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    • 专利摘要:
    The present invention provides a process for dewatering a mineral sludge concentrate and for increasing the production of the resulting filter cake, which essentially consists in mixing an aqueous mineral sludge concentrate with an effective amount of a nonionic surfactant and an effective amount of a cationic polymer to form an aqueous mineral sludge concentrate. treated with nonionic, surfactant and cationic polymer, and subjecting the treated mineral sludge concentrate to a process to remove liquid water to dewater the treated aqueous mineral sludge, and to increase the production of a resulting akalter cake of the dewatering mineral sludge. An improved mineral sludge concentrate composition and an improved mineral concentrate filter cake are also described.
    公开号:SE1000748A1
    申请号:SE1000748
    申请日:2008-05-12
    公开日:2010-07-09
    发明作者:Keith C Hovland；Todd W Groff；Monica A Yorke；Charles R Sundberg；Michael P Lesar；Ruta O Rakutis
    申请人:Neo Solutions Inc；
    IPC主号:
    专利说明:

    Concentrated mineral sludge to reduce the level of liquid water in the treated sludge which is subjected to filtration. In theory, dewatering aids should increase production rates as well as reduce the amount of water present in the filtered ore or solid charcoal cakes. the total production increase. However, this is not seen in practice. By using the Since the filtered solids contain less water, additives and additive combinations known to those skilled in the art are expected to not only reduce the moisture content of the filtered solids but also reduce the production of the solids compared to the untreated ore sludge. Traditionally, polymers have been used to agglomerate solids and to increase the filtration rate. However, polymers tend to draw in water along with the solids and thus cause the moisture content of the ore cake to increase. In many cases, the end use or processing of coal or metal ore is adversely affected by the higher moisture content.
    Until now, an efficient process for dewatering mineral sludge has been seen as an opportunity to increase the production of solids by lowering the residual moisture content in the product and means increased production through better and faster filtration. Elimination of moisture in the filter cake or in the centrifuged solids increases the amount of mineral or ore contents on a weight percentage basis, thereby reducing shipping costs required for transportation or energy costs for further drying or processing per kilogram of the mineral, coal or ore solid. However, the use of only one dewatering aid results in some production loss of the filter cake compared to no treatment at all.
    Thus, it is known to those skilled in the art that generally when the moisture content of an aqueous mineral sludge concentrate is advantageously reduced by the use of certain additives, a disadvantage also arises in that the production of the resulting filter cake is reduced at the expense of the advantageous dewatering. None of the background engineering processes have addressed both the need to reduce the residual liquid water content of the concentrated mineral sludge, while at the same time increasing the production of the mineral concentrate filter cake resulting from the water removal process such as, but not limited to, a filtration process. The present applicant has developed such a process and such a synergistic additive combination which advantageously provides a reduction of the residual content of liquid water in the concentrated mineral sludge, while also providing an increased production of the filter cake resulting from the process for removing water.
    U.S. Patent No. 4,207,186 (Wang et al. '186) provides a process for dewatering mineral and carbon concentrates which comprises mixing an aqueous slurry of a mineral concentrate and an effective amount of a dewatering aid which is a combination of hydrophobic alcohol having an aliphatic group having eight titles eighteen carbon atoms 3 and a nonionic surfactant of the formula R- (OCH 2 CH 2) XOH where x is an integer between 1-15, R is a branched or straight aliphatic group containing six to twenty-four carbon atoms in the alkyl moiety, and subjecting the treated sludge to filtration. Wang et al '186 state that when a hydrophobic alcohol such as decyl alcohol is combined with a nonionic surfactant, lower moisture contents of iron ore concentrate are obtained than if a dewatering aid had not been used. Wang et al. '186, however, is not about increasing the production of the resulting filter cake.
    U.S. Patent No. 4,210,531 (Wang et al. '531) provides a process for dewatering mineral concentrate which essentially consists of first mixing an aqueous slurry of mineral concentrate with an effective amount of a polyacrylamide flocculant and then mixing the flocculant treated slurry with an effective amount of a combination of an anionic composition of surfactant and a water-insoluble organic liquid selected from aliphatic hydrocarbons, aromatic hydrocarbons, aliphatic alcohols, aromatic alcohols, aliphatic halides, aromatic halides, vegetable oils and animal oils, wherein the water-insoluble organic liquid differs from any water-insoluble liquid present in the anionic composition of surfactant, and then removing the water as a liquid from the sludge. Want et al. However, '531 does not absorb and does not care to reduce the residual liquid water content of the concentrated mineral sludge or to increase the production of the resulting filter cake.
    The present applicants have found unexpected results of the process of the present invention in that the present applicants are able to (1) reduce the moisture (surface water) content of a mineral sludge concentrate which has been treated with their synergistic combination of a nonionic surfactant and cationic polymer and exposed for a filtration process, and (2) increase the production of the resulting filter cake. Thus, Applicant's method and synergistic composition combination provide the added economic benefit of increased filter cake production compared to the use of known synergistic combinations of additives that only reduce the liquid water content of the mineral sludge concentrate. Thus, the applicant's process and synergistic composition combination fill a long known but hitherto unmet need in the mineral processing industry.
    SUMMARY OF THE INVENTION The present invention provides a process for dewatering a mineral sludge concentrate and for increasing the production of the resulting filter cake, which essentially consists of mixing an aqueous mineral sludge concentrate with an effective amount of a nonionic surfactant and an effective amount of a cationic polymer. to form an aqueous mineral sludge concentrate treated with nonionic surfactant and cationic polymer, and subjecting the aqueous mineral sludge concentrate treated with nonionic surfactant and cationic polymer to an aqueous removal process to dewater the treated aqueous mineral sludge and to increase the production of the resulting filter cake of the dewatered mineral sludge.
