Optimising the dewatering behaviour of clay tailings through interfacial chemistry, orthokinetic flocculation and controlled shear

The effect of shear on dewatering behaviour and particle interactions of Na-exchanged smectite and kaolinite clay dispersions has been investigated at pH 7.5, using hydrolysable Ca(II) and Mn(II) ions as coagulants and high molecular weight anionic and non-ionic polyacrylamide (PAM A and PAM N, respectively) and polyethylene oxide (PEO) flocculants. Metal ion addition enhanced the flocculation performance by dramatically reducing the magnitude of the particle zeta potential and, in the case of smectite pulp, suppressing osmotic swelling. Under optimum orthokinetic flocculation conditions of controlled agitation rate and duration, PAM A and PEO-based flocs settled faster than those of PAM N whilst kaolinite pulps produced higher sedimentation rates than smectite pulps. The settling rates are nearly an order of magnitude greater than those observed under standard flocculant–pulp mixing/flocculation methods of inversion and plunging. The difference in the flocculant behaviour is attributed to the more expanded conformation of PAM A and PEO polymer chains in contrast to PAM N, whilst the lower yield stresses, reflecting inter-particle bridging and floc network structure strength that are conducive to faster clarification, were displayed by kaolinite pulps. Following shear, similar consolidation enhancement of ≈ 5–7 wt.% solid for both pulps was achieved at an optimum agitation range of 100–200 rpm. This was accompanied by decreased yield stress in the case of PAM A-based pulps, indicating non-reversible disruption of polymer mediated particle and floc network structure. In contrast, the yield stresses of PAM N and PEO flocculated dispersions indicated similar and stronger particle interactions, respectively, upon consolidation following shear. The findings show clear links between effect of shear, interfacial chemistry and polymer structure on pulp particle interactions and dewaterability.