210  Mineral Processing Technology (MPT 2007)

Effect of Various Flocculants on the Settling

Characteristics of Iron Ore Ultra- Fines
R.P. Bhagat, K.V. Rao and S. Chandra Sekhar
MNP Division, National Metallurgical Laboratory Jamshedpur-831 007, India

Abstract: The effect of polymeric Flocculants on settling characteristics of iron ore ultra fines from
Karnataka, India are presented here. The Flocculating efficacies of the flocculants namely, Magnafloc E 10,
Magnafloc 1011, FL 4934 and RF 8140 have been investigated at various dosages and their performance has
been evaluated in terms of the settling rate. A remarkable improvement in the settling rate has been observed
with the addition of the flocculant(s) when compared with the blank condition (without any flocculant). The
settling rate increases with increasing flocculant dosage. Batch settling test has been employed to study the
kinetics of particle sedimentation. The settling curves have reflected two distinct settling zones: (a) initial
settling zone, where the slope of the curve is constant and steepest (b) the compression zone which is
characterized by a non-linear segment of the curve with decreased settling rate when compression starts.
Empirical model has been developed for the setting in the compression zone which is based on the premises
that the rate of descent of the supernatant/suspension interface is proportional to the height of the suspension.

1. INTRODUCTION 2.1. Materials

Flocculation of mineral suspensions using poly
acryl amides has been investigated by many
authors (Heller & Pugh, 1960; Healy 1961; Healy
& Lamer, 1962). In relation to iron ore fines,
these polymers are generally used as flocculating
agents to enhance the thickener performance.
Several models, such as, Richardson & Zaki
(1954), Kynch (1952), Hawkesly (1951), Steinour
(1944) etc, have been well-described in the
literature relating the particle settling rate to solid
concentration. Mathematical correlations such as
those developed by Richardson & Zaki (1954)
describe the maximum settling rate in terms of
Stock’s settling velocity and volume
concentration of solid. Previous study on typical
iron ore slimes has shown that kinetics data
follow Michaels and Bolger (1962) equation
derived from the Richardson and Zaki model in
the initial settling zone of the settling curve
(Bhagat 1994), whereas these follow first order
kinetics in the compression zone (Bhagat 1995).
However these correlations pertained to the
unflocculated (without any addition of flocculant)
iron ore slimes. In the present paper we have
established the model in the compression zone
when flocculants are used.
2. MATERIALS AND METHODS
All flocculation experiments were conducted
using iron ore ultra fines from M/S Mineral Sales
Private Limited, Karnataka, India. The sub- sieve
analysis of the sample indicated that 96.8% wt.
fraction was below 40 micron size. The chemical
analysis of the sample in wt % is Fe (T): 56.34,
SiO2 : 16.13 and Al2O3 : 1.5. Mineralogical study
of the sample reveals that hematite was the major
mineral phase, other phases that could be
identified in the sample are: Quartz, Gibbsite, and
Kaolinite.
2.2 Flocculants
Magnafloc 1011 & Magnafloc E10, procured
from M/s Allied Colloids Ltd. Magnafloc 1011
was a high molecular weight and Magnafloc E10
was a very high molecular weight slightly anionic
polyacrylamide. RF 8140 a low anionic high
molecular weight polyacrylamide was supplied
by M/S Rishabh Metal and FL 4934 was high
molecular weight polyacrylamide supplied by
SNF India Ltd, Hyderabad, India. Their acid no
are determined in our laboratory are found to be
3.366; 11.92; 8.976 and 11.92 for Magnafloc E10;
211  Mineral Processing Technology (MPT 2007)
Magnafloc 1011; FL 4934 and RF 8140 250
225
respectively.

Interface Height (mm)

200
175
2.3 Zeta Potential 150
125 0.004 Kg/T
Zeta-potential values of the sample were 100
Without Flocculant
determined using a Laser Zee Meter (Pen Kem 75 Magna Floc E10
Inc., model 501) equipped with video system 50 Magna Floc 1011
FL 4934
25
apparatus employing a flat cell. 1.0 g/l mineral RF 8140
0
suspension was prepared in 10-3KNO3 supporting
0 1 2 3 4 5 6 7 8 9 10
electrolyte solution conditioned for 1 hour at
room temperature (280 C) at a specified pH. A Time (min)
temperature correction was made using the
formulae supplied with the instrument. The values Fig. 1: Settling curves at 0.002 Kg/T.
of zeta potential (in mV) were –3.7, -24.2 and
–50.13 at 1.5, 6.2 and 10.3 pH respectively. It is
250
apparent that the PZC was below 1.5 pH.
225
200
2.4 Settling Tests
Interface Height (mm)