    The process includes the case where the nonionic surfactant is an alkyl ethoxylate alcohol having the chemical formula R- (OCH 2 CH 2) XOH, wherein x is an integer from about 1 to 15, and R is a straight or branched aliphatic group which comprises from about 6 to about 24 carbon atoms in the alkyl moiety, and having a hydrophobic-lipophilic ratio from about 1 to about 15. Such as the terms "alkyl etoxylate alkoho |", "ethoxylate alcohol", "ethoxylated alcohol ", and" alcohol ethoxylate "as used herein, they refer to the same composition designated by this chemical formula described herein and these terms may be used interchangeably herein.
    In a preferred embodiment of this process described herein, the alkyl ethoxylate alcohol comprises an R group having from about 6 to about 24 carbon atoms, and which is either a straight, primary ethoxylated alcohol, a branched, primary ethoxylated alcohol or a secondary ethoxylated alcohol. More preferably, the process is included wherein the R group has from about 11 to about 16 carbon atoms.
    In view of the ethoxylate groups, it is preferred that x be a number from about 1 to about 5. It is known to those skilled in the art that in ethoxylation, since the commercially available alcohols are mixtures of different chain lengths, a mixed ethoxylate is obtained. This is also true for the degree of ethoxylation (ie the number of "x" groups) on the alcohol. The value of "x" used herein is an average number of ethoxylations. Thus, those skilled in the art will appreciate that mixed ethoxylates are within the scope of this invention.
    In another embodiment of this invention, the process comprises the nonionic surfactant being a mixture of the alcohol ethoxylate, as described herein, with another alcohol. The second alcohol is an alcohol having from about one carbon atom to about 18 carbon atoms, and preferably from about 8 carbon atoms to about 13 carbon atoms. The second alcohol may be primary or secondary and may be straight or branched, as well as mixtures thereof. The mixture of nonionic surfactants may comprise from about 1% to about 99% by weight of the other alcohol.
    Another embodiment of the process of the invention as described herein includes when the nonionic surfactant is an amine toxicalt having the chemical formula R ~ N - ((CH 2 CH about 15, and R is a straight or branched aliphatic group comprising from about 6 to about 24 carbon atoms, in the alkyl moiety, or a mixture of amine toxylate and alkyl ethoxylate alcohol, as described herein. The mixture of nonionic surfactants may comprise from about 1% to about 99% by weight of amine toxylate.
    The process of the present invention as described herein, wherein the cationic polymer is derived from at least one cationic monomer comprising a quaternary diallyldialkylammonium monomer, a cationic acrylamide monomer, a quaternized derivative of an acrylate or methacrylate, salts thereof and combinations thereof. More preferably, the cationic polymer is derived from at least one cationic monomer selected from the group consisting of acryloyloxyethyltrimethylammonium chloride, akryloyloxietyltrimetyiammoniummetosulfat, aminomethylated polyacrylamide, metakrylamidopropyltrlmetylammoniumklorid, acrylamido- propyltrimethylammonium chloride, methacryloyloxyethyltrimethylammonium chloride, trimethylammonium methosulphate metakryloyloxietyl-, diallyldimethylammonium chloride, diallyldiethylammonium chloride, and diallyldimetylammoniumbromid diallyldietylammoniumbroid. In another embodiment of this invention, the cationic polymer is a copolymer derived from a cationic monomer which is a quaternary diallyldialkylammonium monomer and an acrylamide. Most preferably, in another embodiment of this invention, the cationic polymer is derived from a cationic monomer which is acryloyloxyethyltrimethylammonium chloride and an acrylamide. In another embodiment of the present invention, the cationic polymer is polydiallyldimethylammonium chloride. In a further embodiment of this invention, the cationic polymer is a Mannich condensation polymer, and preferably a Mannich condensation polymer comprising acrylamide, dimethylamine or diethylamine and formaldehyde.
    Another embodiment of this invention provides an improved mineral sludge concentrate composition consisting essentially of a concentrate of an aqueous mineral sludge, a nonionic surfactant and a cationic polymer described herein. In another embodiment of this invention, there is provided an improved mineral concentrate filter cake consisting essentially of a substantially dehydrated mineral concentrate, a nonionic surfactant and a cationic polymer, as described herein.
    BRIEF DESCRIPTION OF THE DRAWING Fig. 1 is a graph showing the dry filter cake production compared to moisture content in filter cake when the method of the present invention is used in comparison with no treatment or treatment using only a dewatering aid. DETAILED DESCRIPTION OF THE INVENTION The present invention relates to (a) a process for dewatering a mineral sludge concentrate and increasing the production of the resulting filter cake, (b) an improved mineral sludge concentrate, and (c) an improved mineral concentrate filter cake .
    As used herein, "effective amount" refers to the amount of composition necessary to achieve a desired result, such as, for example, the amount required to effect the removal of water from an aqueous mineral sludge concentrate while increasing the production of a resulting filter cake. .
    As used herein, "substantially dehydrated mineral concentrate" refers to an aqueous mineral sludge concentrate having a desired amount of moisture removed, and preferably the amount of moisture removed is more than about 40 percent (%) by weight.
    Thus, for example, but not limited to, a substantially dehydrated mineral concentrate is one in which the initial moisture content prior to treatment after treatment is reduced to a desired level as reported in the various examples provided in Tables 1-5 herein.
    The present invention provides a process for dewatering a mineral sludge concentrate and for increasing the production of the resulting filter cake which essentially consists of mixing an aqueous mineral sludge concentrate with an effective amount of a nonionic surfactant and an effective amount of a cationic polymer to form a concentrate treated with nonionic surfactant and cationic polymer and subjecting the aqueous mineral sludge concentrate treated with nonionic surfactant and cationic polymer to a process for removing liquid water to dewater the treated aqueous mineral sludge and to increase the production of a resulting filter cake of the dewatered mineral sludge.
