Quantifying the effect of polyacrylamide dosage, Na+ and Ca2+ concentrations, and clay particle size on the flocculation of mature fine tailings with robust statistical methods

High efficiency regulating sedimentation and rheological properties of copper tailings using polycarboxylate superplasticizers

The recovery of low grade and fine particle copper ore usually requires sufficient dissociation, which reduces the particle size to the submicron level, presenting new challenges in subsequent copper tailings disposal. Flocculants can improve tailings sedimentation efficiency, but they also change the rheological properties of the slurry, resulting in low efficiency and high energy consumption during long-distances pumping. To address this issue, this study introduced polycarboxylate ether (PCE) superplasticizers as auxiliary additives for tailings treatment to improve fine particles sedimentation efficiency while enhancing slurry flowability. The results showed that compared to non-ionic polyacrylamide (NPAM) treated slurries, the synergistic effects of PCE and NPAM increased the initial sedimentation rate (ISR) by up to 3.4 times while decreasing the yield stress by up to 8 times and the thixotropic loop area by 10.5 times. DLVO theory calculations showed that PCE mainly affects particle interactions through a significant decrease in electrostatic repulsion. By in-situ monitoring with a focused beam reflectance measurement (FBRM) device, it was demonstrated that the synergistic effect of PCE improved the flocculation ability, strength, and regrowth ability of flocs. Furthermore, strong correlations were found between floc properties and fluid rheological properties. Overall, this study indicated that PCE additive was a promising reagent for fine particles slurry rapid settling and flowability enhancement, providing a new approach for copper tailings disposal.

Compressive Yield Stress of Flocculated Kaolin Suspensions in Seawater

The mining industry has resorted to using seawater while trying to find a solution to the water shortage, which is severe in some regions. Today, the industry looks to tailings dams to recover more water and, thus, increase recirculation. The migration of interstitial water due to the consolidation of particle networks can give rise to large water mirrors in different dam areas. These pools can contain enough water to be recovered and recirculated if the external stress caused by the weight of the pulp exceeds the compressive yield stress. The density and rheological properties of the discarded pulps determine the feasibility of water expulsion during tailings consolidation. As these conditions are largely established in the thickening stage, it is necessary to revisit operations, looking at the dam as a water source. Thus, a thorough understanding of the compressive properties that determine the level of consolidation of typical pulps and their relationships to aggregate properties, such as size and fractal dimension, is crucial. Here, the effect of two types of water, industrial water and synthetic seawater, on kaolin flocculation, sedimentation rate, yield stress, and compressive yield stress were studied. In addition, the relationship of these properties with the flocculant dose and the resulting aggregate size and fractal dimension was examined. One promising finding to practitioners was that salt and small doses of high molecular weight flocculant improved the consolidation of kaolin slurries under compression. These conditions generated low compressive yield stress compared to fresh water and water with low salt content, favoring the consolidation of the pulps and the release of water.

Towards globally relevant, small-footprint dewatering solutions: Optimal conditioner dose for highly variable blackwater from non-sewered sanitation

Globally, the sanitation needs of three billion people are met by non-sewered sanitation. Small-footprint treatment technologies are needed that are appropriate for dense urban areas. Blackwater (BW) (or fecal sludge), contains more than 95% liquid, and dewatering it without conditioning requires large footprints. Chemically-enhanced dewatering with conditioners is a promising option to increase dewatering performance and reduce required footprints. However, before implementation of this solution there is a need for increased knowledge on selection and dosing of conditioners. This study evaluated bio-based and synthetic conditioners (chitosan, tannin-, and starch-based, synthetic with and without poly-acrylamide) with 14 types of BW from five countries. The supernatant after settling with jar-tests was analyzed to quantify optimal dose and dewatering performance. The reduction of total chemical oxygen demand (COD) was >55%, achieved by removal of particulate constituents with mainly soluble COD remaining in the supernatant. A reduction in particulate COD could lead to increased efficiency of soluble COD in supernatant treatment. Bio-based conditioners are as effective as synthetic conditioners, and when performance was variable, it was due to differing properties of TSS, TS, EC and pH. Optimal conditioner dose for synthetic conditioners and chitosan could be predicted using concentrations of total solids (TS) (R² > 0.7), whereas optimal dose for starch- and tannin-based conditioners could be predicted with electrical conductivity (EC) (R² > 0.8), and colloid titration (R² > 0.8). In addition, real-time optical TSS and EC sensors could accurately predict chitosan dose for fresh BW treated at source (R² = 0.97, R² = 0.95). This study validates that use of conditioners for dewatering with highly variable BW can be implemented with real-time measurements for optimal dose, in globally relevant implementations.

