Rheological Perspectives of Clay-Based Tailings in the Mining Industry

The mining industry faces a significant problem in regions with water scarcity and has had to put in place new strategies to preserve its environmental and economic sustainability. An attractive option in recent years has been the direct use of seawater, avoiding the construction of reverse osmosis plants to desalinate. But, some operational complexities are the subject of discussion and research for engineers; for example, the difficulties by the high presence of complex gangues like clays and the location of the plants, far from the coast and at high altitude. The latter requires high investments in pumping, the only option in some cases. In this scenario, it is imperative to improve the efficiency of water use and advance to effective closures of water circuits. A critical stage is the thickening that allows water to be recovered from the tailings, reusing it in upstream operations. However, the performance of the tailings management is usually limited by the rheological properties of the thickened slurries, which impact on the discharge from the underflow of the thickeners, pumping energy costs, disposal on the tailings storage facilities (TSFs). This text describes the consequences caused by a saline medium on the rheological properties of clay-based tailings, analysing scenarios that allow tackling this operation

Improving the Flocculation Performance of Clay-Based Tailings in Seawater: A Population Balance Modelling Approach

A population balance model described the flocculation of clay-based mining tailings in treated seawater with reduced magnesium content. For the treatment, 0.06 M of lime was added to the liquor, generating solid magnesium complexes that were subsequently removed by vacuum filtration. Magnesium content varied between 10–1440 ppm when mixing raw seawater with treated seawater. The aggregate size was analysed by the Focused Beam Reflectance Measurement (FBRM) technology. The model follows the dynamics of the aggregation-rupture and it provides a good approximation to the temporal evolution. A decrease in collision efficiency was implemented as an indicator of the polymer depletion, describing the size reduction. Lower magnesium content makes larger aggregates with a higher fractal dimension, but an increase in the concentration of clays reduces both the size of aggregates and the fractal dimension, indicating more open and porous structures, with higher permeability to the passage of fluid. The model efficiently illustrates the experimental data, with R-square (R2) greater than 0.9 and Goodness of Fit (GoF) greater than 95% in most cases, wherein the fitting parameters allowed for analysing the impact of magnesium and clays on the collision efficiency, collision frequency, and fragmentation rate. The model is predictive with few parameters, and it is potentially a powerful tool for water management optimisation

Chemometric Optimisation of a Copper Sulphide Tailings Flocculation Process in the Presence of Clays

The presence of fine and ultra-fine gangue minerals in flotation plants can contribute to sub-optimal valuable ore recovery and incomplete water recycling from thickeners, with the performance of the latter equipment relying on adequate flocculation. In order to study the dependence of the flocculation process on the suspension-flocculant mixing conditions, a series of experiments—chosen using chemometric analysis—were carried out by varying mixing conditions, solid concentration, water salinity and flocculant dosage. To this purpose, two different tailings (both featuring coarse and fine content) were considered and a response surface methodology based on a Doehlert experimental design was used. The results suggest that the operational conditions to optimise the flocculated tailings settling rate and the suspended solids that report to a thickener overflow are not necessarily the same. This is a reasonable outcome, given that the settling rate depends on the coarse aggregates generated in the slurry, while the overflow solids content is governed both by either fine particle content (and its characteristics) or small aggregates. It is inferred that to maximise dewatering performance two stages should be involved—a separate treatment of the thickener overflow to remove fine content and thickening at optimal flocculant dosage to enhance this process

Analysis of Kaolin Flocculation in Seawater by Optical Backscattering Measurements: Effect of Flocculant Management and Liquor Conditions

Optical backscattering (OBS) signal values were used to evaluate the flocculation of kaolin slurries and seek the implications of using seawater. Two anionic flocculants were applied to kaolin suspensions at several dosages and in water of varying pH and electrolyte concentration. An OBS height scan method was used to estimate the degree of aggregation, supernatant quality, and solids concentration of the sediments. The residual solids of the supernatant depended of the extent of particle coagulation before flocculant was added, where the pH and salinity displayed a significant impact on flocculation. The OBS results were highly sensitive to the presence of fine particles, which was estimated in parallel from the focused beam reflectance measurements (FBRM.) In seawater, without flocculant added, the samples had increased root-mean-square scattering (Frms) values and larger final sediment volume than samples prepared in water with lower electrolyte concentration. This indicates a higher initial state of aggregation of the particles in seawater. Then, the aggregation degree was best linked to the square-weighted chord length distribution of the FBRM data, which intensifies the sensitivity to coarse aggregates.Applied Science, Faculty ofNon UBCMining Engineering, Keevil Institute ofReviewedFacult

Reducing Magnesium within Seawater Used in Mineral Processing to Improve Water Recovery and Rheological Properties When Dewatering Clay-Based Tailings

In areas where access to water for mineral processing is limited, the direct use of seawater in processing has been considered as an alternative to the expense of its desalination. However, efficient flotation of copper sulfides from non-valuable phases is best achieved at a pH > 10.5, and raising the pH of seawater leads to magnesium precipitates that adversely affect subsequent tailings dewatering. Seawater pre-treatment with lime can precipitate the majority of magnesium present, with these solids then being removed by filtration. To understand how such treatment may aid tailings dewatering, treated seawater (TSw) was mixed with raw seawater (Rsw) at different ratios, analyzing the impact on the flocculated settling rate, aggregate size as measured by focused beam reflectance measurement (FBRM), and vane yield stress for two synthetic clay-based tailings. A higher proportion of Tsw (10 mg/L Mg2+) led to larger aggregates and higher settling rates at a fixed dosage, with FBRM suggesting that higher calcium concentrations in Tsw may also favor fines coagulation. The yield stress of concentrated suspensions formed after flocculation decreased with higher proportions of Tsw, a consequence of lower flocculant demand and the reduced presence of precipitates; while the latter is a minor phase by mass, their high impact on rheology reflects a small particle size. Reducing magnesium concentrations in seawater in advance of use in processing offers advantages in the water return from thickening and subsequent underflow transport. However, this may not require complete removal, with blending Tsw and Rsw an option to obtain acceptable industrial performance

