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Methods of Measurement and Improvement of Rheological Properties of

Bauxite Residue

Conference Paper · November 2021

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 TRAVAUX 50, Proceedings of the 39th International ICSOBA Conference, 22 - 24 November 2021

Methods of Measurement and Improvement of Rheological Properties

of Bauxite Residue
Lawrence J. Andermann Jr.
SUEZ – Water Technologies & Solutions
Feasterville-Trevose, PA, USA
Corresponding author: [email protected]

Abstract

The concentration and transportation of bauxite residue and bauxite slurry are two common
challenges alumina refineries face today. Alumina refineries are seeing lower available alumina
and increased gangue-minerals that make handling of bauxite residue more difficult. Difficulties
in handling of bauxite residue can lead to a shorting of an alumina plant’s working life due to the
filling of bauxite residue waste lakes, or there can be difficulty in filtration of bauxite residue at
the end of a counter current deceanting circuit. While synthetic polymers are necessary to achieve
faster liquid-solid separation rates, polymers can impart negative rheological characteristics to
slurries of bauxite residue or bauxite slurry. This paper will discuss the increasing rheological
properties caused in part or total by the mineralogical components within bauxite residue,
operational philosophies, unit-operation’s design and equipment, and the addition of chemical
additives. In addition, this paper will cover methodologies for measurements of rheological
properties of bauxite residue and bauxite slurry.

Keywords: Rheology, Alumina, Bauxite Residue, Yield Stress, Slurry

1. Introduction

In alumina refineries and other mining processes, challenges exist in the dewatering and transport
of slurries. Substrate characteristics and solution salt concentrations, as well as other factors, such
as chemical treatment, affect liquid-solid separations and subsequent pumping of aqueous
dispersions also known as mining slurries. Also, alumina refineries are processing bauxite (ore)
that contain a higher content of gangue minerals that require higher polymer dosages. Polymers
are necessary to achieve fast rates of liquid solid separation and maintain suitably high plant flows
for economic viability, but these polymers impart negative rheological characteristics to the
concentrated aqueous dispersions (bauxite residue in the Bayer process) that make transport and
washing more difficult. Aqueous dispersions that have lower threshold energy (yield stress) and
uninhibited flow (lower viscosity) result in consistently faster flow rates through mining
processes, including alumina refineries. New rheology modification technology; when combined
with any number of synthetic polymers, has been successful in bench-top, pilot, plant trials, and
commercialized sites, yielding improved rheological characteristics of concentrated aqueous
dispersions. Benefits to the preparation plants include:

• Higher levels of throughput

• Improved efficiency and productivity
• Lower energy costs
• Consistency of unit operations
• Avoidance of additional CAPEX

In this article, the author will provide results from bench-top experiments to full plant trials to
show the efficacy of the combination rheology modifier and a synthetic polymer to provide value
in achieving the mill or plants operational objectives.

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 TRAVAUX 50, Proceedings of the 39th International ICSOBA Conference, 22 - 24 November 2021

2. Background

Rheology modifiers effectively treat process slurries, tailings and concentrates. Other benefits
over treatment with flocculant alone, include increased settling rate, less scaling, and improved
filtrate clarity.

Trials of the rheology modifiers focused on applications characterized by difficult to process

aqueous dispersions due to ore quality, process material quality, nature of aqueous solution,
under-designed unit operations. Multiple studies of aqueous dispersions have identified and
characterized properties that have negative impacts on liquid-solid separation and transport. For
example, Klein et al [1] outline factors that impact of the rheological properties of slurries;

• Solids concentration
• Particle morphology
• Particle size distribution
• pH
• Ionic strength of aqueous phase
• Chemical additive

Examples of unit operations that are affected by the aforementioned factors are:

• Pumping
• Transport
• Grinding
• Gravity concentration
• Flotation
• Mixing
• Leaching
• Thickening
• Tailings disposal