Lime/Sodium Carbonate Treated Seawater to Improve Flocculation and Sedimentation of Clay-Based Tailings

Seawater treated with lime and sodium carbonate in different proportions to reduce magnesium and calcium contents is used in flocculation and sedimentation tests of artificial quartz and kaolin tailings. Solid complexes were separated from water by vacuum filtration, and factors such as lime/sodium carbonate ratio, kaolin content, flocculation time, and flocculant dose are evaluated. The growth of the aggregates was captured in situ by a focused beam reflectance measurement (FBRM) probe. Solid magnesium and calcium complexes are formed in raw seawater at pH 11, impairing the performance of flocculant polymers based on polyacrylamides. The results show that the settling rate improved when the treatment’s lime/sodium carbonate ratio increased. That is, when a greater removal of magnesium is prioritized over calcium. The amount of magnesium required to be removed depends on the mineralogy of the system: more clay will require more significant removal of magnesium. These results respond to the structural changes of the flocs, achieving that the more magnesium is removed, the greater the size and density of the aggregates. In contrast, calcium removal does not significantly influence flocculant performance. The study suggests the necessary conditions for each type of tailing to maximize water recovery, contributing to the effective closure of the water cycle in processes that use seawater with magnesium control.

Flocculation Efficiency and Spatial Distribution of Water in Oil Sands Tailings Flocculated with a Partially Hydrophobic Graft Copolymer

This work investigates the effect of partially hydrophobic grafted polymers on flocculation and dewatering of oil sands mature fine tailings. Here, we combine confocal microscopy and rheology to investigate how the graft density of ethylene-propylene-diene grafted with hydrolyzed poly(methyl acrylate) (EPDM-g-HPMA) affects its dispersion in water and flocculation efficiency in terms of sediment solids content and long-term dewatering of oil sands tailings. Increasing the graft density from 30 to 50% makes the flocculant easier to disperse, increases the rate of initial dewatering, and also enhances the viscoelastic response of the flocculated sediments. Conversely, the long-term rheological properties of the flocculated sediments were similar for all flocculants. Tri-dimensional microscopic details of the spatial distribution of water within the flocculated sludge provide novel insights into the performance of the flocculants. Increasing the graft density in EPDM-g-HPMA traps more water within the individual flocs and, consequently, decreases the post-flocculation dewatering rate. Our systematic approach confirms the importance of the spatial distribution of water in the flocculated sediment, which depends on how the flocculant is dispersed and how it retains water in the flocs.

Effect of ultrasound on the flocculation-sedimentation and thickening of unclassified tailings

In back-fill mining, how to rapidly increase the concentration of tailings is an important problem facing mining engineers. In this paper, the effects of ultrasound frequency (17-25 kHz), power (50-100 W), duration (5-20 min) and start time (3-12 min) on the final underflow concentration (FUC) of unclassified tailings (UTs) were investigated. The flocculation-sedimentation and thickening of tailings were compared with and without ultrasound application. The response surface method was applied to analyze the primary and secondary relationships and interactive relationships between the various ultrasound operating parameters and the FUC, and the optimal conditions were determined. In addition, Environmental Scanning Electron Microscope (E-SEM) was used to analyze the structural changes of underflow aggregates and clearly demonstrated a denser underflow after ultrasound treatment. The results indicated that ultrasound can significantly improve the underflow concentration of the UTs slurry. The frequency and power are the most important influencing factors. The best conditions for ultrasound application are a frequency of 20.4 kHz, power of 90 W, duration of 6.2 min and start time at 15.0 min. The FUC reached 71.75% after several minutes of sonication, which is 4.31% higher than the FUC of free flocculation. The results of E-SEM analysis showed significant differences among the microstructures of settled tailings (STs) after free flocculation and 17 and 20 kHz ultrasound treatment. Ultrasound at a frequency of 20 kHz has a more effective mechanical vibration and cavitation action and can therefore effectively break the polymer flocculant chains into shorter chains and promote the compaction of tailings and the release of water. The size distributions of the flocs before and after sonication also support this conclusion.

