

Influence of initial compaction and confining pressure on the hydraulic conductivity of compacted iron ore tailings

The hydraulic conductivity of iron tailings is an important factor affecting the stability of tailings storage facilities. Stacking compacted filtered ore tailings is a promising alternative for safer tailings disposal. These tailings storage facilities’ internal drainage systems must be designed appropriately to avoid excessive seepage pressure, saturation, and slope failure. In this context, the factors that affect hydraulic conductivity must be adequately evaluated. Therefore, the hydraulic conductivity behavior of compacted iron ore tailings still needs to be investigated. In addition, the effect of high confining pressure on hydraulic conductivity needs to be evaluated. This study investigates the impact of the initial compaction and the confining pressure on hydraulic conductivity. For this, the flexible wall permeameter tests were carried out on filtered ore tailings compacted in three degrees of compaction: 77, 94, and 101% of optimum dry density as determined by the standard Proctor method. These specimens were saturated and then consolidated with different confining pressure. It is possible to affirm that the increased confining pressure decreases the hydraulic conductivity. The hydraulic conductivity decreases by less than one order of magnitude, regardless of the initial compaction. Moreover, the data suggest that hydraulic conductivity’s decay rate depends on initial compaction—the hydraulic conductivity of the loose specimen decays at a greater rate than that of the dense specimens. However, the reductions of the void ratio under the confining pressure of 1600 kPa and 2200 kPa were not enough to decrease the hydraulic conductivity. Thus, under high-stress confining, the hydraulic conductivity becomes practically constant.

Characteristics of oxide films formed on SA106 Gr.B and SA335 P22 in a flowing condition at the microscopic and atomic scales

The objective of this study is to investigate the oxide film characteristics formed on SA106 Gr.B and SA335 P22 in a flowing alkaline solution. A porous magnetite was formed on SA106 Gr.B, while a compact iron oxide containing some amount of Cr was formed on SA335 P22. The oxide of SA106 Gr.B revealed a higher Gibbs free energy of formation reactions, solubility, point defect density, double layer capacitance, and lower charge transfer resistance compared to that of SA335 P22. The corrosion resistance of the test materials was well correlated with these oxide properties.

Mechanical and Microstructural Response of Iron Ore Tailings under Low and High Pressures Considering a Wide Range of Molding Characteristics

The dry stacking of filtered tailings is an option to deal with safety-related issues involving traditional slurry disposition in impoundments. Filtered tailings can be compacted to pre-define design specifications, which minimizes structural instability problems, such as those related to liquefaction. Yet, comprehending the tailing’s response under various stress states is essential to designing any dry stacking facility properly. Thus, the present research evaluated the mechanical response of cemented and uncemented compacted filtered iron ore tailings, considering different molding characteristics related to compaction degree and molding moisture content. Therefore, a series of one-dimensional compression tests and consolidated isotropically drained triaxial tests (CID), using 300 kPa and 3000 kPa effective confining pressures, were carried out for different specimens compacted at various molding characteristics. In addition, changes in gradation owing to both compression and shearing were evaluated using sedimentation with scanning electron microscope tests. The overall results have indicated that the 3% Portland cement addition enhanced the strength and stiffness of the compacted iron ore tailings, considering the lower confining pressure. Nevertheless, the same was not evidenced for the higher confining stress. Moreover, the dry-side molded specimens were initially stiffer, and significant particle breakage did not occur owing to one-dimensional compression but only due to shearing (triaxial condition).

Effects of force chain on the jamming during iron powder compaction

Effects of force chain on the jamming during iron powder compaction

High pressure compaction of soft magnetic iron powder

High pressure compaction of soft magnetic iron powder

Structural features of a composite material produced by electric pulsed pressing from iron‑based multi‑component powder mixtures

The study is dedicated to the electric pulse pressing use for the composite materials production from diffusion‑alloyed iron powders. It is shown that the addition of a low–melting metal component, tin, has a positive effect on the compaction of the composite iron powder during electric pulse pressing. The density of samples from Dystaloy AB iron powder with the addition of 10 % tin reaches 7.3–7.5 g/cm3. It is impossible to obtain such a density in the conventional cold pressing process at a pressure of 100– 120 MPa. It is established that due to the short duration of thermal exposure during electric pulse pressing, diffusion processes do not have time to pass and the distribution of alloying elements in the iron base is uneven. A short thermal exposure causes oxidation of the surface of the powder particles, which also negatively affects the diffusion processes. Therefore, when obtaining alloyed powder materials by electric pulse pressing, the process must be carried out in a protective atmosphere. The revealed presence of a nanoscale substructure formed due to the effects of intense plastic deformation and temperature indicates the hardening of the powder composite material during electric pulse pressing. These features can be useful in the development of technologies alternative to the warm pressing of plasticized powders.