Chemical additives, such as flocculants, coagulants, and dispersants, create particle to particle
aggregation, networks. Another study depicts an increase in slurry viscosity as these structures
develop [2]. As with other authors, the author of this paper propose that the morphology of
networks resulting from chemical treatment without the use of rheology modifiers can negatively
affect the rheological properties of these aqueous dispersions [3]. Rheology is the study of
deformation of flow and matter, which included both viscosity, yield stress, etc. Viscosity is the
internal friction of a fluid that gives the tendency to resist flow; that is defined as the ratio of the
shear stress to the shear rate. Since mining slurries are non-Newtonian fluids, flow does not begin
until the slurry’s yield stress is exceeded. Yield stress is the critical shear stress that must be
exceeded before irreversible deformation and flow may occur. In measuring yield stress, it is
important that the yield stress be measured at the same point in the compaction regime. That is,
measurements of yield stress should be taken at or near terminal compaction (point closest to
maximum compaction attainable due to repulsive forces of polymer and other repulsive forces).
Otherwise, there would be a variation in the results obtained in the rheological measurements;
that is, workers have shown that with a variation of time, the magnitude of the rheological
measurement changes. Yield stress is conveniently determined by a vane technique. The authors
utilized the yield measurement to characterize treated and untreated slurry’s rheological properties
very similar to that used by Liddell and Boger for their work with yield stress measurements in
concentrated suspensions [4,5]. Typically, rheologist test a combination of rheology modifiers
with a range of synthetic flocculants, whereby the right flocculant and rheology modifier were
chosen for a particular substrate that results in a network morphology that is conducive for flow,

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 TRAVAUX 50, Proceedings of the 39th International ICSOBA Conference, 22 - 24 November 2021

compaction, and sedimentation. The studies contained in this paper relied on empirical data
obtained on the bench-top laboratory testing, pilot trials, and full-scale plant trials with the metrics
of pumping rate, rake torque, underflow concentrations, etc., to show that the rheology modifier
reduces rheological properties in mining slurries. In the case of the Bayer Process, washing
efficacy is implied due to the increase solids concentration.

3. Method for Rheological Measurement

Many Rheologist in mining utilize vane rheometry for measurement of yield stress. Boger et al
have used pioneered vane rheometry to investigate how process conditions and mineralology
affects the rheology properties of Bingham Plastic Slurries of mining processes (Figure 1) [5].

Figure 1. Rheometer using vane for measurement of a dynamic yield stress.

Most of the error associated with measurement of rheological properties such as yield stress
revolve around measuring a slurr while the slurry has not reached terminal compaction (Figure
2). That is, at “terminal compaction” in solid-liquid sedimentation tests, the measurement of
volume versus time will show a zero slope after time final ( t f). If measurements of rheological
properties are taken before the slurry approaches terminal compaction, the researcher will obtain
statistically problematic data.

Slurries within alumina refineries change with time and decrease of temperature; and degree of
settling. To avoid this conditions that would skew the data, red-mud slurries are allowed to
achieve atomosheric conditions and approach terminal compation before the rheological
properties are measured.

to t1 t24 tt to t1 t24 tt
Figure 2. Achieving terminal compaction before measuring rheological properties.

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 TRAVAUX 50, Proceedings of the 39th International ICSOBA Conference, 22 - 24 November 2021

After solid-liquid separation testing, slurries are transferred to rheometry cups to allow the slurry
to approach terminal compaction before testing ensues. In as much, a researcher could observe
the effect of speciality chemicals such as flocculants, viscosity modifiers, and rheology modifiers
on the solid-liquid separation and rheological key performance indicators such as settling rate,
compaction, turbidity, and yield stress.

Dynamic yield stress utilizes low revelations per minute (rpms) with a variation of angular
velocity ranging from 0.01 rpm to 0.350 rpms. Each of the angular velocities will be held for a
given time interval until. The dynamic yield stress utilizes both the elastic and plastic rheological
data points taken from a graph that depics shear stress versus shear rat where the slope of the line
is the yield stress. Most rhelogist utilze the Casson Model for yield stress measurements of
Bingham Pastic Slurries emunating from mining and mineral processes.

4. Case Histories

Rheology modifiers have been used in combination with synthetic polymers in several mining
processes such as alumina, phosphate, mineral sands, gold, copper, and coal preparation plants
for tailings, concentrates, and ores. Bench-top laboratory trials, pilot plant trials, and full-scale
plant trials with the rheology modifier series have demonstrated a reduction in yield stress
between 12.5 – 57.8%, as illustrated in Table 1.