    As used herein, the term "nonionic surfactant" refers to a dewatering aid (abbreviated "DWA" elsewhere herein). The nonionic surfactant or DWA is an alkylethoxylate alcohol having the chemical formula R- (OCH 2 CH 3 xOH, wherein x is an integer from about 1 to 15, and R is a straight or branched aliphatic group comprising from about 6 to about 24 carbon atoms in the alkyl moiety, and having a hydrophobic-lipophilic ratio (HLB) of from about 1 to about 15 and preferably an HLB number from about 1 to about 10. Preferably comprises The alkyl ethoxylate alcohol has an R group having from about 8 to about 20 carbon atoms, and is one of a straight primary ethoxylated alcohol, a branched primary ethoxylated alcohol, or a secondary ethoxylated alcohol. 11 to about 16 carbon atoms In view of the ethoxylate groups, x is preferably a number from about 1 to about 5. The cationic polymer is derived from at least about 16 carbon atoms. a cationic monomer comprising a quaternary diallyldialkylammonium monomer, a cationic acrylamide monomer, a quaternized derivative of an acrylate or methacrylate, salts thereof and combinations thereof.
    More preferably, the cationic polymer is derived from at least one cationic monomer QYUDP akryloyloxietyltrimetylammoniummetosulfat, aminometyleradpolyakrylamid, metakrylamido- selected from the consisting of acryloyloxyethyltrimethylammonium chloride, propyltrimethylammonium chloride, acrylamidopropyl, metakryloyloxi- etyltrimetylammoniumklorid, metakryloyloxietyltrimetylammoniummetosulfat, diallyldimetyl- ammonium chloride and diallyldiethylammonium chloride, acryloyloxyethyltrimethylammonium Most. Preferably, the cationic polymer is a diallyldimethylammonium bromide and diallyldiethylammonium bromide. preferably the cationic monomer is a copolymer derived from a cationic monomer which is a quaternary diallyldialkylammonium monomer and an acrylamide. In another embodiment of this invention, the cationic polymer is polydiallyldimethylammonium chloride. In yet another embodiment of this invention, the cationic polymer is a Lvlannich condensation polymer.
    Preferably, the Mannich condensation polymer comprises acrylamide, dimethylamine or diethylamine and formaldehyde. For example, but not limited to, the Mannich polymers can be synthesized using a 1: 1: 1 molar ratio of acrylamide, dimethylamine (or diethylamine) to formaldehyde. As is known to those skilled in the art, the Mannich process uses ammonia or primary or secondary amines with formaldehyde and a carbonyl function next to an acidic proton to create a beta-amino-carbonyl compound. Here, for example, the carbonylene is acrylamide and the secondary amine is dimethylamine. The average molecular weight ranges for Mannich polymers range from about 3 million to about 10 million.
    As used herein, the term "diallyldialkylammonium monomer" refers to any water-soluble monomer of the formula DADAAX "denoting diallyldialkylammonium X", wherein each alkyl is independently selected from an alkyl group of from about 1 to 18 carbon atoms in length, and preferably from about 1 to 6 carbon atoms in length, and wherein X 'is any suitable counterion Preferably, the counterions are selected from the group consisting of halide, hydroxide, nitrate, acetate, hydrogen sulfate, methyl sulfate and primary sulfates. some halide and more preferably it is selected from the group consisting of fluoride, bromide and chloride Preferably the quaternary diallyldialkylammonium halide monomer is selected from the group consisting of diallyldimethylammonium chloride, diallyldiethylammonium chloride, diallyldimethylammonium bromide and diallyldimethylammonium bromide.
    The cationic polymer component of this invention may contain one or more other moieties without departing from the concept of the invention. Copolymers, terpolymers, etc., such as, for example, polymers comprising diallyldimethylammonium chloride and acrylamide or acryloyloxyethyltrimethylammonium chloride and acrylamide can be used as the cationic polymer component of the present invention. In a preferred embodiment of this invention, the cationic polymer is a copolymer derived from at least one of the cationic monomers previously mentioned herein and at least one of a nonionic monomer selected from the group consisting of acrylamide, methacrylamide and NN-dimethylacrylamide, van ' the ratio of the cationic monomer to the nonionic monomer is from about 9911 to about 1:99.
    Preferably, the weight ratio of the cationic monomer to the nonionic monomer is from about 10 to about 95. It will be appreciated by those skilled in the art that the ratio of more units to such copolymers is generally determined by the amount of cationic units necessary in the present composition. to impart the present moisture reduction in the aqueous mineral sludge concentrate, while the desired production of the resulting filter cake is achieved when such treated mineral sludge concentrate undergoes the water removal (dewatering process, such as, but not limited to, filtration, centrifugation or combinations thereof, with or without pressure thereof). or under vacuum.
    In another embodiment of this invention, the nonionic surfactant is a mixture of alcohol ethoxylate, as described herein, and another alcohol (i.e., the other alcohol is different from the alcohol ethoxylate). The second alcohol is an alcohol having from about one carbon atom to about 18 carbon atoms, and preferably from about 8 carbon atoms to about 13 carbon atoms. The second alcohol may be primary or secondary and may be straight or branched, as well as mixtures thereof. The nonionic mixture of surfactants may comprise from about 1% to about 99% by weight of other alcohol.
    Another embodiment of the process of this invention as described herein is wherein the nonionic surfactant is an amine toxylate (ie an ethoxylated amine) having a chemical formula RN - ((CH 2 CH 2 O) -H) 2, wherein x is an integer from and with about 1 to about 15, and R is a straight or branched aliphatic group comprising from about 6 to about 24 carbon atoms in the alkyl moiety, or wherein the nonionic surfactant is a mixture of the amine toxylate and the alkyl ethoxylate alcohol described in herein, the nonionic surfactant mixture may comprise from about 1% to about 99% by weight of amine toxylate.
    An effective amount of the nonionic surfactant and cationic polymer should be used in the process of this invention. It will be appreciated by those skilled in the art that the dosage of the nonionic surfactant and the dosage of the cationic polymer added to the aqueous mineral sludge concentrate being treated depends on the level of dehumidification and filter cake production desired. Preferably, an effective amount in the process of the present invention is, for example, but not limited to at least about 0.005 pounds (2.27 g) to about 3.0 pounds (1360 g) of the nonionic surfactant per unit weight. long ton (1016 kg) of mineral sludge concentrate on a mineral dry weight basis, and from at least about 0.002 pounds (0.907 g) to about 3.0 pounds (1360 g) of the cationic polymer per long ton of mineral sludge concentrate on a mineral dry weight basis. As the term is used herein, "long ton" (IT) refers to two thousand two hundred and forty pounds (2,240 | bs = 1,016 kg).
