Description:Embodiments herein generally relate to building materials, 5 particularly, a
method for manufacturing bricks utilizing gold ore tailings.
Description of the Related Art
[0002] Tailings bricks are construction materials derived from tailings, the
10 byproducts of mining and processing gold ore. The tailings consist of water and residual
chemicals used during mineral extraction and processing. Despite being systematically
stacked in designated areas, tailings may contribute to land degradation if not managed
properly. Therefore, ensuring the material consistency, strength, and durability of tailings
bricks requires careful mixing and compaction, along with diligent monitoring of moisture
15 content and effective drying processes.
[0003] The tailings recycling encompasses the repurposing of waste materials
generated from mining and mineral processing into valuable resources or products. Rather
than treating tailings as mere waste, recycling extracts additional value through various
techniques and technologies, thereby maximizing resource utilization and minimizing
20 environmental impact. By recovering valuable minerals or metals from tailings, mining
companies can optimize resource utilization and extend the lifespan of existing mineral
reserves.
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[0004] The existing method for burning-free block brick includes a wide range of
industrial waste materials like tailings, fly ash, and coal gangue. The materials are mixed,
molded, and cured for 7-28 days, eliminating the need for firing. The existing method
involves a wide range of raw materials (10-80 parts of various industrial waste residues),
which can introduce variability in brick quality and make it challenging to 5 execute consistent
performance due to differing material characteristics. Using materials like construction waste
in the existing method may raise environmental concerns regarding contamination. The
production process in the existing method is also more complex and lengthier, requiring 7-28
days for natural curing, which can slow down production. The variability in the existing
10 method could affect the durability and strength of the bricks over time.
[0005] Another existing method for producing water-permeable bricks is using gold
ore tailings. The process involves preparing gold ore tailing powder spheres as aggregates,
mixing bottom and surface layer materials, forming the bricks, and maintaining them. The
existing method requires multiple steps, including preparing gold ore tailing powder spheres
15 and separate layers for the water-permeable bricks, making the process more time-consuming
and intricate. The bricks are designed specifically for water permeability, which limits their
application mainly to drainage-related construction, The added step of creating powder
spheres in the existing method further complicates material preparation. The multi-step
process involved in the existing method could result in higher production costs.
20 [0006] Existing method for producing aerated bricks using gold mine and fluorite
tailings. The process involves decyanizing the tailings, mixing them with other materials like
quicklime and aluminum powder, forming a foamy slurry, and curing the bricks in an
autoclave. The existing method involves a more complex and time-consuming process, as it
4
requires multiple steps such as decyanization, slurry making, and autoclaving. This not only
increases the difficulty of the manufacturing process but also introduces the need for
specialized equipment like autoclaves, which adds to the production costs. The existing
method requires handling hazardous cyanide-contaminated tailings during the decyanization
step, raising safety and environmental concerns, Furthermore, the 5 existing method's
autoclaving process is energy-intensive, leading to higher energy costs.
[0007] The existing method for producing a composite cement curing agent at curing
gold slag obtained from gold ore tailings after iron separation. The process involves mixing
85 wt% of gold slag with 15 wt% of the curing agent, which includes an alkaline and sulfate
10 activator, followed by the addition of water and thorough stirring. The existing involves a
more complex curing process that requires a composite cement curing agent containing
various activators, leading to complex formulation and handling, which complicates
production. The existing method's dependence on chemical additives introduces variability in
the curing process and raises safety and environmental concerns. The existing method's
15 effectiveness relies on the availability of specific waste materials, such as gold slag and
activators, which may not always be readily available.
[0008] The existing method focuses on the development of unfired thermal insulation
bricks using a blend of fly ash and red mud, which are byproducts of primary aluminum
production. The mix consists of 45% red mud, 40% fly ash, 10% lime, and 5% gypsum,
20 attaining a maximum strength of 6.30 MPa after 28 days of water curing. The existing
method relies on byproducts from aluminum production that may not be widely accessible.
Additionally, the existing method attains moderate strength (6.30 MPa), which could limit its
structural application. The existing method also requires specific curing conditions, such as
5
steam curing at elevated temperatures, increasing production complexity and energy costs.
Furthermore, the existing method primarily focuses on thermal insulation, which may not
meet all construction needs, particularly for load-bearing applications. The existing method
relies on additional materials like gypsum and lime may lead to a larger environmental
5 footprint.
[0009] Therefore, there arises a need to address the aforementioned technical
drawbacks.
SUMMARY OF THE INVENTION
[00010] In view of the foregoing, an embodiment herein provides a method for
10 manufacturing bricks utilizing gold ore tailings. The method includes (a) mixing, (i) 26%-
34% weight by weight (w/w) of gold ore ultrafine tailings,(ii) 3%-5% w/w of a rice husk
ash,(iii) 2%-3% w/w of gypsum, and (iv) 5%-7% w/w of lime to obtain a first mixture, (b)
homogeneously grinding, the first mixture with water in a homogeneous grinding unit to
obtain a second mixture comprising a reduced particle size of about 75 to 125 microns, (c)
15 transferring, the homogeneous second mixture into molds designed for the bricks formations,
(d) applying pressure of about 25 tons to the molds to shape the homogeneous second
mixture into the bricks, and (e) drying the formed bricks at room temperature for a period of
7 to 8 days.
