Flocculation Formulation for Mine Tailings Water Separation
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Solution Overview
Problem
Current methods for treating mine tailings, particularly from oil sands, face challenges in efficiently separating water from solid particles, leading to large storage volumes and environmental hazards due to the slow sedimentation rate of mature fine tailings, and issues with foaming caused by high concentrations of naphthenic acids, which complicates the use of flocculants.
Innovation Solution
A flocculation formulation comprising a copolymer prepared from nonionic and anionic monomers, combined with fatty acid esters and additional compounds, is used to enhance the separation of water from mine tailings, addressing the lubrication and foaming issues during the grinding process, and improving the sedimentation rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional flocculants are used in the presence of high concentrations of naphthenic acids, then the flocculation process should work, but foaming occurs which complicates the dissolution and handling of the polymer
Solution Approach 1:
The patent converts the harmful foaming effect caused by naphthenic acids into a beneficial feature by selecting a nonionic flocculant that is inherently foam-resistant. The nonionic monomer units in the copolymer structure prevent foam formation while maintaining flocculation effectiveness, thereby eliminating the need for additional defoaming agents and simplifying the process.
Solution Approach 2:
The patent changes the chemical parameter of the flocculant from cationic to nonionic to alter its interaction with naphthenic acids. This parameter change eliminates the foaming phenomenon while preserving the flocculation function, as the nonionic character prevents the formation of stable foam structures that occur with cationic polymers in the presence of naphthenic acids.
2Productivity
If the sedimentation process is accelerated to reduce storage volumes, then the treatment efficiency improves, but the natural sedimentation rate of mature fine tailings is extremely slow requiring centuries
Solution Approach 1:
The patent introduces a copolymer flocculant as an intermediary substance that mediates between the fine clay particles and water. The copolymer with molecular weight 5-50 million forms bridges between particles, accelerating their aggregation and sedimentation. This intermediary action reduces the sedimentation time from centuries to a manageable period while maintaining environmental safety.
Solution Approach 2:
The patent uses a composite flocculant structure comprising nonionic and anionic monomer units in specific ratios. This composite material combines the foam-resistant properties of nonionic polymers with the particle-binding capabilities of anionic polymers, achieving accelerated sedimentation without the harmful foaming effects that would otherwise require additional treatment time.
3Ease of manufacture
If large volumes of tailings are stored in open air basins to allow natural sedimentation, then the process is simple, but this creates environmental hazards particularly in the event of dam rupture
Solution Approach 1:
The patent applies the skipping principle by rapidly accelerating the sedimentation process through the use of high-molecular-weight copolymer flocculants. Instead of allowing slow natural sedimentation over centuries, the flocculant induces rapid particle aggregation and settling, reducing the residence time of tailings in storage basins and minimizing the window of environmental risk.
Solution Approach 2:
The patent changes the physical parameter of particle settlement velocity by introducing the copolymer flocculant. This parameter change transforms the extremely slow natural sedimentation into a rapid process, thereby reducing the time tailings remain in hazardous storage conditions and lowering environmental risk while maintaining operational simplicity.
4Adaptability or versatility
If the concentration of naphthenic acids in process waters increases due to recycling, then water reuse is maintained, but this causes the production water to foam easily and complicates flocculant dissolution
Solution Approach 1:
The patent converts the harmful interaction between naphthenic acids and cationic flocculants (which cause foaming and dissolution problems) into a beneficial situation by using nonionic flocculants. The nonionic character eliminates adverse interactions with naphthenic acids, allowing easy dissolution and effective operation even in highly recycled water with high naphthenic acid concentrations, thereby maintaining water recyclability without operational complications.
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
The formulation significantly reduces foaming during polymer dissolution, accelerates the sedimentation process, and increases the net water release, enabling more efficient recycling and handling of mine tailings, thereby reducing storage volumes and environmental risks.
Implementation Method 1
a flocculation formulation comprising: at least one flocculating agent, said agent being a copolymer prepared from at least one nonionic monomer and at least one anionic monomer
Implementation Method 2
at least one surfactant selected from among fatty acid esters; at least one additional compound of formula (I)
Implementation Method 3
The heavier material, chiefly sand, deposits on the bottom whilst the water rises to the surfaces and can be recycled
Data Source
AI summary
The invention concerns a flocculation formulation. The invention also concerns the treatment of mine tailings in the form of aqueous effluents comprising solid particles. With the method of the invention, it is possible to separate all or part of the water from an aqueous effluent comprising solid particles.