Evaluation of a Novel Polymeric Flocculant for Enhanced Water Recovery of Mature Fine Tailings

The novel cationic flocculant, poly(lactic acid) choline iodide ester methacrylate (poly(PLA4ChMA)), has been shown to provide improved flocculation of 5.0 wt.% mature fine tailings (MFT) diluted in deionized water compared to commercial anionic polymers, with continued dewatering of the sediment occurring as the polymer undergoes partial hydrolytic degradation. However, the elevated dosages (10,000 ppm) required would make the polymer costly to implement on an industrial scale. With this motivation, the impact of MFT loading and the use of process water is explored while comparing the settling performance of poly(PLA4ChMA) to available commercial alternatives such as anionic FLOPAM A3338. Improved consolidation of 5.0 wt.% MFT diluted with process water could be achieved at reduced dosages (500 ppm) with poly(PLA4ChMA). However, the final compaction levels after polymer degradation were similar to those achieved with the nondegradable commercial flocculants. Flocculation-filtration experiments with undiluted MFT are also conducted to compare the performance of the polymers. Significantly faster rates of water release were observed with the cationic flocculants compared to FLOPAM A3338, but no improvement in the overall tailings compaction was found either before or after poly(PLA4ChMA) degradation. Thus, the improved dewatering observed with poly(PLA4ChMA) in dilute MFT suspensions does not extend to conditions that would be encountered in the field.

Relationship between the structure of chitosan-based flocculants and their performances in the treatment of model azo dyeing wastewater

Chitosan-based flocculants are efficient and biodegradable, possessing the potential application in water treatment. A chitosan-based flocculant, CTS-g-PAM, was prepared via grafting copolymerization. Two main structures of CTS-g-PAM were detected by X-ray photoelectron spectroscopy (XPS), and they related to the different performances of CTS-g-PAM in the treatment of model azo dyeing wastewater in terms of removal efficiency, floc size and zeta potential. CTS-g-PAM with the optimal ratio of CN to -NH- owned the best performance. CN reinforced the interaction between CTS-g-PAM and azo dyes and charge neutralization while the flocs formed in the case were large and compacted. However, excessive CN accelerated itself hydrolysis and leaded to the decomposition of CTS-g-PAM, deteriorating the performance of the flocculant.

Flocculation-dewatering prediction of fine mineral tailings using a hybrid machine learning approach

Polymer-assisted flocculation-dewatering of mineral processing tailings (MPT) is crucial for its environmental disposal. To reduce the number of laboratory experiments, this study proposes a novel and hybrid machine learning (ML) method for the prediction of the flocculation-dewatering performance. The proposed ML method utilizes principle component analysis (PCA) for the dimension-reduction of the input space. Then, ML prediction is performed using the combination of particle swarm optimisation (PSO) and adaptive neuro-fuzzy inference system (ANFIS). Monte Carlo simulations are used for the converged results. An experimental dataset of 102 data instances is prepared. 17 variables are chosen as inputs and the initial settling rate (ISR) is chosen as the output. Along with the raw dataset, two new datasets are prepared based on the cumulative sum of variance, namely PCA99 with 9 variables and PCA95 with 7 variables. The results show that Monte Carlo simulations need to be performed for over 100 times to reach the converged results. Based on the statistic indicators, it is found that the ML prediction on PCA99 and PCA95 is better than that on the raw dataset (average correlation coefficient is 0.85 for the raw dataset, 0.89 for the PCA99 dataset and 0.88 for the PCA95 dataset). Overall speaking, ML prediction has good prediction performance and it can be employed by the mine site to improve the efficiency and cost-effectiveness. This study presents a benchmark study for the prediction of ISR, which, with better consolidation and development, can become important tools for analysing and modelling flocculate-settling experiments.

Experimental Studies on Interfacial Shear Characteristics between Polypropylene Woven Fabrics