175
150
Settling test was carried out in a batch 500 ml 125
0.002 Kg/T
graduated cylinder. Suspension of the required 100 Without Flocculant
concentration was taken in a cylinder. It was 75 Magna Floc E10
Magna Floc 1011
dispersed by inverting the cylinder up and down 50 FL 4934
ten times. The settling rate of particles was 25 RF 8140
measured by noting down the movement of 0
suspension-liquid interface as a function of time 0 1 2 3 4 5 6 7 8 9

till the situation when compression of slurry ends. Time (min)

The settling rate was determined by plotting the
height, z, of the interface plane between the slurry
and supernatant as function of time.
3. RESULTS AND DISCUSSION
3.1 Various Zones of Settling
The results on settling have been depicted in
(Figs. 1-2) for 14% initial solid concentrations/
pulp density (PD) with 0.002 Kg/T and 0.004
Kg/T flocculants dosage respectively.
It is apparent from these figures that the,
two distinct zones of settling namely, (a) settling
at constant rate and b) settling in compression
zone, as described earlier in the paper, were
observed.
Fig. 2: Settling curves at 0.004 Kg/T
3.2 Effect of Flocculant Type and
Dosage
Different flocculants used in the present study had
different flocculation efficacy as apparent from
the settling characteristics shown in Tables 1&2.
With the increase in the dosage of flocculant
from 0.002 Kg/T to 0.004 Kg/T (solid/solid basis)
following observations were noted:
(a) enormous increase in the initial settling rate at
all the PDs and significant decrease in the
liquid/solid ratio at ultimate pulp at 14% PD in
relation to RF 8140. (b) In case of FL 4934
significant increase in the initial settling rate at all
PDs.The liquid/solid ratio at ultimate pulp density
decreased marginally at 14% PD, however the
same increased at 10 & 12% PDs. (c) Flocculant
Magnafloc E10 exhibited trend similar to RF
8140. Significant increase in the initial settling
Effect of Various Flocculants on the Setting Characteristics of Iron Ore Ultra-Fines 212
rate and decrease in liquid/solid ratio at ultimate no change in the liquid/solid ratio at ultimate pulp
pulp density at all PDs. The changes were more density was observed at 10% and 12% PDs. At
prominent at 12 and 14% PDs compared to 10% 14% PD the liquid to solid ratio at ultimate pulp
PD. (d) In relation to Magnafloc 1011 enormous density decreased to a minimum value (0.27).
decrease in the initial settling rate at all PDs while

Table 1: Settling characteristics of iron ore fines at 0.002 Kg/T dosage.

Initial Settling Rate Pulp Density after 19h Water with solid after Liquid/Solid ratio at
Pulp (mm/min) 19h (ml) ultimate Pulp Density
Density (g/g)
10 % 12% 14 % 10% 12% 14% 10% 12% 14% 10% 12% 14%
No 51.7 49.5 43.8 1.67 1.71 1.75 17 25 25 0.34 0.42 0.36
Flocculant
Magnafloc 100 90.2 83.9 1.43 1.5 1.56 22 26 31 0.44 0.43 0.44
1011
Magnafloc 98.9 113 98.5 1.43 1.33 1.4 25 35 35 0.5 0.58 0.5
E10
FL 4934 64.3 65.8 54.9 1.43 1.5 1.4 22 20 34 0.44 0.33 0.49
RF 8140 128 139 83.9 1.43 1.5 1.4 27 31 42 0.54 0.52 0.6

Table 2: Settling characteristics of iron ore fines at 0.004 Kg/T dosage.

Pulp Initial Settling Rate Pulp Density after 19h Water with solid after Liquid/Solid ratio at
Density (mm/min) 19h (ml) ultimate Pulp Density
(g/g)
10 % 12% 14 % 10% 12% 14% 10% 12% 14% 10% 12% 14%
Magnafloc 51.1 35.4 30.7 1.43 1.5 1.75 22 25 19 0.44 0.42 0.27
1011
Magnafloc 100 192 179 1.43 1.5 1.46 21 23 28 0.42 0.38 0.4
E10
FL 4934 85.2 112 88.7 1.35 1.39 1.4 25 31 31 0.5 0.52 0.44
RF 8140 204 220 202 1.43 1.33 1.4 25 32 34 0.5 0.53 0.49