Table 1. Rheology modification performance of the combination of rheology modifiers and

synthetic polymers compared to the use of synthetic polymers alone
Flocculant and
Flocculant
Feed Final Rheology Percent
Mining Type of Only
Solids Solids Modifier Reduction
Segment Slurry Yield
%(W/W) %(W/W) Yield (%)
Stress, N/m2
Stress,N/m2
Coal Tailings 3.9 25 30.8 21.0 31.82
Gold Concentrate 16.5 53 255.0 223.0 12.55
Phosphate Ore 13 62 62.1 26.2 57.81
Bauxite
Alumina 4 36 310.0 195.0 37.10
Residue
Mineral
Tailings 3 25 9.2 7.8 15.23
Sands

4.1 Laboratory Trial

For the tailings of coal process plants, rheology modifiers were used in combination with typical
copolymers of polyacrylate/polyacrylamide flocculants. Yield stress of underflow solids was used
as the metric for determining the amount of reduction in rheological properties of slurries that
were treated with the rheology modifier plus synthetic flocculant as well as slurries treated with
only synthetic flocculant. Previous studies conducted have shown an experimental relationship
between yield stress and underflow solids concentration after treatment with a synthetic polymer
which correlates to other studies that are found in literature. To maintain flow rates or increase
solids, coal preparation plants will often increase the synthetic polymer dosage, resulting in higher
rheological properties such as yield stress. The authors replicated this approach to achieve higher
coal tailings concentrations; however, the results were unfavorable in terms of the magnitude of
the resulting yield stress due to the increase in underflow solids. In these laboratory trials,
4%(W/W) feed solids were used at a slightly alkaline pH of 8. The tailings were dosed between
10 – 40 grams per ton on a dry solids basis. An increase in Dosage resulted in an increase in
compaction (Figure 3). With an increase in compaction, the resulting yield stress also increased
in a classical exponential relationship between yield stress and compaction (Figure 4). Other

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 TRAVAUX 50, Proceedings of the 39th International ICSOBA Conference, 22 - 24 November 2021

studies have shown similar exponential relationships between yield stress and percent solids [6,7].
For a polymer dosage of 15 grams per ton synthetic polymer, increasing the rheology modifier
dosage to the synthetic polymer dosage decreased yield stress (Figure 5). With the synthetic
polymer and rheology modifier at about 60% ratio, there was about a 30 percent decrease in yield
stress. When flocculant was used alone at higher flocculant dosages, the experimental data has
shown a six-fold increase yield stress as opposed to a decrease in yield stress when the
combination of the rheology modifier and synthetic polymer were used as a two-product solution.

30

25
Underflow Compaction %(W/W)

20

15

10

0
0 5 10 15 20 25 30 35 40 45
Polymer Dosage (g/T)

Figure 3. Coal tailings treated at 4%wt feed solids with increasing amounts of synthetic
polymer – compaction versus polymer dosage

Figure 4. Coal tailings treated at 4%wt feed solids with increasing amounts of synthetic
polymer – yield stress versus underflow compaction

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 TRAVAUX 50, Proceedings of the 39th International ICSOBA Conference, 22 - 24 November 2021

35

30
Underflow Yield Stress (N/m2)

25

20

15

10

0
0 10 20 30 40 50 60 70
Rheology Modifier to Synthetic Polymer Percent Dosage Ratio

Figure 5. Coal tailings treated at 4%wt feed solids with same synthetic polymer dosage
and increasing amount of rheology modifier– yield stress versus ratio of rheology modifier
dosage to synthetic polymer dosage in percent format

