Density / (t·m−3) | Bulk density / (t·m−3) | Average size / μm | Porosity / vol% | Content (<20 μm) / wt% | Content (>74 μm) / wt% | pH value |
2.97 | 1.37 | 49 | 53.87 | 31.5 | 21.6 | 11 |
Cite this article as: |
Shi Wang, Xue-peng Song, Xiao-jun Wang, Qiu-song Chen, Jian-chun Qin, and Yu-xian Ke, Influence of coarse tailings on flocculation settlement, Int. J. Miner. Metall. Mater., 27(2020), No. 8, pp. 1065-1074. https://doi.org/10.1007/s12613-019-1948-9 |
Xiao-jun Wang E-mail: xiaojun7903@126.com
Qiu-song Chen E-mail: qiusong.chen@csu.edu.cn
Adding flocculants to deep cone thickeners to thicken and dehydrate the tailings slurries (TSs) with low concentrations transported from dressing plants can effectively improve the settling efficiency of the TSs and prevent overflow of water caused by mixing [1-3]. This technology has been widely applied here and abroad. However, because the ore and rock properties of different mines differ, and because large differences exist in the ore processing technologies, the particle size distributions of the tailings produced by the dressing plants vary considerably [4]. Therefore, the particle size composition and the surface physicochemical characteristics of different particles also differ. Additionally, the process of inducing flocculation by combining particles and flocculant molecules is complex. The strength and fractal dimension of the flocculation mesh structure within the flocs are also substantially different. Moreover, different TSs exhibit different flocculation settlement behaviors; i.e., the finer the tailings, the slower the settling velocity [5-6]. Several flocculation settlement phenomena in mines have demonstrated that the particle size distribution of unclassified tailings strongly influences the actual sedimentation [7-8]; e.g., the settling velocity of tailings slurries in gold mines is usually lower than that in iron mines under the same conditions.
The unclassified tailings are a type of a heterogeneous group of particles with a wide range of particle sizes. Furthermore, the bridging effect of macromolecular flocculant is mainly targeted at tailings particles with a particle size less than 30 μm [9]. When the particle size of the tailings is greater than 30 μm, their participation in bridging becomes difficult. Tailings particles smaller than 37 μm are defined as fine particle tailings (FPTs), whereas those larger than 37 μm are defined as coarse particle tailings (CPTs). The FPTs are bridged with the macromolecular flocculant to form larger floccules in the full tailings slurry, whose structure is loose, amorphous, and interconnected but not very stable [7,10]. A large amount of space and several tiny networks exists inside the floccules, which indicates the presence of flocculent structures (FSs). The floccules contain a large amount of liquid, which results in the density of the flocculation being similar to that of the liquid itself. Thus, the settling velocity is low. The CPTs sink quickly by overcoming resistance with their own gravity.
The interaction mechanism between different flocculant molecules and particles is overwhelmingly complex. Autier et al. [11] used a scanning electron microscopy (SEM) and laser particle size analysis (LPSA) to analyze the influence of polycarboxylic acid on the particle dispersion characteristics in cement slurry. They identified the different types of particles and their mesostructural organization, along with the particle transfer that can occur between the different granulometric classes. Lee et al. [12] demonstrated that the particle-binding bridges enhanced flocculation and aggregated kaolinite particles in large, easily settleable flocs, whereas the polymer-binding bridges increased the steric stabilization by developing polymer layers that covered the kaolinite surface. Bürger et al. [13] developed a mathematical model for batch and continuous thickening of flocculated suspensions in vessels with various cross-sections. Zou et al. [14] studied the influence of anionic polyacrylamide (APAM) on the surface free energy of coal particles and kaolinite particles, and established that APAM changed the value of the potential energy of interaction between particles but did not change the state of attraction/repulsion of the total potential energy of interaction between particles. Benn et al. [15] proposed an experimental system to provide high-fidelity sedimentation data for the sedimentation modeling of flocculated systems and used turbulent pipe flow flocculation to offer aggregate size monitored in-line. Kazzaz et al. [16] used poly(acrylic acid) (PAA) to analyze the flocculation of aluminum oxide particles with various sizes (0.06−0.6 μm) to investigate the effect of the aluminum oxide particle size on the flocculation effectiveness of PAA. Garmsiri and Shirazi [17] studied the effects of grain size, grain size reduction, and solution ageing of an anionic high-molecular-weight flocculant on its preparation, and the results indicated that, for smaller grain sizes, a shorter ageing was required to achieve a certain settling rate. Ng et al. [18] used a turbidity testing method to confirm the flocculation of fine hematite particles with poly-N-isopropylacrylamide, which deslimed the surface of the coarser particles.
