Institute of Comprehensive Exploitation of Mineral Resources of the Russian Academy of Sciences:

D. R. Caplunov, Chief of Mine Design Theory Department, Doctor of Engineering Sciences, Corresponding Member of Russian Academy of Sciences, phone: +7 (495) 630-08-23

M. V. Rylnikova, Leading Researcher, Professor, Doctor of Engineering Sciences

“Mekhanobr-tekhnika” Company:

V. A. Arsentev, Director for Development and Research, Doctor of Engineering Sciences

V. V. Kvitka, Director for Mining and Metallurgy Industry, Doctor of Engineering Sciences

“Uchalinsky GOK” Company:

R. Sh. Mannanov, Chief Executive Officer, Doctor of Engineering Sciences

High energy consumption for crushing rockfill up to an optimum grain size is an essential shortcoming of backfill preparation technology. Also existing and projected backfill plants are highly metal-intensive, which raises the capital costs and makes cemented backfill ineffective for mining mineral material of low value, small scale and far-off deposits.

The problem can be solved by using in a modular backfill plant new generation inertial crushers (jaw and gyratory) instead of milling rock material. Wide range of inertial crusher’s types makes it possible to construct backfill plant, applicable for different specifications. For example combination of SHCHDS 400×600 (jaw crusher) и KID-600 (gyratory crusher) can produse 100–120 tph of rockfill with 30–40% sized less than 0.074 mm. Moreover gyratory crusher performs both wet or dry crushing and mechanical activation of binder agent and rock fill. The equipment works in an open cycle and provides low energy consumption and doesn’t require heavy concrete foundation. This makes the equipment mobile so it can follow work front. Placing the modular backfill plant underground or on the surface it is possible to reduce dramatically length and complexity of a backfill pipeline and to backfill underground voids rapidly before a dangerous deformation takes place.

Backfill for worked-out underground stopes usually based on a rockfill, including rock from mine workings. Underground placement of a modular backfill plant can reduce amount of material moved onto the surface and change flowsheet of a mine. Besides, it reduces energy consumption and pipeline length. The latter can raise efficiency of backfilling underground voids and draw into development ore bodies with different size and geology.

The projected resource-saving mining technology and equipment for high-productive backfill of worked-out voids for underground mining of solid minerals is to be tested and implemented at “Uchalinsky GOK” mines. The technology is unique and can lead to modernization of the whole Russian mining industry. The technology of mobile backfill plant marks a new trend in researches on comprehensive exploitation of ore deposits.

Work is carried out with financial support of the Ministry of Edication and Science of the Russian federation (The State Contract No. 16.525.12.5001).