Geotextile tubes are used in dam construction because fine tailings are difficult to use. The shear characteristics of geotextile tubes during dam operation are closely related to those of the materials used to construct the tubes. Pull-out tests can accurately reflect the interfacial shear characteristics between geosynthetics in practice, so pull-out tests were carried out for different interfacial types of polypropylene woven fabrics under dry and wet states. The effects of the type of interface and dry-wet states on the interfacial shear characteristics were investigated, and the impact mechanisms were also discussed. The results indicated that P-type interfaces (the warp yarn on the interface is parallel to the pulling direction) tended to harden. However, PTP-type (the warp yarn on the interface is perpendicular to each other) and T-type (the weft yarn on the interface is parallel to the pulling direction) interfaces softened first and then tended to plateau after reaching peak shear stress, and softening became more obvious at higher normal stresses. The displacement corresponding to peak shear stress (referred to as “peak displacement” in this paper) of interfaces was positively correlated with the normal stress, and the wet state reduced the interfacial peak displacement. For different types of interfaces, the peak displacement of the T-type interface was the largest, followed by PTP-type and P-type. Interfacial shear characteristics conformed to Mohr–Coulomb strength theory and, compared with quasi-cohesion values ranging from 1.334 to 3.606 kPa, the quasi-friction angle significantly contributed to the interfacial shear strength. The quasi-friction angle of the interface was composed of a sliding friction angle and an occlusal friction angle. The shear strength of the interface was more sensitive to the interface types than whether they were in the dry or wet state. For different types of interfaces and dry-wet states, the change in the interfacial shear strength is respectively affected by the occlusal friction angle and the sliding friction angle on the interface.

Optimization of Flocculation Settling Parameters of Whole Tailings Based on Spatial Difference Algorithm

In order to obtain the optimum parameters of total tailings flocculation settling, an optimization method of total tailings flocculation settling parameters based on the spatial difference algorithm was proposed. Firstly, the input and output factors of the whole tailings flocculation settling parameters are effectively analyzed, and the relevant factors affecting the flocculation settling parameters are obtained. Secondly, the flocculation settling velocity of the whole tailings is optimized by combining the spatial difference algorithm with the mathematical symmetry algorithm, and the optimal value of the flocculation settling velocity of the whole tailings is obtained. The experimental results show that anionic flocculation has the best flocculation settling effect on the whole tailings. The optimal settlement velocity is close to the actual settlement velocity, and the error of settlement velocity is less than 3.5%. The results show that compared with the traditional method, this method is an effective method to optimize the flocculation and settlement parameters of the whole tailings.

Advanced Polymer Flocculants for Solid-Liquid Separation in Oil Sands Tailings

The generation of tailings as a by product of the bitumen extraction process is one of the largest environmental footprints of oil sands operations. Most of the tailings treatment technologies use polymer flocculants to induce solid-liquid separation. However, due to the complex composition of tailings, conventional flocculants cannot reach the same performance achieved in other wastewater treatments. Over the last couple of decades, the oil sands industry has used acrylamide-based flocculants to treat tailings, achieving major progress in process optimization and integration with mechanical operations, but they still could not reach the required land reclamation targets. Over the last 5 years, the group designed, synthesized, and tested several novel polymer flocculants tailored for oil sands tailings treatment. This feature article communicates recent developments in these innovative polymers. The article first provides a background on tailings generation and treatment, followed by the description of advanced polymer flocculants categorized according to their microstructures such as linear, branched, and graft. The other tailings remediation technologies and one of the initial works on modeling of tailings flocculation is discussed.

Polymer reaction engineering tools to design multifunctional polymer flocculants

A series of multifunctional terpolymers, poly(N-isopropyl acrylamide/2-(methacryloyloxy) ethyl trimethyl ammonium chloride/N-tert-butylacrylamide) [P(NIPAM-MATMAC-BAAM)], were designed to flocculate and dewater oil sands mature fine tailings (MFT). The hydrophobic BAAM comonomer helped in expelling water from the sediments, while the cationic MATMAC comonomer promoted the charge neutralization of negatively charged particles suspended in MFT. The chemical composition distributions of these terpolymers were designed based on the knowledge of the reactivity ratios of all comonomers, instead of by trial and error, as usually done for most polymer flocculants. The binary reactivity ratios of the comonomers were estimated by synthesizing the binary copolymers with various mole fractions of each comonomer in the feed and experimentally measuring the corresponding fraction of comonomer in the copolymers. Polymer reaction engineering tools were used to minimize compositional drift and guarantee the synthesis of terpolymers with narrow chemical composition distributions suitable for MFT dewatering. Focused beam reflectance measurement (FBRM) experiments showed that terpolymers promoted the formation of large MFT flocs (120 μm). The initial settling rate decreased with the increase in flocculant hydrophobicity, likely because the hydrophobic terpolymer segments did not take part in the bridging of the MFT particles. In contrast, the sediment dewaterability increased with the increase in terpolymer hydrophobicity. This study provides guidelines to design a polymer flocculant from first principles and demonstrates the potential of using hydrophobically modified cationic polymers to flocculate MFT effectively.