Although numerous experiments and theoretical analyses have been conducted on the microscopic mechanism of action between admixtures and particles, the influence of particle size on the flocculation and settlement of TSs has rarely been studied. In the present study, the relationship between the CPTs composition, flocculant unit consumptions (FUCs), and settling velocity of solid−liquid interface (SLI) was determined on the basis of the flocculation and settlement test rules of TSs with different CPTs compositions in a copper mine. In addition, APAM, which is widely used in mines, was used in this study. The SEM test was used to observe the particle size distribution in the flocculating area in the accelerated and free settling process (AFSP), the LPSA was used to measure the particle distribution in the flocculation area, and the influence of the CPTs composition on the change in the SLI settling velocity of the TSs is discussed. The present study provides important background information for ensuring rapid thickening of TSs and realizing continuous mine backfilling.
The unclassified tailings were obtained from a copper mine in Jiujiang, Jiangxi Province, China. The particle size distribution of these tailings was analyzed using a Winner 2000 laser particle size analyzer. A pycnometer was used to measure the specific gravity, a small relative density meter was used to measure the unit density, and the pH value of the unclassified tailings slurry with an original content of ~35wt% was measured onsite using a METTLER TOLEDO pH meter. Domestic water was used as the test water. The results are presented and depicted in Table 1 and Fig. 1, respectively. The average particle size of the total tailings was 49 μm, and the tailings with a particle size greater than 37 μm accounted for 63.6wt%; the original slurry was alkaline (see Table 1 and Fig. 1). The composition of the main elements in the unclassified tailings was determined by X-ray fluorescence spectrometry (see Table 2).
Density / (t·m−3) | Bulk density / (t·m−3) | Average size / μm | Porosity / vol% | Content (<20 μm) / wt% | Content (>74 μm) / wt% | pH value |
2.97 | 1.37 | 49 | 53.87 | 31.5 | 21.6 | 11 |
Si | Ca | Al | Mg | Fe | S |
33.02 | 15.68 | 2.56 | 1.82 | 10.37 | 4.55 |
Pb | Mn | F | K | P | Cu |
0.0095 | 0.085 | 0.080 | 0.37 | 0.049 | 0.065 |
The unclassified tailings are dried and dehydrated, and then divided into two parts using the standard top-impact-type vibrating screen: CPTs (≥37 μm) and FPTs (<37 μm). The reassembled tailings slurries (RTSs) were adjusted according to the contents of the CPTs after measurement, which were 90wt%, 80wt%, 70wt%, 60wt%, 50wt%, and 40wt%. The RTSs were then labeled from Z-1 to Z-6 in order and mixed separately. The particle size distribution of the RTSs is shown in Fig. 2.
Following a series of flocculant selection tests, APAM with a molecular weight of 10 million, obtained from Xinyu Chemical Co., Ltd., Zhengzhou, China, was found to exhibit good flocculation and sedimentation performance for tailings obtained from the copper mine in Jiangxi Province. An appropriate amount of converted flocculant solution, which needs to be added to the unclassified tailings slurry as required, was calculated before the test. The addition of the APAM solution can be defined as follows [19]:
$${M_{\rm{x}}} = \dfrac{{{C_{\rm W}} \cdot V \cdot {J_{\rm{x}}} \cdot {\rho _{\rm{s}}}}}{{{{10}^6} \cdot {\gamma _{\rm{n}}} \cdot {\rho _{\rm{x}}}}},$$ | (1) |
where Mx is the APAM addition in mL; CW is the content of the unclassified tailings slurry in wt%; V is the volume of the unclassified tailings slurry in mL; Jx is the optimal APAM dosage in g·t−1; γn is the APAM content in wt%; ρs is the density of the unclassified tailings slurry in g·cm−3; and ρx is the density of APAM in g·cm−3.