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

A Criterion for Estimating the Strength of Flocculated Aggregates in Salt Solutions

A simple criterion is proposed to quantitatively estimate the resistance of aggregates based on incremental mechanical shear disturbances. Aggregate strength can be affected by the hydrodynamic conditions under which flocculation occurs; therefore, an experimental method is standardized to determine the resistance of aggregate structures that are formed under defined conditions of salinity (NaCl 0–0.1 M), mixing time (3 min), and mean shear rate (G = 273 s−1). Kaolin particles were flocculated in saline solutions with an anionic flocculant of high molecular weight. The method involves increasing the mean shear rate (G = 0–1516 s−1). Each increment represents a new experiment that starts from the base of 273 s−1. Target aggregates are increasingly fragmented as mechanical disturbance increases. The monotonic relationship between the mean shear rate increments (ΔG) and the final size of the aggregates is used for a quantitative estimate of the resistance of the target aggregates since this resistance underlies this relationship. The evolution of aggregate size is analyzed by the Focused Beam Reflectance Measurement (FBRM) method, which may capture the chord length distribution on concentrated slurries. To estimate and compare the resistance of the target aggregates in solutions with different salinities, a pseudo-first-order model that describes the rupture degree as a function of shear rate increments obtains the characteristic shear rate. The rupture percentage is reached with considerably lower agitation increments at higher salinity than at low salinity. This criterion is expected to help improve the efficiency of solid–liquid separation processes, especially in plants operating with seawater, be it raw or partially desalinated

Toward the Implementation of Circular Economy Strategies: An Overview of the Current Situation in Mineral Processing

Funding Information: The authors thank the financial support from Agencia Nacional de Investigación y Desarrollo, ANID, through PIA program grant number ACM 170005. L.A.C. thanks the supported of MINEDUC-UA project, code ANT1856 and Fondecyt program grant number 1211498. R.I.J. and J.I.O thank the support of Fondecyt program by their projects 11171036 and 11170616, respectively. Publisher Copyright: © 2021 Taylor & Francis Group, LLC.Mining resources have played a leading role in the development of humanity, and the demand for these raw materials is expected to increase in the foreseeable future. In addition, new technologies also require the extraction of new critical materials. These trends pose various challenges as there is a limited supply of natural resources, and standard mining and mineral processing practices are associated with significant environmental impacts, such as waste generation, energy and water consumption, and CO2 emissions. The circular economy (CE) has recently gained attention as a model to address such a complex scenario. This work analyzes the current efforts toward the application of CE in mineral processing. Although advances have been made, this review shows that the most significant material flows and environmental impacts occur near the production sites, which currently limits the closure of loops. Besides, mining industries are conservative regarding the adoption of new technologies or processing strategies, which is another hindrance to the implementation of the CE. Thus, and with few exceptions, while some sectors are already facing advanced stages of CE (namely, CE 3.0), the mineral processing field struggles to advance from the basic CE requirements (i.e, CE 1.0 to CE 2.0).Peer reviewe

Estimating the Shear Resistance of Flocculated Kaolin Aggregates: Effect of Flocculation Time, Flocculant Dose, and Water Quality

The resistance of kaolin aggregates to shearing in water clarification and recovery operations is a critical input in designing thickener feed wells. A recently formulated but already available criterion is used to determine the shear strength of flocculated kaolin aggregates. The flocculant is a high molecular weight anionic polyelectrolyte. The resistance of the aggregates is evaluated as a function of flocculation time, flocculant dosage, and water quality. The determination is based on a standardized experimental method. First, the time evolution of the average size of kaolin flocs is measured when aggregates are exposed to incremental shear rates from a predetermined base value. Then, the results are fitted to a pseudo-first-order model that allows deriving a characteristic value of the shear rate of rupture associated with the upper limit of the strength of the aggregates. In seawater, at a given dose of flocculant, the strength of the aggregates increases with time up to a maximum; however, at longer times, the resistance decreases until it settles at a stable value corresponding to stable aggregates in size and structure. A higher flocculant dosage leads to stronger aggregates due to more bridges between particles and polymers, leading to a more intricate and resistant particle network. In industrial water with very low salt content, the resistance of the kaolin aggregates is higher than in seawater for the same dose of flocculant. The salt weakens the resistance of the aggregates and works against the efficiency of the flocculant. The study should be of practical interest to concentration plants that use seawater in their operations

Manganese Nodules in Chile, an Alternative for the Production of Co and Mn in the Future—A Review

Given the active growth of emerging technology industries, it has become essential to have large quantities of critical metals to meet the current demand. In the Chilean mining industry, there is a depletion of high-grade mineral ores, and there is hence a need to increase production levels in the copper industry and diversify its market by extracting other elements. One of the strategies is to foster the production of lithium batteries, but the manufacture requires reserves of cobalt (Co) and manganese (Mn). Currently, Co reserves are not being exploited in Chile, and Mn production is almost negligible. This is due to the apparent shortage of high-grade ores on the land surface of the country. Given this scenario, the seabed manganese nodules are presented as a good alternative due to their high average grades of Co and Mn, which in turn would allow the growth of strategic value-added industries including lithium battery production. Chile’s current environmental regulations prevent the exploitation of marine resources. However, given technological advances worldwide, both in collection mechanisms and extractive processes, in addition to the needs generated from the future strategic plans, leads us to think about a project to exploit manganese nodules locally