Reuse of Mine Tailings Through Geopolymerization Applied to 3D Printing: A Review of Progress, Challenges and Perspectives

Carlos Genaro Morales Aranibar, Adolfo La Rosa Toro Gómez, José Luiz da Silva, Luis Morales-Aranibar and Diego Arán ()
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Carlos Genaro Morales Aranibar: Grupo de Investigación de Electroquímica Aplicada, Facultad de Ciencias, Universidad Nacional de Ingenieria, Tupac Amaru Av. 210, Rimac, Lima 15333, Peru
Adolfo La Rosa Toro Gómez: Grupo de Investigación de Electroquímica Aplicada, Facultad de Ciencias, Universidad Nacional de Ingenieria, Tupac Amaru Av. 210, Rimac, Lima 15333, Peru
José Luiz da Silva: Grupo de Investigación de Electroquímica Aplicada, Facultad de Ciencias, Universidad Nacional de Ingenieria, Tupac Amaru Av. 210, Rimac, Lima 15333, Peru
Luis Morales-Aranibar: Departamento de Ingeniería Civil y Ciencias Básicas, Universidad Nacional Intercultural de Quillabamba, Quillabamba 08741, Peru
Diego Arán: LEAF—Linking Landscape, Environment, Agriculture and Food Research Center, Associate Laboratory TERRA, Instituto Superior de Agronomia, Universidade de Lisboa, Tapada da Ajuda, 1349-017 Lisbon, Portugal

Sustainability, 2025, vol. 17, issue 6, 1-34

Abstract: The increasing global demand for metals, driven by technological progress and the energy transition, has led to an acceleration in the expansion of the mining and metallurgical industry, resulting in an increase in the generation of mine tailings. This waste, which is of heterogeneous composition and has high contaminant potential, represents significant environmental and social challenges, affecting soils, water, and the geotechnical stability of tailings. The accumulation of these mine tailings poses a problem not only in terms of quantity, but also in terms of physicochemical composition, which exacerbates their environmental impact due to the release of heavy metals, affecting ecosystems and nearby communities. This article reviews the potential of geopolymerization and 3D printing as a technological solution for the management of tailings, offering an effective alternative for their reuse as sustainable building materials. Alkaline activation of aluminosilicates facilitates the formation of N–A–S–H and C–A–S–H cementitious structures, thereby providing enhanced mechanical strength and chemical stability. Conversely, 3D printing optimizes structural design and minimizes material consumption, thereby aligning with the principles of a circular eco-economy and facilitating carbon footprint mitigation. The present study sets out to compare different types of tailings and their influence on geopolymer reactivity, workability, and mechanical performance. In order to achieve this, the study analyses factors such as the Si/Al ratio, rheology, and setting. In addition, the impact of alkaline activators, additives, and nanoparticles on the extrusion and interlaminar cohesion of 3D printed geopolymers is evaluated. These are key aspects of their industrial application. A bibliometric analysis was conducted, which revealed the growth of research in this field, highlighting advances in optimized formulations, encapsulation of hazardous waste, CO 2 capture, and self-healing geopolymers. The analysis also identified technical and regulatory challenges to scalability, emphasizing the necessity to standardize methodologies and assess the life cycle of materials. The findings indicated that 3D printing with tailings-derived geopolymers is a viable alternative for sustainable construction, with applications in pavements, prefabricated elements, and materials resistant to extreme environments. This technology not only reduces mining waste but also promotes the circular economy and decarbonization in the construction industry.

Keywords: geopolymerization; mining tailings; circular economy (search for similar items in EconPapers)
JEL-codes: O13 Q Q0 Q2 Q3 Q5 Q56 (search for similar items in EconPapers)
Date: 2025
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