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MANAGEMENT IN QUARRIES
F. BOURGEOIS, G. BAUDET, M. BIZI and H. GABORIAU
BRGM, Environment and Process Division, Orléans, France
D
riven by increasingly stringent environmental regulations on water usage, many
European quarries are in the process of adding thickening circuits to their wash
plants for managing clayey tailings. One of the critical components of this circuit is
slurry conditioning. With typical water consumption over 1 m3 per ton of washed aggregates,
quarries produce dilute slime streams that are conditioned with high occulant dosages to
maintain water clarication rates as high as possible. At present, conditioning systems used in
the quarrying industry are designed from elementary rules-of-thumb derived from experience.
Practitioners acknowledge that conditioning system design criteria should be investigated
further in order to design more efcient full-scale conditioning systems. This work focuses on
weir-based conditioning tanks used in European quarries. The paper presents an applied
analysis of such conditioning systems based on a comparison between a full-scale conditioning
circuit and a controlled laboratory conditioning set-up. Within the range of plant operating
conditions, this approach shows that full-scale conditioning is essentially governed by average
shear rate and conditioning time. However, ne oc size distribution measurements reveal that
quarry slimes conditioning is a dynamic process. This explains the high sensitivity of the
process to variations in hydrodynamics, and the challenges of industrial conditioning system
design.
quarries. This gravity-driven conditioning system consists of hydrodynamic environment during conditioning from rst
a conditioning tank with high and low weirs followed by a hand observations:
series of connecting pipes that feed the thickener. Emphasis
the power Pb (Wt) dissipated across a given head loss h:
is placed on the overall conditioning system including both
the conditioning tank and the connecting pipe section. Pb ˆ rp £ Qf £ h £ g (1)
The 2 m3 conditioning box presented in Figure 1, which is
operating at a 220 t h¡1 quarry in the northwestern part of where g is the gravitational acceleration.
France, is divided into compartments delimited by indivi- the average shear rate G (s 1 ):
dual occulant injection points. The design of the tank is s!!!!!!!!!!!!!!
· ˆ Pb
such that the slurry has to go around a number of low and G (2)
high weirs. The height of and spacing between weirs are V £ mp
calculated based on a maximum ow velocity set point
the product between average shear rate and residence time
inside the conditioning tank. The design rationale consists
G t (dimensionless);
of delivering a high mixing energy input per unit volume of
the maximum shear rate Gmax —there is no available
slurry without developing regions of high shear rates.
formula for calculating maximum shear rate inside weir-
A basic circuit analysis was carried out for the nominal
based conditioning tanks; this information could be
slurry ow rate Qf ˆ 0.106 m3 s¡1 and slurry density
obtained by laser doppler velocimetry or CFD simulation,
rp ˆ 1022 kg m¡3. The absolute slurry viscosity mp was
however such techniques are not readily available in
calculated using Heiskanen and Laapas’ (1979) viscosity
practice; it is likely that areas of high shear will occur
model for an average oc porosity of 0.96. Such a value
in the vicinity of low weirs where local contractions might
was obtained by applying a fractal analysis to oc size
develop;
distributions obtained with a dedicated laser sizer. The
the volume specic energy input Es (J m 3):
slurry, which consists of washing cyclones’ overow, had
a d80 ˆ 80 mm. P £t
Es ˆ b (3)
Analysis of the conditioning system starts with estimation V
of volumes and residence times. The volumes of individual the micro-turbulence length l (m) (Spielman, 1977):
compartments (cf. Table 1) were estimated by measuring Á !1=4
free surface heights during operation. The head loss h mp 3 V
between adjacent compartments was obtained directly by lˆ (4)
rp 2 Pb
measurement of the free surface height drops from one
compartment to the next. Free surface height drops between this turbulence length is related to the mechanical power
adjacent compartments 1, 2 and 3 were 0.23, 0.20 and 0.22 m, expanded per unit volume of slurry; it is caused by the
respectively. A standard analysis of major and minor losses energy-containing eddies that carry and dissipate most of
yielded a head loss h ˆ 0.52 m in the 13 m long pipe section. the uid’s kinetic energy;
Next is a series of hydrodynamic parameters the macro-turbulence L (m)—essentially a function of
(Akers, 1975) that can be used for characterizing the geometry (Tomi and Bagster, 1978), there is no known
Table 2. Conditioning results obtained at full-scale for three operating feed rates.
of ocs whose characteristics reect the dynamics of oc for small ocs from the surface of large ocs, or if G is
growth and oc breakage. higher than the shear strength of large ocs, the maxi-
Above all, these results demonstrate that the short condi- mum oc size decreases with both G and Gmax .
tioning times used in the quarrying industry imply fast
kinetics and conditions far remote from those that can At a constant conditioning time (t ˆ 15.3 s), the conco-
lead to a stable maximum oc size in a stress eld governed mitant increase in the mode size of the population of large
by G · . Hence, quarry slimes conditioning is an utterly ocs, their maximum size d99, their volume fraction and the
dynamic process. This means that using a given value of decrease in supernatant turbidity and volume fraction of
G· cannot be sufcient for the laboratory system to comple- small ocs when G · goes from 100 to 600 s¡1 clearly
tely match the performance of the full-scale conditioning illustrate this mechanism. The second mechanism is
system, nor is it a reliable basis for designing full-scale revealed by the ner mode size of the small ocs’ popula-
conditioning systems. tion at higher G· values. This reduction in the mean size of
Together, Figures 5 and 6 highlight most of the mechan- the small ocs corresponds to the birth of a second popula-
isms involved in slimes conditioning. Before proceeding tion of small ocs whose mode is less than that of the single
further, it is important to note that Figure 6 reveals the primary oc population formed at short conditioning times.