A Portable Measurement Device Based on Phenanthroline Complex for Iron Determination in Water.

In this work, a newly developed self-contained, portable, and compact iron measurement system (IMS) based on spectroscopy absorption for determination of Fe2+ in water is presented. One of the main goals of the IMS is to operate the device in the field as opposed to instruments commonly used exclusively in the laboratory. In addition, the system has been tuned to quantify iron concentrations in accordance with the values proposed by the regulations for human consumption. The instrument uses the phenanthroline standard method for iron determination in water samples. This device is equipped with an optical sensing system consisting of a light-emitting diode paired with a photodiode to measure absorption radiation through ferroin complex medium. To assess the sensor response, four series of Fe2+ standard samples were prepared with different iron concentrations in various water matrices. Furthermore, a new solid reagent prepared in-house was investigated, which is intended as a "ready-to-use" sample pre-treatment that optimizes work in the field. The IMS showed better analytical performance compared with the state-of-the-art instrument. The sensitivity of the instrument was found to be 2.5 µg Fe2+/L for the measurement range established by the regulations. The linear response of the photodiode was determined for concentrations between 25 and 1000 µg Fe2+/L, making this device suitable for assessing iron in water bodies.

INFLUENCE OF CATHODE MATERIAL ON COMBINED CATHODE PROCESSES IN AQUEOUS SOLUTIONS OF IRON(II) SULPHATE

Sulfuric acid is present in many enterprises for metal processing and manufacturing of metal parts. Existing methods of regeneration of spent solutions are not effective, in particular, spent sulfate solutions are neutralized with lye or waste from other industries containing solid carbonates and hydroxides. At the same time, sulfate waste is formed, which requires disposal at special landfills. Electrochemical regeneration of spent solutions of sulfate-acid treatment of steel solves the problem of disposal of such spent sulfate solutions with the inclusion of iron sulfates. The kinetics of combined cathodic processes in aqueous solutions of iron (II) sulfate at a concentration of 0.5 mol.·dm–3 of iron (II) sulfate, depending on the cathode material was studied. The research methodology was as follows: model aqueous solutions with a composition (mol∙dm–3): 0.5 iron (II) sulfate with the addition of 0.5 sulfuric acid and a control solution – 1.0 sulfuric acid were prepared from chemicals of high stage of purification by dissolution in distilled water. The study of the kinetics of combined cathodic processes in model aqueous solutions was carried out by the method of linear voltammetry using the MTech PGP-500 S potentiostat. The auxiliary electrode is platinum. The reference electrode is mercury sulfate. Determination of iron (II) ions in the solution was carried out by the permanganatometric method. Based on the analysis of the obtained current-voltage curves, the effectiveness of the application of electrochemical regeneration of model solutions of iron (II) sulfate with sulfuric acid was established, which makes it possible to cathodically deposit iron in the form of foil or metal powder, and through the course of the anodic process - convert sulfates into sulfuric acid. During this process, oxidation of Fe2+ to Fe3+ takes place at the slightly soluble anode. Therefore, it is proposed to use polymer porous diaphragms to prevent Fe2+ from entering the anode space. Platinum and copper were used as cathode material. The choice of cathode material was based on different electrochemical properties of these metals in relation to the hydrogen reaction. The balance research on the regeneration of the model solution was carried out in a three-chamber electrolyzer. The initial test solution was fed into the middle chamber. The cathodic current density was 0.025 and 0.035 A∙cm–2, the working area of the anode and cathode was 85 cm2. A compact iron deposit was obtained on the cathode with 08X12N10T, which peeled off. The analysis of the cathode deposit showed the presence of 0.065% hydrogen in iron. Output according to the current of iron was 92%. The end of the Tafel section of the course of cathodic reduction of iron with electrochemical control occurs due to Fe2+ concentration limitations and the ohmic resistance of adsorbed hydrogen at the boundary of heterogeneous phases. It is proposed to eliminate these limitations due to electrolyte mixing.