    As used herein, the high molecular weight cationic polymer refers to an average molecular weight of greater than about 100,000, including, and preferably, greater than 1,000,000. More preferably, the high molecular weight cationic polymer of the present invention has a molecular weight. of over about 2,000,000 and more preferably an average molecular weight ranging from about 2,000,000 to 20,000,000 or higher.
    The nonionic surfactant of the present invention can be prepared using any conventional technique known to those skilled in the art.
    The cationic polymers of the present invention can be prepared using any conventional polymerization technique known to those skilled in the art.
    The nonionic surfactant and cationic polymers of the present invention may be added to the aqueous mineral sludge concentrate at any convenient point. It will be appreciated by those skilled in the art that the exact points (places) of additive will be specific to each plant. There is no necessary addition order for the addition of the nonionic surfactant and the cationic polymer to the aqueous concentrated mineral sludge. The nonionic surfactant may be added to the aqueous mineral sludge concentrate first and then followed by the addition of the cationic polymer to the aqueous mineral sludge concentrate treated with nonionic surfactant, or the cationic polymer may be initially added to the aqueous mineral sludge concentrate and then the nonionic , the surfactant is added to the aqueous mineral sludge concentrate treated with cationic polymer. In another embodiment of this invention, the process is included wherein the nonionic surfactant and the cationic polymer can be added simultaneously to the aqueous. Furthermore, another embodiment of this invention provides a process wherein the nonionic mineral sludge concentrate, either at the same or different additive points. the surfactant and the cationic polymer can be premixed together to form a mixture of nonionic surfactant and cationic polymer and then this mixture is added to the aqueous mineral slurry concentrate. Any suitable additive method known in the art may be used. A preferred method of addition includes suitable dilution to effect dispersion of the nonionic surfactant and the cationic polymer entirely in the aqueous mineral sludge concentrate. In another embodiment of the present invention, there is provided an improved mineral sludge concentrate composition consisting essentially of an aqueous mineral sludge concentrate, a nonionic surfactant and a cationic polymer. The nonionic surfactant and cationic polymer of the invention are as described herein. In a further embodiment of the present invention, there is provided an improved mineral concentrate filter cake consisting essentially of a substantially dehydrated mineral concentrate, a nonionic surfactant and a cationic polymer. The nonionic surfactant and cationic polymer of the invention are as described herein.
    EXAMPLES The following examples demonstrate the invention in greater detail. These examples are not intended to limit the scope of the invention in any way. In the present invention, the use of nonionic dewatering aids together with cationic polymers optimally reduces the moisture content of a mineral sludge concentrate while increasing the production of a resulting mineral concentrate filter cake which was previously not possible without any treatment at all, or by using a nonionic dewatering aid alone, or by using a anionic dewatering aid or in combination with a cationic polymer. In the examples presented in Tables 1 to 5, the following compositions were used as nonionic surfactants (DWA) and cationic polymers (otherwise referred to herein as process aids "PA"): Nonionic surfactants (DWA "dewatering aids)): DWA A C12- C14 secondary ethoxylated alcohol, wherein "x" is from 2 to 5 DWA B C12-C14, branched, primary alcohol ethoxylate, wherein "x" is from 2 to 5 DWA C C12-C14, secondary alcohol ethoxylate, wherein "x" is from 2 to 5 DWA E C11 alcohol ethoxylate, wherein "x" is from 3 to 7 DWA F mixtures of C18 amine ethoxylate (having from 2 to 5 degrees ethoxylation) and C11-C16 alcohol ethoxylate, wherein "x" is from 2 to 5 cationic polymer (Process aid "PA"): PAI 40 mol% feed copolymer of Acryloyloxyethyltrimethylammonium chloride and acrylamide, average molecular weight about 2 to about 6 million PAll 80 mol% feed copolymer of Acryloyloxyethyltrimethylammonium chloride and acrylamide, average 25 about 25 million PA 10 III 60 mol% feed, copolymer of Acryloyloxyethyltrimethylammonium chloride and acrylamide, average molecular weight about 9 to about 13 million.
    PAV 100 mol% charge polydiallyldimethylammonium chloride, about 100,000 average molecular weight PA Vl 100 mol% feed polydiallyldimethylammonium chloride, about 500,000 average molecular weight PA Vll 100 mol% feed Mannich condensation polymer of acrylamide, dimethylamine and formaldehyde, 1 mol 6 million to 4.7 PA Vlll 10 mol% feed copolymer of Acryloyloxyethyltrimethylammonium chloride and acrylamide, average molecular weight about 2 to about 6 million PA IX 30 mol% feed copolymer of Acryloyloxyethyltrimethylammonium chloride and acrylamide, average molecular weight was about 4 million which has a formula Fe3O4, which differs from hematite, Fe2O3. The differences in the molecular compositions of magnetite and hematite-based iron ore give different crystal structures and consequently different chemical and physical properties. ON ANALYTICAL TEST FOR SEPARATION OF SOLID SUBSTANCES AND LIQUIDS Filter Leaf Test (a) A sample of ore concentrate is taken from the unit process feed for the separation of solids / liquids. In this example, we assume that it is a vacuum alter. For the sake of simplicity, we will call it "Filter feed" (ie the mineral sludge concentrate). A typical sample can be 20-30 gallons (75.7-113.55 liters) in 5 gallon buckets (18.925 liters). We deliver the buckets with filter filters to a laboratory where we have a set-up of a filter scale test device in a bench scale set up. A Filter Blade Test is commercially available from Komline-Sanderson (Peapack, New Jersey, USA). placed and suction is applied through the filter medium with a hose connected to the vacuum pump.The surface area of the filter blade is a known value so the factory filter productivity can be estimated based on laboratory results c) The buckets are stirred until uniform and density checked the other buckets) with a standard Marcy Cup and Density Scale, commercially available from Legends Inc. (Sparks, NV, USA) 10 15 20 25 30 35 12 d) A 5 liter sample is taken from the larger sample buckets and placed under a stirrer to keep the sample uniform e) When ready for testing, or ready to run a filter blade test, set the vacuum on the vacuum pump according to gt factory conditions and turn on. The stirrer in the 5-liter sample is switched off and the filter blade is immersed in the 5-liter sample by Filter Feed to a predetermined depth. f) After a predetermined time (set to copy factory conditions), remove the filter blade from the Filter Feed Sample and turn the stirrer back on. g) The vacuum is left on, again for a predetermined period of time to simulate factory vacuum dry time for the filter cake. h) When the cake formation and drying times are exactly completed, the vacuum is switched off and the filter cake is removed from the filter sheet filter medium. By obtaining the wet and oven dry weights (4 hours at 100 degrees Celsius) of the filter cake produced, one can determine the filter cake moisture% and the dry weight of filter production. Results and treatment (s), if any, are recorded through individual filter blade tests. (i) Drainage aids and process aids may be added based on the remaining sample being stirred. The addition can be accomplished using syringes and a measured amount based on the volume, density and specific gravity of the 5 ~ liter sample to achieve a correct dosage ((pounds per long ton ("# / lT") are typical units in ore sludge). A new filter blade test is run using the same procedure consistently.