existence of two basic populations of ocs whose mode size Indeed, Figure 6(a) clearly shows that a short condition-
and volume fraction are totally inter-connected and extre- ing time (t ˆ 5 s for G· ˆ 228 s¡1 ) that is close to the theore-
mely sensitive to changes in hydrodynamic conditions. The tical mixing time yields a single population of small ocs. It
analysis of the interactions between these two distinct is only for longer conditioning times that large oc forma-
populations reveals interesting features about the dynamic tion is observed. The second small oc population is the
nature of quarry slimes conditioning. probable result of erosion of the large oc population. The
· and t values achieved in full-scale measured increase in both d99 and the mode size for the large
In the range of G · is indicative of an aggregation mechan-
oc population with G
conditioning systems, it can be observed that the evolution
ism. However, Figure 6(b) shows a reduction of the width of
of these populations of ocs follows antagonistic mechan-
the large oc population’distribution when it is unique and the
isms of the occulation process:
birth of a second population of large ocs whose mode size is
the rst mechanism is the aggregation of particles then of less than that of the population formed at lower G · values.
small ocs for which medium values of G yield a These observations conrm that large ocs are also subjected
monotonic increase in the rate of both particle capture to a breakage mechanism at higher G · values.
and oc growth; · value (228 s¡1 ), the
At an intermediate constant G
the second mechanism involves both breakage and
increase in conditioning time from 5 to 50 s leads to:
erosion of large ocs. This oc degradation process
increases with G , t and oc size. If the value of G The birth of a population of large ocs generated by
exceeds the detachment shear strength for particles or aggregation of small ocs from the unique log-normal
Figure 4. Comparison between full-scale (solid symbols) and laboratory conditioning systems (empty symbols). (a) Supernatant turbidity; (b) oc settling rate
distribution.
Figure 5. Sensitivity of quarry slimes conditioning to variations in G, t and G t. Flocculant dosage: 168 g t 1 . (a) G 228 s 1 ; (b) t 15:3 s;
(c) G t 3500 (100 s 1 < G < 600 s 1 ; 6 s < t < 35 s).
population (mode 171 mm in Figure 6a) obtained by at high values of G · (400 and 600 s¡1). These short condi-
aggregation of the initial particles and micro-ocs. The tioning times are not sufcient for residual particles and
reduction of the small ocs’ volume fraction and the micro-ocs to aggregate and form small or large ocs. This
increase in the volume fraction of the large oc popula- effect is particularly signicant given the low solids concen-
tion are clearly connected, large ocs growing at the tration (8 g l¡1 ) typical of quarries and the signicant
expense of small ocs. Globally, the increase in d99, proportion of colloidal clayey minerals with high structural
large oc volume fraction and size of the large oc charge (e.g. montmorillonite). As a result, supernatant
population indicate a continuous aggregation process turbidity increases with G · . The lower maximum oc size
with conditioning time at a moderate G value. However, for G· ˆ 228 s¡1 and t ˆ 15:3 s indicates that G · ˆ 100 s¡1
the relatively low increase in the mode size between and t ˆ 35 s is a more efcient combination of G · and t in
30 and 50 s, combined with the birth of a second popula- terms of turbidity and oc size. For G · ˆ 100 s¡1, G · has
tion of large ocs, are further proofs of the competing a purely positive effect on d99, whereas t has a purely
effects of breakage and erosion mechanisms for the negative effect on turbidity and a positive effect on d99. With
large ocs. Compared with the effect of G , the moderate G· ˆ 228 s¡1 and t ˆ 15:3 s, the increase in G · is not
reduction in the mode size of the small oc population sufcient to compensate for the reduction in d99 caused by
indicates that less erosion is taking place, which is a the relatively short conditioning time. For other combina-
consequence of the moderate G value used to test the tions of G· and t, the increase in G· is sufcient to offset the
effect of conditioning time. lower conditioning times, leading to a moderate increase in
A reduction in supernatant turbidity. This trend conrms d99. Overall, these experimental observations highlight the
an aggregation process for the residual initial particles complex interaction between G · and t.
and the micro-ocs responsible for water turbidity.
More experimental work is necessary to fully characterize
At a moderate constant value of the dimensionless · and t. However, the complexity of
the interaction between G
· £ t (ˆ3500), conditioning times are very short
product G the interactions brought to light by this work is enough to
Figure 6. Sensitivity of oc size distribution to variations in G and t (values shown represent the mode and volume fraction of the small and large
oc populations). Flocculant dosage: 168 g t 1 . (a) G 228 s 1 ; t variable. (b) t 15:3 s; G variable.
conclude that the dimensionless product G · £ t does not REFERENCES
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Coal Preparation Society), Vol V, Part 12.
V conditioning volume, m3
Qf volumetric ow rate, m3 s 1 ACKNOWLEDGEMENTS
N impeller rotational speed, rpm
G (or G) mean shear rate, s 1 The authors wish to express their gratitude to SNF FLOERGER and
Gmax maximum shear rate, s 1 SOTRES Lamex for their continuing technical support.
h head loss, m
g gravitational acceleration, m s 2 ADDRESS
d80 80% passing size, m
Correspondence concerning this paper should be addressed to Dr F.
d99 99% passing size or maximum size, m Bourgeois, BRGM, Environment and Process Division, 3, Av. Claude
Guillemin, 45060 Orleans, France.
Greek symbols E-mail: f.bourgeois@brgm.fr
L macro-turbulence length, m
t residence (or conditioning) time, s The paper was presented at the 9th Congress of the French Society of
rp slurry density, kg m 3 Chemical Engineering held in Saint-Nazaire, France, 9–11 September
mp slurry viscosity, Pa s 2003. The manuscript was received 7 February 2003 and accepted for
l micro-turbulence length, m publication after revision 8 September 2003.