[00011] This method repurposes tailings (waste materials) from mineral extraction
20 into bricks, thereby mitigating land degradation and supporting net-zero goals. This method
also reduces the demand for conventional building materials like clay and sand, conserving
natural resources and minimizing environmental impacts. This method employs a specific
combination of gold ore ultrafine tailings, rice husk ash, gypsum, and lime, allowing for
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control over the mixture and resulting in consistent brick quality and enhanced durability.
This method targets environmentally friendly waste types that are less likely to leach harmful
substances. This method also enables an efficient production process, allowing bricks to dry
at room temperature within 7-8 days, which leads to quicker turnaround times. This method
enhances the structural integrity of the bricks through proper mixing 5 and compaction,
minimizing cracks and deformations while increasing load-bearing capacity. This method
incorporates monitoring moisture content and facilitating controlled drying, which reduces
the risk of shrinkage or unevenness, ensuring the final product's durability. This method of
integrating tailings bricks into local construction projects fosters infrastructure development
10 in mining communities. In some embodiments, the second mixture is combined with (i) 10%-
15% w/w of an M-sand, (ii) 24%-26% w/w of a river-sand, and (iii) 7%-10%w/w of fly ash.
[00012] In one aspect, a gold ore tailings-based brick is provided. The gold ore
tailings-based brick includes (i) 26%-34% weight by weight (w/w) of gold ore ultrafine
tailings, (ii) 3%-5% w/w of a rice husk ash, (iii) 2%-3% w/w of gypsum, and (iv) 5%-7%
15 w/w of lime.
[00013] In some embodiments, the second mixture is combined with (i) 10%-15%
w/w of an M-sand, (ii) 24%-26% w/w of a river-sand, and (iii) 7%-10%w/w of fly ash.
[00014] These and other aspects of the embodiments herein will be better appreciated
and understood when considered in conjunction with the following description and the
20 accompanying drawings. It should be understood, however, that the following descriptions,
while indicating preferred embodiments and numerous specific details thereof, are given by
way of illustration and not of limitation. Many changes and modifications may be made
within the scope of the embodiments herein without departing from the spirit thereof, and the
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embodiments herein include all such modifications.
BRIEF DESCRIPTION OF THE DRAWINGS
[00015] The embodiments herein will be better understood from the following
detailed descriptions with reference to the drawings, in which:
[00016] FIG. 1 illustrates a block diagram of a brick manufacturing 5 system for
manufacturing bricks utilizing gold ore tailings according to an embodiment herein; and
[00017] FIG. 2 is a flow diagram that illustrates a method for manufacturing bricks
utilizing gold ore tailings according to an embodiment herein.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
10 [00018] The embodiments herein and the various features and advantageous details
thereof are explained more fully with reference to the non-limiting embodiments that are
illustrated in the accompanying drawings and detailed in the following description.
Descriptions of well-known components and processing techniques are omitted so as to not
unnecessarily obscure the embodiments herein. The examples used herein are intended
15 merely to facilitate an understanding of ways in which the embodiments herein may be
practiced and to further enable those of skill in the art to practice the embodiments herein.
Accordingly, the examples should not be construed as limiting the scope of the embodiments
herein.
[00019] As mentioned, there remains a need for recycling gold ore tailings into
20 sustainable bricks. The embodiments herein achieve this by repurposing the waste material,
known as tailings, generated during gold extraction into environmentally friendly building
materials, specifically bricks. Gold ore tailings consist of fine particles left behind after the
extraction of the gold. Instead of disposing of these tailings, which can be harmful to the
8
environment, the tailings are mixed with binding agents and other materials to form durable
bricks. This method reduces waste, and lower the environmental impact of mining. Referring
now to the drawings and more particularly to FIGS. 1 through 2, where similar reference
characters denote corresponding features consistently throughout the figures, there are shown
preferred 5 embodiments.
[00020] “Gold ore tailings” refer to the leftover or waste materials produced during
the extraction of gold from ore. After the gold has been separated from the ore through
processes such as crushing, grinding, and chemical treatment, the remaining materials often
consisting of finely crushed rock, minerals, and chemicals are known as tailings. “Source
10 material” refers to the raw materials used to manufacture bricks. This can include natural
resources such as clay, shale, or sand, as well as alternative materials like industrial
byproducts, including fly ash, gold ore tailings, or slag. These source materials are mixed,
shaped, and fired to produce bricks, with the composition of the materials influencing the
brick's durability, strength, and other properties.
15 [00021] “Binding materials” refers to substances that are used to bind the raw
materials together, ensuring the bricks maintain their shape and structural integrity during
and after production. These materials often include clay, lime, or cement, which are bind the
particles of the brick mix when shaped and fired.