    The differences in cake production and moisture in individual filter tests can then be compared with the results of the untreated samples to get the relative improvements in filter cake productivity and filter cake moisture (drier years better). In general, in the results shown in Tables 1 to 5, the nonionic surfactant (dewatering aid) was initially added to the aqueous mineral sludge concentrate followed by (sequential) addition of the cationic polymer (process aid) to the aqueous mineral sludge concentrate treated with nonionic average. Applicants have achieved similar results as shown in Tables 1 to 5 when the order is varied, for example but not limited to, when the process aid is initially added to the aqueous mineral sludge concentrate followed by the addition of the dewatering aid, or when the dewatering aid and the process aid are first mixed together and then added. as a mixture to the aqueous mineral sludge concentrate. Thus, it will be appreciated by those skilled in the art that the order and physical points / physical point of addition of the dewatering aid and the process aid to the untreated aqueous mineral sludge concentrate were not critical to achieving the synergistic results of Applicant's invention. required to test many j) The cycles can be repeated as often as possible dosages / combinations of filter aids and procedure aids. Continuous comparison of untreated results ensures testing accuracy. 13 As shown in Tables 1 and 4, the iron ore sludge I was obtained from the Minnesota Mesabi Iron Ore Range Mineral Processing Plant, and included a mineral iron ore having a magnetite composition. The iron ore sludge III reported in Tables 2 and 5 was obtained from the Michigan Negaunee Iron Ore Range Mineral Processing Plant 1 and included a mineral ore having a magnetite composition. The iron ore sludge II reported in Table 3 was obtained from the Michigan Negaunee Iron Ore Range Mineral Processing Plant 2 and included a mineral ore having a magnetite composition.
    TABLE 1 Effects of drainage aids and process aids on filter cake production and filter cake moisture Iron ore sludge I Location: Minnesota Mesabi Iron Ore Range Mineral Processing Plant Dewatering Process Dewatering. Procedure. %%%% moisturizing aids aids Aids. Help. production prod. moisture decrease Dose # / IT Dose # / IT increase None * None None None 100 0 10.84 0 A 0.1 101 1 9.93 8.4 A PA V 0.1 0.005 104.42 4.4 9.45 12.8 A PA V 0.1 0.02 118.55 18.6 9.64 11.1 A PA V 0.1 - = 0.05 120.88 20.9 9.87 8.9 None * None None None 100 0 10.84 0 A PA VI 0.1 0.005 108.35 8.4 10.32 4.8 A PA VI 0.1 0.02 110.07 10.1 10.42 3.9 A PA VI 0.1 0.05 117.51 17.5 10.23 5.6 A PA VI 0.1 0.1 118.73 18.7 10.51 3 None * None None None 100 0 10.84 0 A PA I 0.1 0.02 102.03 2 10.17 6.2 A PA I 0.1 0.05 110.63 10.6 10.4 7.4 A PA I 0.1 0.1 126, 35 26.4 10.25 5.4 None * None None None 100 0 10.84 0 A PA VIII 0.1 0.02 100 0 10.2 5.9 A PA VIII 0.1 0.05 111.67 11.7 10.07 7.1 A PA VIII 0.1 0.1 123.46 23.5 10.5 3.1 None * None None None 100 0 10.84 0 14 A PA III 0.1 0.005 103 .87 3.9 10.34 4.6 A PA III 0.1 0.02 117.26 17.3 10.07 7.1 A PA lll 0.1 0.05 140.29 40.3 10.37 4.3 A PA III 0.1 0.1 175.92 75.9 10.46 3.5 None * None None None 100 0 10.84 0 IA PA IX 0.1 0.005 112.16 12.2 9, 65 11 A PA IX 0.1 0 .02 123.28 23.3 9.92 8.5 A PA IX 0.1 0.05 139.19 39.2 9.61 11.3 A PA IX 0.1 0.1 175.61 75.6 10 7.7 None * None None None 100 0 10.84 0 A PA VIII 0.1 0.005 117.1 17.1 9.69 10.6 A PA VIII 0.1 0.02 129.19 29.2 9 .83 9.3 A PA VIII 0.1 0.05 151.84 51.8 9.45 12.8 A PA VIII 0.1 0.1 174.43 74.4 9.71 10.4 None * None None None 100 0 10.84 0 A PA II 0.1 0.02 104.24 4.2 10.61 2.1 A PA II 0.1 0.05 119.39 19.4 9.86 9 A PA II 0.1 0.1 163.59 63.6 9.96 8.1 * Nothing is the mean of all samples without any process aid or dewatering aid Table 2 Effects of dewatering aids and various process aids on filter cake production and filter cake moisture Iron ore sludge lll Location: Michigan Negaunee Iron Ore Range Mineral Processing Plant In Drainage Procedure- Drainage. Procedure. %% prod. % F% F- aids aids Aids. Help. production increase (humidity) decrease Dose # / lT Dose # / IT on None None None None 100 13.5 A None 0.1 None 100.3 0.3 12 11.1 A PA I 0.1 0.04 105, 2 5.2 12.5 7.4 None None None None 100 13.2 A None 0.2 None 98.4 -1.5 10.9 17.4 A PAI 0.2 0.03 97.6 2.4 10 .9 17.4 15 A PA I 0.2 0.06 100.6 0.6 11.2 15.2 A PA I 0.2 0.09 100.3 0.3 11.4 13.6 None None None None 100 13.1 A None 0.3 None 98 -2 10.1 22.9 A PA II 0.3 0.06 111.3 11.3 10.3 21.4 A PA II 0.3 0, 12 132.5 32.5 10.9 16.8 A PAII 0.3 0.18 160.1 60.1 11.6 11.5 None None None None 100 13 A None 0.5 None 87.7 -12 .3 9.6 28.5 A PA II 0.5 0.08 110 10 10.3 20.8 A PA II 0.5 0.12 124 24 10.4 20 None None None None 100 13.5 A None 0.1 None 96 -4 11.3 16.3 A PA II 0.1 0.04 109.4 9.4 12.1 10.4 A PA II 0.1 0.08 109.5 9.5 12 .5 7.4 A PAII 0.1 0.12 117 17 13.2 2.2 None None None None 100 13.3 A None 0.3 None 90.9 -9.1 10 24.8 A PA III 0 .3 0.08 106 6 11 17.3 A PAIII 0.3 0.12 114 14 11.4 14.3 None None None None 100 13.2 A None 0.5 None 90.2 -9.8 9.3 29.5 A PA III 0.5 0.08 106 6 9.9 25 A PA III 0.5 0.12 118.6 18.6 10.2 22.7 None None None None 100 13 A None 0.3 None 92.8 -7.2 9.9 23.8 A PA VII 0.3 0.4 109.7 9.7 10.2 21.5 A PA VII 0.3 0.8 117.6 17.6 10.4 20 A PA VII 0.3 1.2 131.7 31.7 10.8 16.9 None None None None 100 13.4 A None 0 .5 None 93.2 -6.8 9.5 29.1 A PA VII 0.5 0.4 101.2 1.2 9.4 29.9 A PA VII 0.5 0.8 113.7 13 .7 9.7 27.6 A PA VII 0.5 1.2 120.5 20.5 9.8 26.9 None None None None 100 13.2 16 C None 0.3 None 93 -7 9.7 26.5 C PA VII 0.3 0.4 104.2 4.2 10.2 22.7 C PA VII 0.3 0.8 122.7 22.7 10.5 20.5 C PA VII 0, 3 1.2 124.1 24.1 10.8 18.2 None None None None 100 13.4 C None 0.5 None 94 -6 9.7 27.6 C PA VII 0.5 0.4 100, 2 0.2 9.7 27.6 C PA VII 0.5 0.9 109.1 9.1 9.9 26.1 C PA VII 0.5 1.2 125.8 25.8 10 25.4 None None None None 100 13.1 A None 0.3 None 93.6 -6.4 9.9 24.4 A PA VI 0.3 0.16 100.4 0.4 10.8 17.6 None None None None 100 12.9 C None 0.1 None 93.9 -6.1 12.1 6.2 C PA III 0.1 0.04 104.6 4.6 12.3 4.7 C PA III 0.1 0.08 123.3 23.2 12.9 0 Table 3 Effects of dewatering aids and various process aids on filter cake production and filter cake moisture Iron ore sludge II Location: Michigan Negaunee Iron Ore Range Minerals 2 Dewatering Procedure Dewatering. Procedure. %% prod. %% F- aids aids Aids. Help. production increase F decrease Dose # / IT Dose # / IT none none none none none 100 0 12, 0 2 A None 0.25 None 89 -11 9.9 19 A PA VIII 0.25 0.4 119 19 10 18 A PA VIII. Procedure. %%%% F- aids aids Aids. Help. production prod. Decrease Dose # / | T Dose # / | T increase none None none None 100 0 10.3 0 B none 0.5 none 92 -8 7.4 28 B PA Vll 0.2 0.8 146 46 9.9 4 B PA VII 0.5 1 117 17 7.9 23 B PA Vll 0.5 1.5 170 70 8.44 18 B PA Vll 0.5 2 170 70 8.45 18 Table 5 Effects of dewatering aids and various procedural aids on filter cake production and filter cake moisture Iron ore sludge III Location: Michigan Negaunee Iron Ore Range-Mineral Processing Plant I Drainage Procedure- Drainage. Procedure. %% prod. %% F- aids aids Aids Aids Aids. production increase F decrease Dose # / | T Dose # / | T None None None None 100.00 0.0 14.1 0 E None 0.1 None 97.14 -2.9 13.9 1 E None 0.3 None 91.16 -8.8 11.4 19 E None 0.5 None 74.64 -25.4 10.6 25 None None None None 100.00 0.0 14.4 0 E PA VII 0.5 1 .5 120.85 20.9 9.2 36 None None None None 100.00 0.0 13.9 0 A None 0.1 None 100.09 0.1 13 A None 0.3 None 94.87 -5 , 1 10.8 22 A None 0.5 None 94.87 -5.1 10.1 27 A PA VII 0.5 0.8 117.49 17.5 10 28 10 15 20 25 18 none None None None 100 .00 0.0 14.2 0 B None 0.1 None 98.47 -1.5 12.7 11 B None 0.3 None 97.66 -2.3 10.5 26 B None 0.5 None 104 , 41 4.4 10.2 28 B PA VII 0.5 0.8 121.76 21.8 9.8 31 None None None None 100.00 0.0 14.2 F None 0.1 None 104.30 4.3 13.9 F None 0.3 None 110.38 10.4 12.2 14 F None 0.5 None 107.70 7.7 12.1 15 F PA VII 0.5 0.8 122.38 22.4 11.3 The data presented in Tables 1 to 5 show that the process according to surfactant (dewatering aid) together with a cationic polymer ( The present invention, which uses a nonionic synergist, lowers the residual water levels in filter cakes and increases the production of solids from 9% to over 50% compared to the use of the nonionic surfactant alone (dewatering aid).