The height change rules of the SLI were recorded after the flocculating sedimentation tests of the RTSs with different CPTs compositions. The flocculation area was solidified by the silicate substitution method, and its microstructure was observed by SEM. Meanwhile, the TSs in the flocculation area were extracted and then the change rules of the particle size distribution were analyzed using the Winner 2000 laser particle size analyzer. The test process is illustrated in Fig. 3.
The flocculating settlement test was conducted in a graduated cylinder as follows.
(1) One gram of APAM was weighed and placed in a graduated cylinder containing 1000 mL of water. The mixture was stirred at 40 r·min−1 for 60 min using an electric agitator, and the APAM was prepared with a content of 0.1wt%.
(2) An appropriate amount of the combined tailings and water was electronically weighed, and the RTSs were prepared with contents of 15wt% in six different 1000 mL graduated cylinders, which were labeled ZJ-1 through ZJ-6. The density of each slurry was approximately 1.11 t·m−3.
(3) APAM solution (1.67 mL) was transferred to the six graduated cylinders according to the FUC, which was 10 g·t−1.
(4) The solutions were stirred with a glass rod for 30 s, and the height of the SLI of the RTSs was recorded at intervals of 0, 0.25, 0.5, 0.75, 1, 2, 3, 4, 5, 8, 12, and 15 min.
(5) The second step was repeated, and the following three tests were performed. The APAM solution with 3.34, 5.01, and 6.68 mL was transferred to six graduated cylinders according to the FUC, which was 20, 30, and 40 g·t−1, respectively. The fourth step was then repeated.
Slurries ZJ-1 through ZJ-6 were again prepared. The APAM solution, whose FUC was 20 g·t−1, was added to the graduated cylinders containing the slurries, and then the flocculating settlement test was conducted. The slurry 1 cm below the SLI was rapidly extracted from the RTSs using pipettes with long tubes 15 s after sedimentation and then transferred to two small beakers. An appropriate amount of liquid sodium silicate (Na2SiO3) was added to one of the beakers, and the distribution of the tailings particles was solidified in the process of flocculation settlement according to its permeability and air hardening property. Finally, the samples were sprayed with gold and their microstructures were observed using an XL30W/TMP scanning electron microscope [20-23].
The slurry in the other beaker was dried. Tailings samples were collected at four points in this beaker, and their particle size distribution was measured by LPSA. The average of the results was determined, and the changes in particle size in the flocculation area of different RTSs were recorded.
To analyze the change rules of the velocity of the SLI in the RTSs, the maximum settling velocity,
$${v_{{S_{\!y}}}} = \dfrac{{{h_{{S_{{\!y} - 1}}}} - {h_{{S_{\!y}}}}}}{{{S_{\!y}} - {S_{{\!y} - 1}}}}$$ | (2) |
where
The change rules of the relative reduction,
$${d_{i\!jk}} = \dfrac{{{v_{i\!j90}} - {v_{i\!jk}}}}{{{v_{i\!j90}}}} \times 100{\text{% }}$$ | (3) |
where
The relationship between the height of SLI in RTSs and time is drawn when different FUCs were added to RTSs after processing test data, as shown in Fig. 4. By analyzing Fig. 4, we determined the change values of
Three main following conclusions were obtained from Figs. 4-6.
(1) The CPTs considerably influence the settling velocity of SLI in RTSs; however, when its content is less than 50wt%, the influence evidently weakened. First, when the FUC was 20 g·t−1,
(2) The optimal FUC was approximately 20 g·t−1, and the sedimentation result did not considerably improve with increasing amount of flocculant. First, when the FUC was increased from 10 to 40 g·t−1, the
(3) The promoting effect of CPTs on the settlement velocity was reflected in the period of 0−1 min. First, when the value of FUC was 10 g·t−1, the RSP of slurries ZJ-1 through ZJ-5 occurred within 0−2 min; however, when the value of FUC was 20−40 g·t−1, the RSP of slurries ZJ-1 through ZJ-6 occurred within 0−1 min, as shown in Figs. 4(a)-4(d). The RSP of different RTSs was varied according to the amount of flocculant. Second, when the value of FUC was 10 g·t−1, the SSP of slurries ZJ-1 through ZJ-5 occurred within 2−5 min; the settling velocity was then slowly reduced to zero. However, when the value of FUC was 20−40 g·t−1, the SSP of slurries ZJ-1 through ZJ-6 occurred within 1−3 min, as shown in Figs. 4(a)-4(d). The SSP of different RTSs also varied according to the amount of flocculant.
