Electrokinetic Dewatering of Phosphatic Clay

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Solution Overview

Problem

The slow consolidation of phosphatic clay suspensions in clay settling areas, which can take up to 25 years to reach a solids content of 25-40 wt %, poses a significant challenge in phosphate ore beneficiation, leading to extensive land usage and high energy costs for water removal.

Innovation Solution

The application of an electrokinetic dewatering system that utilizes an electric field to enhance the separation of water from solids in phosphatic clay suspensions, achieving a solids content increase through the application of an electric field, reducing the need for additional chemicals or materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Loss of time

If conventional settling and self-consolidation is used, then no additional chemicals or materials are needed, but the consolidation process takes 25 years to reach 25-40 wt % solids content

Engineering Contradiction:

Improveconsolidation timeVSAvoidsystem complexity

Core Design Contradiction:

Loss of timeVSDevice complexity

Solution Approach 1:

The patent replaces the conventional passive gravitational settling mechanism with an active electrokinetic system. DC electrodes generate an electric field that drives electroosmotic flow and electrophoretic migration, accelerating water removal and solid consolidation from 25 years to days or hours. This substitution of mechanical/gravity-based separation with electric field-driven separation resolves the time-loss contradiction.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Productivity

If electrokinetic dewatering is applied, then consolidation time is reduced to 19 hours, but energy costs and device complexity increase

Engineering Contradiction:

Improveconsolidation rateVSAvoidenergy consumption

Core Design Contradiction:

ProductivityVSUse of energy by moving object

Solution Approach 1:

The patent applies parameter changes by adjusting electric field strength (1.2 V/cm), flow rate, and pH conditions to optimize the electrokinetic dewatering process. By controlling these parameters, the system achieves high productivity (25 wt % solids in 19 hours) while managing energy consumption through efficient electrode configuration and operational parameters.

Inventive Principle:

Principle #35Parameter changes

3Quantity of substance

If conventional settling areas are expanded to handle more waste, then land usage increases to 150 square miles, but the solids content increase remains slow

Engineering Contradiction:

Improvesolids contentVSAvoidland area

Core Design Contradiction:

Quantity of substanceVSArea of stationary object

Solution Approach 1:

The patent replaces large-scale gravitational settling areas with compact electrokinetic dewatering systems. By using electric field-driven separation instead of gravity-based settling, the system achieves the same solids concentration (25-40 wt %) in a fraction of the space, reducing land requirements from 150 square miles to much smaller footprint equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Productivity

If flocculating agents are added to accelerate consolidation, then solids content increases faster, but additional chemicals and materials are required

Engineering Contradiction:

Improveconsolidation speedVSAvoidchemical usage

Core Design Contradiction:

ProductivityVSLoss of substance

Solution Approach 1:

The patent substitutes chemical flocculation with physical electrokinetic separation. Instead of adding flocculating agents to accelerate consolidation, the system uses DC electrodes to generate electric fields that drive water removal and solid consolidation, achieving high productivity without chemical additives and avoiding associated environmental and cost issues.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method significantly accelerates the consolidation process, achieving a 25 wt % solids content in 19 hours with an electric field of 1.2 V/cm, while reducing energy costs and operational time, and can be scaled for large areas like one-square-mile clay settling areas.

Implementation Method 1

Electrokinetic separation takes advantage of the charge in the suspended particles

Methodology Applied

Scientific EffectElectroosmosis: Electro-Osmosis

Implementation Method 2

Electrokinetic separation takes advantage of the charge in the suspended particles

Methodology Applied

Scientific EffectElectrophoresis: Electrophoresis

Data Source

PatentUS10486108B2Electrokinetic dewatering of phosphatic clay suspensions

Publication Date: 2019.11.26 UNIV OF FLORIDA RESEARCH FOUNDATION INC

AI summary

Various examples are provided for electrokinetic dewatering of e.g., phosphatic clay suspensions. In one example, among others, a system includes a separation chamber including an anode and a cathode extending ends of the separation chamber and a power supply configured to energize the anode and the cathode to establish an electric field. An inlet at one end of the separation chamber can supply a dilute feed suspension and an outlet at another end of the separation chamber can remove supernatant water. The electric field can consolidate solids in the dilute feed suspension. Consolidated solids may be removed by a removal mechanism. In another example, a method includes supplying a dilute feed suspension including suspended solids, establishing an electric field to consolidate solids, and removing supernatant water.