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.

Study of Concentrated Short Fiber Suspensions in Flows, Using Topological Data Analysis

The present study addresses the discrete simulation of the flow of concentrated suspensions encountered in the forming processes involving reinforced polymers, and more particularly the statistical characterization and description of the effects of the intense fiber interaction, occurring during the development of the flow induced orientation, on the fibers’ geometrical center trajectory. The number of interactions as well as the interaction intensity will depend on the fiber volume fraction and the applied shear, which should affect the stochastic trajectory. Topological data analysis (TDA) will be applied on the geometrical center trajectories of the simulated fiber to prove that a characteristic pattern can be extracted depending on the flow conditions (concentration and shear rate). This work proves that TDA allows capturing and extracting from the so-called persistence image, a pattern that characterizes the dependence of the fiber trajectory on the flow kinematics and the suspension concentration. Such a pattern could be used for classification and modeling purposes, in rheology or during processing monitoring.

Rheology of Highly Concentrated Suspensions with a Bimodal Size Distribution of Solid Particles for Powder Injection Molding

Powder injection molding (PIM) is one of the modern and prospective technologies in processing different materials. We proposed to use bimodal compositions of particles for increasing their content in the final products. A set of model suspension of Al with low-molecular-weight poly (ethylene glycol) as a binder based on theoretical arguments concerning the filling capacity of bimodal suspensions was prepared. Studying the rheological properties of these compositions showed that they demonstrate elasto-viscous behavior with significant plasticity that is favorable for the technological process. Using compositions with bimodal distributions allows for increasing the content of the solid phase up to 75 vol. % for PIM technology, which is significantly higher than the standard practical limit. This rheological approach developed for model formulations was applied to processing compositions containing aluminum oxide as typical ceramics and polyolefines as a binder widely used in technological practice. The obtained sintered ceramic samples have quite acceptable mechanical properties of the usual corundum articles.

Slip in adhesion tests of a Kaolin clay

Adhesion tests were performed on concentrated suspensions of Kaolin clay. At low concentrations samples formed conical deposits on both the top and bottom plates with the central region narrowing to a filament before undergoing breakup. In contrast high concentration samples deformed as a cylinder before apparently fracturing into two pieces. As the concentration of the samples was increased the samples underwent quite different forms of slip which it is shown can be deduced from their respective force distance curves. The type of slip behaviour for a given concentration of clay could be modified with changes to surface roughness, the initial compressive load prior to an experiment and with the separation velocity of the plates. The different slip characteristics appear to arise from the concentration dependent way in which particles interact with the rough surface topography. Graphic Abstract