The SEM images of different RTSs in the flocculation area in the AFSP are shown in Fig. 7. Fig. 7 shows that, when the content of FPTs in RTSs was only 10wt%, several CPTs evidently existed in the flocculation area in the AFSP (see Fig. 7(a)). Thus, these CPTs did not directly settle at the bottom of the cylinder; they instead intertwined with the flocs as a whole. With the increase of the FPTs content in the RTSs, the CPTs in the flocculation area gradually decreased (Figs. 7(b)-7(f)); thus, the influence of CPTs on flocculation settlement gradually weakened. When the content of CPTs in the RTSs reached 50wt%, a marginal amount of CPTs existed in the flocculation area (Fig. 7(f)). Meanwhile, the influence of CPTs on flocculation settlement was no longer evident; the flocs considerably influenced the sedimentation velocity. The experimental results are consistent with those mentioned in conclusion (1) in Section 3.1.
The size gradation curves of tailings in the flocculation zone of different RTSs are shown in Fig. 8, and the content of CPTs in the flocculation zone of RTSs and that of the original CPTs are compared in Fig. 9.
Figs. 8 and 9 show that the contents of CPTs in the ZJ-1 flocculation zone varied from 90wt% to 55.9wt% and that the CPTs contents in the flocculation zones of ZJ-2−ZJ-6 were also relatively reduced. In addition, the extent of reduction gradually decreased such that the content of CPTs of ZJ-6 was reduced by 25.22wt%. A correlation was observed between the CPTs in the flocculation zone and that in the RTSs because CPTs were involved in the sedimentation process. The particle size in the ZJ-1−ZJ-6 flocculation zones with the largest proportion of different RTSs gradually decreased from 79.00 to 17.19 μm, whereas the settlement velocity of ZJ-1−ZJ-6 decreased successively, as shown in Fig. 5. That is, the settlement velocity of slurries was directly proportional to the particle size in the flocculation zone; in addition, the greater the CPTs content in the flocculation area, the faster the slurries settled. The maximum proportion of the particles in the flocculation zone of ZJ-1−ZJ-6 increased from 5.57wt% to 7.25wt%, the content of FPTs gradually reached the maximum value, and the settling velocity of the slurries gradually become stagnant. In summary, CPTs positively influenced flocculation and sedimentation. The experimental results are consistent with those mentioned in conclusion (1) in Section 3.1.
The loose flocs with reticular structures form by bridging FPTs and macromolecular flocculant; these FSs are formed rapidly via mixing at the beginning of the tests [24]. In the AFSP, CPTs settle rapidly because of gravity; in addition, most of them are netted to form a whole with flocs when they were being blocked, pulled, and captured by the FSs. They both then settle together, accelerating the sedimentation process [25]. The influence of CPTs content on the settling velocity of SLI is shown in Fig. 10.
CPTs and flocs form a whole and then settle together; when the content of CPTs is high, the settling velocity of CPTs plays a key role, accelerating the fast settling of flocs (Fig. 10(a)). However, when the content of CPTs is low, the settling velocity of flocs is at a maximum, and a small amount of CPTs cannot match the rapid settlement of several flocs (Fig. 10(b)). The tests show that, when the content of CPTs of this copper mine exceeded 50wt%, the flocculation settlement velocity of the tailings slurry was rapid. Fig. 1 shows that the actual CPTs content in the unclassified tailings of this copper mine was 63.6wt% and that the tailings exhibited good settlement.
