Engineered Reclamation Material Dewatering via Sand-Clay Mixing
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Solution Overview
Problem
The phosphate mining industry faces challenges in consolidating dispersed by-product sand tailings and clays into a suitable reclamation material, leading to inefficiencies in land reclamation due to high water consumption, high costs, and environmental impact.
Innovation Solution
A process involving the formation of a sand-clay slurry, flocculation using polymers, and dewatering using a cyclone and screw classifier, followed by addition of overburden to create an engineered reclamation material (ERM) with improved consolidation and handling properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional dewatering methods are used for phosphatic clays, then the clays can be processed, but the consolidation rate is slow and water consumption is high
Solution Approach 1:
The patent introduces sand as an intermediary material to facilitate rapid dewatering of phosphatic clays. The sand acts as a medium that absorbs and drains water from the clay slurry, enabling fast consolidation without requiring large volumes of water for the process itself. This intermediary approach transforms the dewatering mechanism from direct evaporation or filtration to sand-mediated drainage.
Solution Approach 2:
The patent changes the physical parameters of the clay slurry by controlling the sand-to-clay ratio and water content to optimize dewatering efficiency. By adjusting these parameters, the mixture achieves optimal consistency for rapid water removal while maintaining workability for reclamation applications.
2Quantity of substance
If dispersed by-product sand tailings and clays are used directly, then material availability is high, but the consistency is unsuitable for reclamation
Solution Approach 1:
The patent merges dispersed sand tailings and phosphatic clays into a unified mixture with consistent properties. By combining these previously separate and inconsistent materials in controlled proportions with sand, the process creates a homogeneous engineered reclamation material that meets specification requirements for land reclamation applications.
Solution Approach 2:
The patent creates a composite material consisting of sand, phosphatic clay, and overburden in specific ratios. This composite approach transforms individually unsuitable materials into a combined mixture with desirable engineering properties including consistent consistency, adequate permeability, and suitable strength for reclamation use.
3Ease of manufacture
If traditional reclamation materials are used, then environmental standards can be met, but the cost is high and environmental impact remains
Solution Approach 1:
The patent converts harmful waste materials (phosphatic clays and sand tailings) into beneficial reclamation material. The previously problematic dispersed by-products are transformed through the sand mixing process into a useful engineered material that restores mined lands, thereby turning environmental liabilities into assets and reducing both costs and environmental impact.
Solution Approach 2:
The patent enables the mining operation to self-service its reclamation needs by using its own waste products (sand tailings and phosphatic clays) combined with sand to create reclamation material. This eliminates or reduces the need to import external reclamation materials, lowering costs and minimizing additional environmental disturbance associated with material transportation.
4Productivity
If rapid dewatering is achieved through sand mixing, then productivity increases, but process complexity increases
Solution Approach 1:
The patent segments the dewatering process into distinct operational stages: mixing sand with clay slurry, allowing water to drain through the sand, and separating the dewatered material. This segmentation enables each stage to be optimized independently and simplifies the overall process control while maintaining high productivity.
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 process enables rapid and cost-effective dewatering and consolidation of phosphatic clays, reducing water consumption and environmental impact, while producing a material suitable for land reclamation with enhanced solid content and permeability.
Implementation Method 1
The sand clay slurry can be flocculated using a flocculant polymer dictated by the type of clay
Implementation Method 2
dewatering using a cyclone and screw classifier
Data Source
AI summary
A process and associated system for the improved reclamation of disturbed lands (e.g., mined lands) is disclosed. In particular, the system including a dewatering cyclone, a screw classifier, and a dewatering apparatus (e.g. a dewatering belt) arranged in series to enable rapid and cost effective dewatering of slurries containing dilute clay and sand tailings to create an improved engineered reclamation material (ERM). The ERM formed by the controlled combining of dewatered sand tailings with dilute clay slurry and with a flocculant and overburden. The ratio of clay:sand:overburden of the ERM may be achieved by balancing the solid content (Cw) and water content (1−Cw) materials of the clay slurry, sand tailings and overburden. In some embodiments, the system may include at least one additional component, such as, for example, static screen(s), centrifuge(s), vibrating screens, drum screens, belt screens, belt filters, and/or other liquid-solid separation devices.