4.2 Plant Application of Rheology Modifiers ( Plant No.1 - Jamaican bauxite residue)

In alumina refineries, residues are termed “bauxte residue” and refineries often have difficulty
compacting the bauxte residue due to mineralogy and prevailing process conditions. Throughput
in the alumina refinery’s counter current decanter circuit (CCDC) can be negatively affected by
the degradation of the ore. This degradation makes it more difficult to achieve the desired solid
concentrations in the bauxte residue lakes, thus increasing the footprint of the lakes to achieve the
same dewatering rate. For example, Jamaican bauxite contains high amounts of goethite as well
as other minerals that affect the liquid solid separation. It has been shown that a slight increase in
volume fraction of goethite that there was an increase in yield stress. Mineralogy plays an
important role not only in the separation efficiency but also in the resulting rheological properties
of the slurries. Plant trial data show the effect of treating bauxite residue with rheology modifier
on the rake torque of a high rate thickener versus using synthetic flocculant alone. With treatment
using a rheology modifier and synthetic polymer combination, the refinery experienced a 24%
increase in solids with almost a 50% reduction in rake torque. Moreover, with the application of
a rheology modifier and synthetic polymer combination, bauxte residue drying time did not
increase. Furthermore, at lower bauxite residue concentrations, the bauxite residue lakess will fill-
up at faster rates thereby causing the alumina refinery to rasie the bauxite residue lake levee with
additional lifts. Once a certain height is achieved on the bauxite residue lake’s levee is achieved,
then new levees must be constructed. The additional lifts or new construction can be expesive
costing into the tens of millions of dollars.In addition, difficult to settle bauxite residue may not
have good solid-liquid separation characteristics which most times have implications on filtration
at the end of an alumina refinery’s counter current decantation circuit, and this may affect the
ability of the alumina refinery to efficently handle and dry-stack the bauxite residue.

4.3 Plant Application of Rheology Modifiers ( Plant No.2 - Jamaican bauxite residue)

A plant trial that saw up to 50% of a bauxite reserve of Jamaican bauxite saw large rheometer
demonstrated the efficacy in increasing underflow solids were increasing with a decreasing rake

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 TRAVAUX 50, Proceedings of the 39th International ICSOBA Conference, 22 - 24 November 2021

torque (Figure 6). Historically, the alumina refinery could only process up to 15 percent of this
difficult to process bauxite before the underflow would not be able to be pumped as well as
overloading the rakes in the clarification circuit of the Bayer Process. The initial solids were on
the level of magnitude of about 200 grams per liter without the use of a rheology modifier, and
the level of magnitude of underflow solids was as high on a consistent basis of about 350 grams
per liter; this change in magnitude of the underflow solids represents about percent change greater
than 60 percent.

Figure 6. Alumina refinery plant trial with residue from Jamaican bauxite (high goethite
concentration); underflow solids/rake torque versus flocculant flow aka dosage

With lower rheological properties of the treated bauxite residue, it would be thought that the
bauxte residue would not have a slump. However, the treated material has a controlled flow with
a slope that has not historically been seen for this type of ore reserve (Figure 7). The left picture
was taken at the beginning of the trial, and the picture on the right was taken with the system
came to equilibrium at the higher underflow solids.

Figure 7. Alumina refinery plant trial with Jamaican bauxite residue that encompassed
utilization of a bauxite with a high goethite concentration; slump of untreated bauxite
residue (left) and treated bauxite residue (right)

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 TRAVAUX 50, Proceedings of the 39th International ICSOBA Conference, 22 - 24 November 2021

5. Summary

Return on investment calculations were part of each investigation by the authors to demonstrate
the value of using the new rheology modifier technology. Return on investment due to use of the
rheology modifier for alumina refineries, preparation plants, mills, or refineries were estimated in
some cases to be greater than $20 million per annum due to energy savings, reduced maintenance
costs, washing efficiencies, scale prevention, life span of tailings repositories, optimized chemical
spend, and increased production. The return on investment also benefited from reduced capital
expenditure by eliminating the additional thickeners, bauxite residue lakes, and pumping
equipment. Capex in some of the case studies were as high as $100 Million.

6. References

1. B. Klein and M. Pawlik, “Rheology modifiers for mineral suspensions”, SME Annual
Meeting, 2004, pgs 1-7.
2. D. J. Hallbom, “Pipe flow of homogenous slurry”, Ph.D. Dissertation, University of
British Columbia, 2008.
3. S. J. Adkins and D. T. Smith, “Rheology Aids for effective mud disposal”, Light Metals
2002.
4. P. V. Liddell and D. V. Boger, “Yield stress measurements with the vane”, J. Non-
Newtonian Fluid Mech., Vol. 63, 1996, pgs 235-261.
5. Q. D. Nguyen and D. V. Boger, “Yield stress measurements for concentrated
suspensions”, Journal of Rheology, Vol. 27, 1983, pgs 321-349.
6. D. Spitizer and Qi Dai, “Effect of Flocculant Molecular Weight on Rheology”, Light
Metals 1996, pgs 11-15.
7. H. Heller and R. Keren, “Anionic polyacrylamide polymers effect on rheological
behavior of sodium montmorillonite suspensions”, Soil SCI SOC AM J, Vol 66, January-
February 2002, pgs 19-25.

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