{"id":130811,"date":"2026-09-24T07:05:00","date_gmt":"2026-09-24T10:05:00","guid":{"rendered":"https:\/\/www.ufrgs.br\/jornal\/?p=130811"},"modified":"2026-09-23T17:00:39","modified_gmt":"2026-09-23T20:00:39","slug":"alternative-binder-made-from-waste-material-is-a-sustainable-solution-to-handle-mining-tailings","status":"publish","type":"post","link":"https:\/\/www.ufrgs.br\/jornal\/alternative-binder-made-from-waste-material-is-a-sustainable-solution-to-handle-mining-tailings\/","title":{"rendered":"Alternative binder made from waste material is a sustainable solution to handle mining tailings"},"content":{"rendered":"\n

Engineering | A solution proposed in a research project by the Civil Engineering Graduate Program involves stabilizing tailings with an alternative product that reduces waste and facilitates transportation<\/strong><\/h4>\n\n\n\n

*First published September 18th, 2025
*Photo: Test specimen for laboratory testing (Credit: Pietro Scopel\/JU)<\/em><\/p>\n\n\n\n

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Proposing alternatives to dam construction is not a new development in the field of engineering; significant body of research has been proposing the treatment of iron ore tailings at these sites \u2014 which are currently monitored by the National Mining Agency (ANM)<\/a>. In general, these studies seek stabilization with the employment of conventional cement (also known as Portland cement). However, this high-performance material is also highly polluting, as the production of each ton of such substance emits approximately 940 kg of carbon dioxide.<\/p>\n\n\n\n

Researcher Diogo Bevilaqua, from the Graduate Program in Civil Engineering at UFRGS, has developed an alternative binder capable of stabilizing mining waste from a threefold sustainability perspective: through the selection of cement ingredients, the concentration of their components, and its formulation method.<\/p>\n\n\n\n

According to laboratory analyses, one of the samples of the alternative binder achieved results equivalent to Portland cement in terms of stiffness, strength, and durability, establishing the new cement as a promising solution.<\/p>\n\n\n\n

Threefold sustainability<\/strong><\/h5>\n\n\n\n

To produce an alternative binder, it is necessary to select the ingredients that will serve as precursors and activators. Drawing an analogy with baking a cake, the flour would be the precursor, while the baking powder would be the activator.<\/p>\n\n\n\n

In this case, the precursors are blast furnace slag and metakaolin, which are residues from pig iron production that are reused thanks to their aluminosilicate-rich chemical composition. <\/p>\n\n\n\n

\u201cWe need the precursor to be rich in aluminosilicates, which contain calcium, aluminum, and silica. If the precursor contains the right amount of such materials, it will more easily go through the hardening process and gain strength,\u201d comments Diogo. \u201cResidues usually have this material, this chemical composition that we need.\u201d<\/p>\n\n\n\n

As for the activators, they need to have a very high or low pH. To achieve this, only sodium hydroxide (NaOH) and sodium silicate (Na\u2082SiO\u2083) were used. Unlike the more common process (called \u2018two-part\u2019), in which water is included as an activator, the one-part method creates a dry mixture and water is only added to it at the location of use. This approach reduces reaction waste and the mixture\u2019s corrosiveness, and facilitates the transportation of the materials as well. <\/p>\n\n\n\n

\u201cThe two-part method is as if I were to take all my materials, mix them with water, bring them to the construction site, and use them for stabilization. In the one-part method, I mix all of the dry ingredients. Then I take the cement I\u2019ve developed, mix it with the waste material, and consecutively add water to the mixture,\u201d explains the engineer.<\/p>\n\n\n\n

Ultimately, the alternative binder developed in this research is also sustainable due to the low concentration of its components, a measure known technically as \u2018binder content\u2019. In the manufacture of conventional cement, this concentration number usually varies between 15% and 30%. However, the researcher has developed the product with cement contents of 2%, 4%, and 6% and achieved a performance equivalent to that of Portland cement in the last sample, overall.<\/p>\n\n\n\n

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\u201cWe wanted to work with small quantities to minimize environmental impact. The more material I use, the deeper the impact on my binder is due to the activator, which is corrosive\u201d<\/em><\/p>\nDiogo Bevilaqua<\/cite><\/blockquote>\n\n\n\n

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In the images above, the Conventional Triaxial and True Cubic Triaxial equipment, used to measure soil shear strength (Photos: Pietro Scopel\/JU)<\/figcaption><\/figure>\n\n\n\n
Alternative binder performance<\/strong><\/h5>\n\n\n\n