    Applicants provide the following prophetic examples of the process of this invention utilizing methacrylate versions of cationic polymer PA II or cationic polymer PA III together with dewatering aid DWA A, as reported above. Applicants estimate that the increase in production in% would be from about 110% to about 150% and that the% moisture would be from about 10% to 10.5%.
    Figure 1 shows the moisture versus production that can be achieved using the method and composite layers of the present invention. As shown in Figure 1, the method and composite zones of the present invention (identifying the boxes and circles in Figure 1) provide synergistic results in increasing the percentage of filter cake production (y-axis in Figure 1) while the percentage of moisture in the resulting the filter cake is lowered (X-axis in Figure 1) against no treatment (identified by the triangle in Figure 1), or by using only a nonionic, surfactant (dewatering aid DWA A). It is known to those skilled in the art that in general, adding only one cationic polymer to a mineral sludge concentrate will increase the percentage of moisture in the resulting filter cake. Thus, it will be appreciated by those skilled in the art that the synergistic effects obtained with the present invention extend far beyond the results that can be obtained with any of the prior art chemical processes. While particular embodiments of the present invention have been described for illustrative purposes, it will be apparent to those skilled in the art that numerous variations and details of the present invention may be made without departing from the present invention as defined in the appended claims.
    权利要求:
    Claims (28)
    [1]
    A process for dewatering a mineral sludge concentrate and for increasing the production of the resulting filter cake, which essentially consists of: mixing an aqueous mineral sludge concentrate with an effective amount of a nonionic surfactant, and an effective amount of a cationic polymer to form an aqueous mineral sludge concentrate treated with a nonionic surfactant and a cationic polymer; said nonionic surfactant being an alkyl ethoxylate alcohol having the chemical formula R- (OCH 2 CH 2) 2 OH, wherein x is an integer from about 1 to 15, and R is a straight or branched aliphatic group comprising from and having about 6 to about 24 carbon atoms in the alkyl moiety, and having a hydrophilic-lipophilic ratio of from about 1 to about 10, an amine toxylate having the chemical formula RN - ((CH 2 CH 2 O) X H) 2, wherein x is an integer from about 1 to about 15, and R is a straight or branched aliphatic group comprising from about 6 to about 24 carbon atoms in the alkyl moiety, or mixtures of said alkyl ethoxylate alcohol and amine toxylate, and wherein said cationic polymer is a Mannich condensation polymer of acrylamide, dimethylamine or diethylamine, and formaldehyde, or wherein said cationic polymer is derived from at least one cationic monomer selected from the group consisting of acryloy loxietyltrimetylammoniumklorid, akryloyloxietyltrimetylammoniummetosulfat, aminomethylated polyacrylamide, methacrylamidopropyltrimethylammonium, acrylamidopropyltrimethylammonium chloride, methacryloyloxyethyltrimethylammonium chloride, metakryloyloxietyltrimetylammoniummetosulfat, diallyldimethylammonium chloride, diallyldiethylammonium chloride, and diallyldimetylammoniumbromid diallyldietylammoniumbromid, and at least one of an acrylamide, methacrylamide, and N, N-dimethyl acrylamide; and subjecting said aqueous mineral sludge concentrate treated with nonionic surfactant and cationic polymer to a process for removing liquid water to dewater said treated aqueous mineral sludge and to produce a filter cake, said amounts being effective in reducing the moisture content and for to increase the production of the resulting filter cake of the dewatered mineral sludge compared to the use of the nonionic surfactant alone.
    [2]
    The method of claim 1, wherein it is included that said effective amount of said nonionic surfactant is from about 0.005 pounds (0.002 kg) to about 3.0 pounds (1.4 kg) per long ton (1016, 05 kg) of said aqueous mineral sludge concentrate on a mineral dry weight basis.
    [3]
    The method of claim 1, wherein it is included that said effective amount of said cationic polymer is from about 0.002 pounds (0.0009 kg) to about 3.0 pounds (1.4 kg) per long ton of said aqueous mineral sludge concentrate on a mineral dry weight basis.
    [4]
    The method of claim 1 wherein it is included that said alkyl ethoxylate alcohol comprises an R group having from about 6 to about 24 carbon atoms, and is one of a straight, primary ethoxylated alcohol, a branched, primary ethoxylated alcohol, or a secondary ethoxylated alcohol.
    [5]
    The method of claim 4, wherein it is included that said R group has from about 11 to about 16 carbon atoms.
    [6]
    The method of claim 1, wherein it is included that said cationic polymer is derived from at least one cationic monomer comprising a quaternary dial | y | diacyl | ammonium monomer, a cationic acrylamide monomer, a quaternized derivative of an acrylate or methacrylate, salts thereof, and combinations thereof.
    [7]
    The method of claim 1, wherein it is included that said cationic polymer is a copolymer derived from a cationic monomer which is a quaternary diallyl dialkyl monomer, and an acrylamide.
    [8]
    The method of claim 1, wherein it is included that said cationic polymer is polydialyldimethylammonium chloride.
    [9]
    The method of claim 1, which comprises first forming a mixture of said nonionic surfactants and said cationic polymer and then adding said mixture to said aqueous mineral sludge concentrate.
    [10]
    The method of claim 1, which comprises simultaneously mixing said nonionic surfactants and said cationic polymer in said aqueous mineral sludge concentrate.
    [11]
    The method of claim 1, which comprises sequentially mixing said nonionic surfactants and said cationic polymer into said aqueous mineral sludge concentrate.