[00022] “Homogeneous grinding process” refers to the uniform reduction of the raw
20 material particles to a consistent size or texture. This process ensures that all particles are
ground evenly, resulting in a mixture with a uniform composition. FIG. 1 illustrates a block
diagram of a brick manufacturing system 112 for manufacturing bricks utilizing gold ore
tailings according to an embodiment herein. The brick manufacturing system 112 includes a
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material mixing unit 102, a homogeneous grinding unit 104, a homogeneous mixture
transferring unit 106, a pressure applying unit 108, and a mixture drying unit 110. The
material mixing unit 102 mixes (i) 26%-34% weight by weight (w/w) of gold ore ultrafine
tailings, (ii) 3%-5% w/w of a rice husk ash, (iii) 2%-3% w/w of gypsum, (iv) 5%-7% w/w of
lime with water to obtain a first mixture. The homogeneous 5 grinding unit 104
homogeneously grinds the first mixture with water to obtain a second mixture comprising a
reduced particle size of about 75 to 125 microns. The second mixture is combined with (i)
10%-15% w/w of an M-sand, (ii) 24%-26% w/w of a river-sand, and (iii) 7%-10%w/w of fly
ash.
10 [00023] The homogeneous mixture transferring unit 106 transfers the homogeneous
second mixture into molds designed for the brick formations. The pressure applying unit 108
applies pressure of about 25 tons to the molds to shape the homogeneous second mixture into
the bricks. The mixture drying unit 110 dries the formed bricks at room temperature for a
period of 7 to 8 days.
15 [00024] The gold ore tailings-based brick includes (i) 26%-34% weight by weight
(w/w) of gold ore ultrafine tailings, (ii) 3%-5% w/w of a rice husk ash, (iii) 2%-3% w/w of
gypsum, and (iv) 5%-7% w/w of lime.
[00025] In some embodiments, the second mixture is combined with (i) 10%-15%
w/w of an M-sand, (ii) 24%-26% w/w of a river-sand, and (iii) 7%-10%w/w of fly ash.
20 [00026] FIG. 2 is a flow diagram that illustrates a method for manufacturing bricks
utilizing gold ore tailings according to an embodiment herein. At step 202, the method
includes mixing, (i) 26%-34% weight by weight (w/w) of gold ore ultrafine tailings, (ii) 3%-
5% w/w of a rice husk ash, (iii) 2%-3% w/w of gypsum, (iv) 5%-7% w/w of lime with water
10
to obtain a first mixture. At step 204, the method includes homogeneously grinding, the first
mixture with water in a homogeneous grinding unit to obtain a second mixture comprising a
reduced particle size of about 75 to 125 microns. At step 206, the method includes
transferring the homogeneous second mixture into molds designed for the brick formations.
At step 208, the method includes applying pressure of about 25 tons to the 5 molds to shape the
homogeneous second mixture into the bricks. At step 210, the method includes drying the
formed bricks at room temperature for a period of 7 to 8 days.
[00027] The foregoing description of the specific embodiments will so fully reveal
the general nature of the embodiments herein that others can, by applying current knowledge,
10 readily modify and/or adapt for various applications without departing from the generic
concept, and, therefore, such adaptations and modifications should be comprehended within
the meaning and range of equivalents of the disclosed embodiments. It is to be understood
that the phraseology or terminology employed herein is for the purpose of description and not
of limitation. Therefore, while the embodiments herein have been described in terms of
15 preferred embodiments, those skilled in the art will recognize that the embodiments herein
can be practiced with modification within the spirit and scope of the appended claims. , C , C , C , Claims:I/We Claims:
1. A method for manufacturing bricks utilizing gold ore tailings, the method comprising the
5 steps of:
mixing, (i) 26%-34% weight by weight (w/w) of gold ore ultrafine tailings, (ii) 3%-
5% w/w of a rice husk ash, (iii) 2%-3% w/w of a gypsum, and (iv) 5%-7% w/w of a lime to
obtain a first mixture;
homogeneously grinding, the first mixture with water in a homogeneous grinding unit
10 (104) to obtain a second mixture comprising a reduced particle size of about 75 to 125
microns;
transferring the homogeneous second mixture into molds designed for the brick
formations;
applying pressure of about 25 tons to the molds to shape the homogeneous second
15 mixture into the bricks; and
drying the formed bricks at room temperature for a period of 7 to 8 days.
2. The method as claimed in claim 1, wherein the second mixture is combined with (i) 10%-
15% w/w of an M-sand, (ii) 24%-26% w/w of a river-sand, and (iii) 7%-10%w/w of fly ash.
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3. A composition for manufacturing bricks utilizing gold ore tailings, wherein the
composition comprises,
(i) 26%-34% weight by weight (w/w) of gold ore ultrafine tailings;
(ii) 3%-5% w/w of a rice husk ash;
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(iii) 2%-3% w/w of a gypsum, and;
(iv) 5%-7% w/w of a lime.
4. The composition as claimed in claim 3, wherein the second mixture is combined with (i)
10%-15% w/w of an M-sand, (ii) 24%-26% w/w of a river-sand, and (iii) 5 7%-10% w/w of fly
ash.
Dated this January 17th, 2025
Arjun Karthik Bala
(IN/PA 1021)
Agent for Applicant