When the FUC added is different, the sedimentation process of RTSs for a flocculation settling time of 30 s is shown in Fig. 11. The FSs formed by the combination of flocculants and FPTs will vary with the addition of flocculant in a certain tailing slurry. When the FUC added is low, some free PFT still exist in the tailings slurry, which cannot be flocculated and form sufficient FSs; this scenario leads to a high solids content in the clear liquid area and to low sedimentation velocity (Fig. 11(a)) [26]. When sufficient FUC is sufficient, almost all of the FPTs collectively form the FSs; thus, the clear liquid area contains less FPTs and the sedimentation velocity is high (Fig. 11(b)). When the FUC added is high, excess flocculants may exist in the flocs or may be free in the aqueous solution, whereas the FSs that are conducive to accelerating the settlement velocity exhibits no obvious change. That is, the “effective flocculation structures” are basically the same as the FSs when sufficient FUC is added; at this moment, the sedimentation velocity does not increase dramatically (see Figs. 11(c) and 11(d)) [27]. The test results show that the most appropriate amount of FUC of tailings slurry in this copper mine is 20 g·t−1.
The AFSP is completed within a brief period of 1 min after flocculant has been added to different RTSs according to the test conclusion (3) in Section 3.1; the accelerating effect of CPTs on settlement is also reflected in this process. The average settling velocity of the SLI at this stage can reach 0.4 cm·s−1. Thus, the height of the free settling zone in the actual concentration facility determines the settling time—specifically, the size of the effective settlement space. In this space, CPTs cause the flocs to settle rapidly; in addition, the free water in the lower section rapidly spills from the pores of the FSs [28]. Meanwhile, at the lower section of the thickening facility, the pore water between the particles is slowly squeezed out because of gravity; however, the floc water is protected by FSs and it is difficult to be extruded. Thus, the settling velocity is low in this situation.
In conclusion, an appropriate amount of CPTs in the tailings slurry can ensure a rapid SLI settling speed according to the aforementioned mechanism analysis. Thus, the results suggest that mines should ensure a certain amount of CPTs in their tailings. When the FUC added is very high, the free macromolecular flocculant in water is difficult to remove, which will affect the recycling of actual water resources in mines. Thus, an appropriate amount of flocculant is recommended to thicken tailings.
To improve the settlement velocity of TSs, an appropriate amount of flocculant should be added according to the actual conditions in engineering. In addition, the content of CPTs (>37 μm) should be greater than 50wt%. The fast settling speed of TSs will lead to faster growth of the thickness of the compression layer in deep cone thickeners, which increases the risk of rake blockage. Thus, the torque of deep cone thickeners should be increased [29-30].
(1) The SEM images show that CPTs do not directly settle at the bottom of the graduated cylinder because of the FSs in the AFSP; instead, they are netted by the floccules to form a whole and then settle rapidly. CPTs accelerate the rapid settlement of TSs. In addition, when the CPTs content exceeds 50wt%, the acceleration effect is evident.
(2) The most appropriate FUC is 20 g·t−1, and the sedimentation result does not considerably improve with increasing amount of flocculant. This result is observed because the “effective flocculation structure” does not substantially change at this time and the excess flocculant molecules are floating free in the water; thus, no evident increase in the settling velocity of the SLI is observed.
(3) In the effective settling space of the thickening facility, free water flowed from the pores of the FSs rapidly; in addition, the CPTs caused the flocs to settle rapidly, which is reflected in the period from 0 to 1 min, and considerably influenced the settling velocity of the SLI.
(4) The main factor restraining the settling velocity of the solid−liquid interface (SLI) is the floccules, which are formed by the FPTs and flocculant during flocculation and settlement. The increase in the CPTs content positively affects the sedimentation velocity, indicating that the settlement velocity can be governed by controlling the CPTs content in engineering.
This work was financially supported by the National Key R&D Program of China (No. 2017YFC0804601), the National Natural Science Foundation of China (Nos. 51804134 and 51804135), the Natural Science Foundation of Jiangxi Province (No. 20181BAB216013), the Program of Qingjiang Excellent Young Talents, Jiangxi University of Science and Technology, and the Doctoral Startup Fund of Jiangxi University of Science and Technology (No. jxxjbs17011).
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Density / (t·m−3) | Bulk density / (t·m−3) | Average size / μm | Porosity / vol% | Content (<20 μm) / wt% | Content (>74 μm) / wt% | pH value |
2.97 | 1.37 | 49 | 53.87 | 31.5 | 21.6 | 11 |
Si | Ca | Al | Mg | Fe | S |
33.02 | 15.68 | 2.56 | 1.82 | 10.37 | 4.55 |
Pb | Mn | F | K | P | Cu |
0.0095 | 0.085 | 0.080 | 0.37 | 0.049 | 0.065 |