    [12]
    A mineral sludge concentrate composition consisting essentially of: an aqueous mineral sludge concentrate; a nonionic surfactant; and a cationic polymer, said nonionic surfactant being an alkyl ethoxylate alcohol having the chemical formula R- (OCH 2 CH 2) XOH, wherein x is an integer from about 1 to 15, and R is a straight or branched aliphatic group which comprises from about 6 to about 24 carbon atoms in the alkyl moiety, and having a hydrophilic-lipophilic ratio from about 1 to about 10, an amine toxylate having the chemical formula RN - ((CH 2 CH 2 O) X H) 2 , wherein x is an integer from about 1 to about 15, and R is a straight or branched aliphatic group comprising from about 6 to about 24 carbon atoms in the alkyl moiety, or mixtures of said alkyl ethoxylate alcohol and amine toxylate, and wherein said cationic polymer is a Mannich condensation polymer of acrylamide, dimethylamine or diethylamine, and formaldehyde, or wherein said cationic polymer is derived from at least one cationic monomer selected from the group n consisting of acryloyloxyethyltrimethylammonium chloride, akryloyloxietyltrimetylammoniummetosulfat, aminomethylated polyacrylamide, methacrylamidopropyltrimethylammonium, acrylamidopropyltrimethylammonium chloride, methacryloyloxyethyltrimethylammonium chloride, metakryloyloxietyltrimetylammoniummetosulfat, diallyldimethylammonium chloride, diallyldiethylammonium chloride, and diallyldimetylammoniumbromid diallyldietylammoniumbromid, and at least one of an acrylamide, methacrylamide, and N, N-dimethylacrylamide
    [13]
    The mineral sludge concentrate of claim 12, wherein said alkyl ethoxylate alcohol comprises an R group having from about 6 to about 24 carbon atoms, and which is one of a straight, primary ethoxylated alcohol, a branched, primary ethoxylated alcohol or a secondary ethoxylated alcohol.
    [14]
    The mineral sludge concentrate of claim 12, wherein it is included that said R group has from about 11 to about 16 carbon atoms.
    [15]
    The mineral sludge concentrate according to claim 12, wherein said cationic polymer is derived from at least one cationic monomer comprising a quaternary diallyldialkylammonium monomer, a cationic acrylamide monomer, a quaternized derivative of an acrylate or methacrylate, salts thereof, and combinations thereof.
    [16]
    The mineral sludge concentrate according to claim 12, wherein said cationic polymer is a copolymer derived from a cationic monomer which is a quaternary diallyl-dialkylammonium monomer, and an acrylamide.
    [17]
    A mineral concentrate filter cake consisting essentially of: a substantially dehydrated mineral concentrate; a nonionic surfactant, and a cationic polymer, said nonionic surfactant being an alkyl ethoxylate alcohol having the chemical formula R- (OCH 2 CH 2) 2 OH, wherein x is an integer from about 1 to 15, and R is a straight or branched aliphatic group comprising from about 6 to about 24 carbon atoms in the alkyl moiety, and having a hydrophilic-lipolytic ratio from about 1 to about 10, an amine toxylate having the chemical formula RN - ((CH 2 CH 2 O) X H) 2, wherein x is an integer from about 1 to about 15, and R is a straight or branched aliphatic group comprising from about 6 to about 24 carbon atoms in the alkyl moiety, or mixtures of said alkyl ethoxylate alcohol and amine toxylate, and wherein said cationic polymer is a Mannich condensation polymer of acrylamide, dimethylamine or diethylamine, and formaldehyde, or wherein said cationic polymer is derived from at least one c atjonisk monomer selected from the group consisting of acryloyloxyethyltrimethylammonium chloride, akryloyloxietyltrimetylammoniummetosulfat, amino methylated polyacrylamide, methacrylamidopropyltrimethylammonium, akrylamidopropyl- trimethylammonium chloride, methacryloyloxyethyltrimethylammonium chloride, metakryloyloxietyltri- metylammoniummetosulfat, diallyldimethylammonium chloride, diallyldiethylammonium chloride, and diallyldimetylammoniumbromid diallyldietylammoniumbromid, and at least one of an acrylamide, methacrylamide, and N, N -dimethylacrylamide
    [18]
    The mineral concentrate filter cake of claim 17, wherein said alkyl ethoxylate alcohol comprises an R group having from about 6 to about 24 carbon atoms, and which is one of a straight, primary ethoxylated alcohol, a branched, primary ethoxylated alcohol or a secondary ethoxylated alcohol.
    [19]
    The mineral concentrate filter cake of claim 18, wherein it is included that said R group has from about 11 to about 16 carbon atoms.
    [20]
    The mineral concentrate klter cake of claim 17, wherein said cationic polymer is derived from at least one cationic monomer comprising a quaternary diallyldialkylammonium monomer, a cationic acrylamide monomer, a quaternized derivative of an acrylate or methacrylate, salts thereof, and combinations thereof.
    [21]
    The mineral concentrate klter cake of claim 17, wherein said cationic polymer is a copolymer derived from a cationic monomer which is a quaternary diallyl-dialkylammonium monomer, and an acrylamide.
    [22]
    The mineral concentrate filter cake of claim 17, wherein said cationic polymer is polydiallyldimethylammonium chloride.
    [23]
    The method of claim 1, wherein it is included that said nonionic surfactants are a mixture of said alkyl ethoxylate alcohol and another alcohol.
    [24]
    The method of claim 23, wherein it is included that said second alcohol comprises from about one carbon atom to about 18 carbon atoms, and is one of a primary or secondary alcohol, and is either straight or branched, and mixtures thereof.
    [25]
    The mineral sludge concentrate composition of claim 12, wherein said nonionic surfactants are a mixture of said alkyl ethoxylate alcohol and another alcohol.
    [26]
    The mineral sludge concentrate composition of claim 25, wherein said second alcohol comprises from about one carbon atom to about 18 carbon atoms, and is one of a primary or secondary alcohol, and is either straight or branched, and mixtures thereof.
    [27]
    The mineral concentrate filter cake of claim 17, wherein said nonionic surfactant is a mixture of said alkyl ethoxylate alcohol and another alcohol.
    [28]
    The mineral concentrate filter cake of claim 27, wherein said second alcohol comprises from about one carbon atom to about 18 carbon atoms, and is one of a primary or secondary alcohol, and is either straight or branched, and mixtures thereof.
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    法律状态:
    优先权:
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