3.3 Settling in Compression Zone: 6

Model Development Magnafloc E10
5 Magnafloc 1011
From Figs (1-2) it is apparent that the rate of FL 4934
Ln(Z ∞-Z),Z in mm

4 RF 8140
settling gradually decreases in the compression
zone as time progress. The model developed in 3 0.002 Kg/T
the present work is based on the premise that the
2
movement of supernatant / suspension interface
was proportional to the height of the suspension. 1
Mathematically,
0
- dZ / dt = K (Z – Z∞) …. (1) (or) 0 0.5 1 1.5 2 2.5 3 3.5
Time ( t - tc ), min
ln (Z– Z∞) = - K ( t– tc ) + ln ( Zc – Z∞ ) .. (2)
Where, Z, Z∞, and Zc are the suspension heights at Fig. 3: Logarithmic settling curves at
time, t, at the infinite time, and at the time when 0.002 Kg/T
the suspension reaches the critical concentration
(the time when compression starts) respectively. Therefore, a plot of ln (Z – Z∞ ) versus the
settling time should result in a straight line.
Fig. (3-4) shows the plots of ln (Z – Z∞) against
213  Mineral Processing Technology (MPT 2007)
the settling time, t, with the addition of flocculant • The efficacy of the flocculants at 0.004 Kg/T
at 14% initial solid concentration for the (S/S wt. basis) dosage in descending order is
0.002 Kg/T and 0.004 Kg/T dosage respectively. RF 8140> MAGNAFLOC E10> FL4934>
The different flocculants result in straight lines MAGNAFLOC 1011. However, at lower
which evidently show that the first order kinetic dosage (0.002 kg/T) the efficacy in
equation (Eq. 2 ) is obeyed. descending order is RF 8140>
MAGNAFLOC E10> MAGNAFLOC 1011
3.5 > FL4934 in terms of settling rate.
Magnafloc E10
3
0.004 Kg/T
Magnafloc 1011 • The liquid to solid ratio at ultimate PD was
FL 4934 lowest at 10% PD when a flocculant was
Ln(Z ∞-Z), Z in mm

2.5 RF 8140
2 lowest value of liquid to solid ratio (0.27)
1.5
1 Magnafloc 1011.
0.5
0
0 0.5 1 1.5 2 2.5 3 3.5
Time ( t - tc ), min
Fig. 4: Logarithmic settling curves
at 0.004 Kg/T
4. CONCLUSIONS
• The settling rate decreases with increasing
the pulp density and was lowest at 14% PD
(compared to 10% and 12%) under blank
condition and also when a flocculant was
used.
• The liquid to solid ratio at ultimate PD had
the lowest value at 10% PD under blank
condition.
• Different flocculant behaved differently in
relation to settling and liquid to solid ratio at
ultimate PD. The effect was also guided by
the dosage of the flocculants.
• The initial settling rate increases with
increasing the flocculant dosage from 0.002
kg/T to 0.004 kg/T in case of Magnafloc
E10, FL 4934 and RF 8140. In case of
Magnafloc 1011 opposite of that prevails.
used with 0.002 kg/T dosage. However, the
was observed at 0.004 kg/T dose in case of
• Magnafloc 1011 exhibited poorly at
0.004 kg/T flocculant dose (compare to at
0.002 kg/T) in terms of settling rate. The
settling rate values were at par with or even
lower than the values under blank condition
(when no flocculant was used).
• When a flocculant was used a 12% PD
seems to be optimum for initial settling rate,
pulp density as well as liquid to solid ratio
after 19h..
REFERENCES
[1] Bhagat, R.P. Steel India, 17 (1994), 36.
[2] Bhagat, R.P. Steel India, 18 (1995), 55.
[3] Hawkesley, P.G.W., Some aspects of fluid flow
Arnold & Co. Lomdon 1951, Ch 7.
[4] Heller , W. and Pugh, T I J. Polymer Sci. 57
(1960), 203.
[5] Healy, T. W.J. Colloid Sci. 16(1961), 609.
[6] Healy, T. W. and Lamer V. K. J. Physical
Chem. 66 (1962), 1835.
[7] Michaels, A.S. and .Bolger J.G. Industrial and
Engg. Chem. Fund. 1(1962), 24.
[8] Kynch G.J. Trans. Farad. Soc. 48 (1952) 166.
[9] Richardson , J.F. and Zaki W.N. Trans. Inst.
Chem. Engg. 32(1954), 35.
[10] Steinour, H.A. Ind. & Engg. Chem. 36, 618,
840, 901 (1944).