The quality evaluation of the product for tailings stabilization was based on its mechanical, chemical, and mineralogical behavior. Among the versions created for comparison, the variables were the binder content (as aforementioned), the dry bulk density (degree of material compaction), and the curing time (the period required for the material to solidify).<\/p>\n\n\n\n

The cement with the best resistance and durability in the tests had three characteristics: it was the version with the highest dry bulk density among the samples (22.2 kN\/m\u00b3), the highest binder content (6%), and the longest curing time (182 days at room temperature).<\/p>\n\n\n\n

While the Portland version reached a peak strength and plateaued after 28 days, the alternative product showed improved mechanical behavior over time.<\/p>\n\n\n\n

Regarding elasticity, on the other hand, the tests proved the alternative product to need an extended thermal curing (i.e., maintaining the mixture at 60\u00b0C for 7 days) in order to meet Portland cement results. The process accelerated the hydration and strength gain of the material, enabling it to achieve better results in a shorter time frame and, in this case, surpass the elasticity index of the conventional product.<\/p>\n\n\n\n

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Mechanical properties of cements<\/strong><\/p>\n\n\n

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Figure 1 \u2013 Performance of conventional cement (Portland) and alternative cement (alkali-activated), according to Bevilaqua (2025)<\/figcaption><\/figure>\n<\/div><\/div>\n\n\n\n
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Alkali-activated cement sample<\/strong><\/p>\n\n\n

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Figure 2 \u2013 The results in Figure 1 refer to only one of the samples developed in the study which exhibit the characteristics mentioned above.<\/figcaption><\/figure>\n<\/div><\/div>\n<\/div>\n\n\n\n
Next steps<\/strong><\/h5>\n\n\n\n

Even after the positive results obtained in the analyses, the research must be continued. The engineer notes that a life-cycle assessment will be essential to understand the reduction in environmental impact achieved by implementing the alternative solution. Evaluations using a higher binder content (above 6%) and a longer curing time (above 182 days) should demonstrate the maximum potential of the alternative binder.<\/p>\n\n\n\n

Furthermore, there is still an obstacle to overcome: the limited availability of blast furnace slag in the Brazilian market. According to Diogo, nowadays this material is essentially monopolized by the cement industry, which consumes it in large quantities as a component to conventional binder.<\/p>\n\n\n\n

\u201cWhat I truly hope is that this issue gets solved, that the materials can be stabilized, and that they no longer have such hazardous social, environmental, and economic impacts. But, at the same time, I don\u2019t know if it will be achieved through my technique or some other one,\u201d he says. \u201cWe\u2019re exploring all possibilities to develop the best material to use.\u201d<\/p>\n\n\n\n

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Tailings drying process (Photo: Pietro Scopel\/JU)<\/figcaption><\/figure>\n\n\n\n
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Dissertation:<\/strong> Stabilization of iron ore tailings treated with alkaline activation by the one-part method<\/a>
Author:<\/strong> Diogo Bevilaqua<\/a>
Supervisor:<\/strong> Nilo Cesar Consoli<\/a>
Co-supervisor:<\/strong> Andr\u00e9s Mauricio Lotero Caicedo<\/a>
Program\/Department:<\/strong> Graduate Program in Civil Engineering \u2013 School of Engineering<\/p>\n\n\n\n

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Translated into English by Fernanda Lopes Flores<\/strong>, undergraduate student enrolled in the course “Supervised Translation Training I (English)” of the Undergraduate Program in Language and Literature, under the supervision and translation revision of Professor Elizamari R. Becker (P.h.D.) – IL\/UFRGS.<\/p>\n\n\n\n

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:: Read in portuguese<\/strong>
Cimento alternativo feito com materiais residuais \u00e9 uma solu\u00e7\u00e3o sustent\u00e1vel para tratar os rejeitos da minera\u00e7\u00e3o<\/a><\/p>\n\n\n\n

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Explore the full section In English<\/strong> <\/a><\/div>\n<\/div>\n\n\n\n
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<\/p>\n<\/div><\/div>\n","protected":false},"excerpt":{"rendered":"

Engineering | A solution proposed in a research project by the Civil Engineering Graduate Program involves stabilizing tailings with an alternative product that reduces waste and facilitates transportationLeia mais<\/a><\/span><\/p>\n","protected":false},"author":1,"featured_media":119676,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_themeisle_gutenberg_block_has_review":false,"page_builder":"","footnotes":"","_ppma_block_editor_authors":"{\"authors\":[6339],\"author_categories\":{\"6339\":\"1\"},\"fallback_author_user\":\"1\",\"ppma_author_box_select\":\"\",\"selected_authors\":[{\"id\":6339,\"display_name\":\"Camila Fernandes de 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