Densification and Strengthening of Ferrous‐Based Powder Compacts Through Cold Sintering Aided Warm Compaction

Cold sintering of surface‐modified iron compacts results in a co‐continuous phosphate interphase between iron particles that provide both enhanced green strength and green density similar to the process that has been successfully introduced in low‐temperature densification of ceramic materials. Relative density as high as 95% along with transverse rupture strength of ≈ 75 MPa, which is almost six times that of conventional powdered metal iron compact and 2.5 times that of warm compacted controls, is achieved. Dilatometry study at different pressures shows a small but significant improvement in densification process during cold sintering relative to the larger densification of warm compacted control. Strength model based on microstructural analysis as well as in situ diffused reflectance infrared Fourier transform spectroscopy (DRIFTS) experiments reveals the nature of the interphase that imparts the large cohesive strength under the cold sintered assisted warm compaction. The process is conducive to produce iron compacts for green machining. Furthermore, the samples when subjected to high‐temperature sintering yield a fully sintered iron compact with density > 7.2 g cm−3 and transverse rupture strength as high as 780 MPa. All in all, there are major new opportunities with the cold sintered assisted warm compaction of powdered metals that will also be discussed.

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.

The effect of graphite number per area on tribological behavior of high-strength compacted cast irons in lubricated tests

The effect of graphite number per area on tribological behavior of high-strength compacted cast irons in lubricated tests

Sintering shrinkage of cold compacted iron: effect of thermodynamic driving force, structural and geometrical activity

ABSTRACT The sintering shrinkage of tapped powders and prior cold compacted specimens of sponge and water atomised iron powders was investigated. The behaviour of the tapped powders is only determined by the driving force and that of the green compacts is strongly affected by modifications caused by cold compaction, which introduce a structural and a geometrical activity that enhance the kinetics of shrinkage. While the tapped powders display only an isothermal shrinkage, the green specimens display an additional large and anisotropic anisothermal shrinkage which is independent on the surface area of the powders. The effect of prior cold compaction tends to run out during the heating step of the sintering cycle.

EVALUATION OF SHEAR STRENGTH OF COMPACTED IRON ORE TAILINGS TREATED LATERITIC SOIL

This paper presents the results of a laboratory study on the evaluation of the shear strength of compacted iron ore tailings (IOT) treated lateritic soil. Lateritic soil used was treated with 0 up to 16% IOT by weight of dry soil. Test performed include index test, compaction (using British Standard Light, BSL and West Africa Standard, WAS energies) and shear strength test. One-way analysis of variance was carried out using Microsoft Excel to determine the level of significance of IOT on the treated soil. The results of the triaxial test show that there is an improvement in the shear strength of soil with the improvement of its shear strength parameters (cohesion and angle of internal friction). Cohesion values decreased from 0 up to 8% IOT content and then increased while the angle of internal friction risen from 0 up to 8% IOT content and then decreased. Also, from the triaxial test carried out with varying cell pressures from 100 to 300 kN/m2, an increase in shear strength parameters and shear strength were recorded. The shear strength increased in value by 49.79% and 18.15% for BSL and WAS compaction at 8% IOT content, respectively. Statistical analysis carried out on the results using analysis of variance (ANOVA) shows that IOT has a significant effect on the lateritic soil. An optimal blend of 8% IOT improved the shear strength of the soil and can be used for geotechnical engineering applications such as roads and embankments.Keywords: angle of internal friction, cohesion, iron ore tailing contents (IOT), Lateritic soil and Shear strength.

Oxide reduction and oxygen removal in water-atomized iron powder: a kinetic study

Reduction of oxides during sintering is a prerequisite for the manufacturing of powder metallurgy steels. Inadequate control of the sintering atmosphere may impede sinter neck formation and cause entrapment and growth of oxides in sinter necks, ultimately deteriorating the mechanical properties of sintered components. In this study, the oxide reduction and oxygen removal in water-atomized iron powder was investigated by means of thermogravimetric analysis in pure hydrogen. Two principal mass loss events were recorded, corresponding to the removal of the surface oxide layer at around 400 °C and reduction of internal and stable oxides in the range 600–1350 °C. The apparent activation energies of these mass loss processes were determined by means of kinetic analyses, giving values around 100 kJ mol−1 and 200–400 kJ mol−1, respectively. The validity of the results was asserted using hematite reference samples which displayed good correlation with the reduction of the surface oxide layer, thereby showing that the powder surfaces are covered by an Fe2O3 oxide. The high-temperature mass loss, with no analogy in the reference samples, is believed to originate from a combination of oxygen removal from internal oxides and stable oxide particulates on the surface. Analysis of the oxide reduction in iron powder compacts show a slightly lower activation energy for the oxide layer reduction, indicating an influence of the compaction step on the initial state of the powder and oxide layer. At the same time, the high-temperature mass loss event was shifted to higher temperatures, which is believed to be caused by the increasingly restricted mass transport of reduction products along the pores in the sintered compact.