BR112019015604A2 - TREATMENT OF WATER COMPOSITIONS INCLUDING FINE PARTICLES - Google Patents

Abstract

consolidation processes of aqueous compositions including fine particles and process water are described. processes include mixing the composition with a highly water-soluble salt or an aqueous solution thereof to destabilize and consolidate solids in the compositions, for example, to destabilize and consolidate fine particles, and to separate the consolidated solids from the process water. a water-soluble polymer and coarse particles, for example, sand, can also be used in the treatment of the compositions.

Description

TREATMENT OF WATER COMPOSITIONS INCLUDING FINE PARTICLES

CROSS REFERENCE TO RELATED APPLICATIONS [0001] This application claims the benefit of U.S. Provisional Application No. 62/452784, filed January 31, 2017; U.S. Provisional Application No. 62/535398, filed July 21, 2017; U.S. Provisional Application No. 62/554220, filed September 5, 2017; and U.S. Provisional Application No. 62/583360, filed November 8, 2017; all descriptions of each are incorporated herein by reference.

TECHNICAL FIELD [0002] The present invention relates to the dewatering and consolidation of aqueous compositions including fine particles such as tailings from the processing ore.

BACKGROUND [0003] Various mining and extraction processes produce a waste stream characterized as a semi-fluid paste of particulate material in water. These tailings often contain components that are hazardous and cannot be discharged directly into rivers and streams. A common practice is to store tailings in reservoirs, which can be very large or span multiple locations. For example, Canada's tar sands tailings reservoirs have recently been estimated to cover an area of about 200 square kilometers. In the USA, the Environmental Protection Agency has identified more than 500 reservoirs of coal ash and slurry, mainly in the Appalachian coal mining region. In Florida, phosphate mining results in the production of approximately 100,000

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2/49 tons per day of phosphate clays in the form of a semi-fluid paste that is also stored in reservoirs. It is very difficult to dewater it and the phosphate industry leaves around 40% of the land mined in unstable clay settlement areas. The mining and extraction processes of aluminum, copper, zinc, lead, gold, silver, etc., also create tailings flows.

[0004] The management and sustainability of the tailings reservoirs represents significant and growing problems. Dams or dams used to form reservoirs are often built from local material and pose a significant potential hazard. The failure of a coal slurry dam in West Virginia resulted in the flooding of Buffalo Creek, which killed more than 125 people. Several other, more recent, failures of dams in tailings containment reservoirs have resulted in significant, if not catastrophic, environmental damage. For example, in 2016, the failure of a tailings dam in China's Henan province, released about 2 million cubic meters of red mud, fully immersing itself in a nearby village. In 2015, a pile of garbage from Jade mining failed in Myanmar, killing at least 113 people.

[0005] In the oil sands industry, fine particles are defined as particles with a diameter of 44 μιη or less. They are part of a waste stream that settles much more slowly than coarse sand, leaving a layer of water with some fine particles entrained near the surface of the reservoirs. This water is reused in the bitumen extraction process.

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3/49

Initially, most fine particles (mainly silica and clay particles) form an intermediate layer of so-called fine fluid tailings (FFT). This fluid has a low solids content, between 15% and 30% and is also referred to as fine particulate waste (TFT). Over time, additional accommodation occurs, but the negative surface charge of the mineral particles limits aggregation and a distinct layer of so-called mature fine tailings (MFT) is formed. The solids content of the MFT is, on average, around 30%, but varies with depth. It has gel-like properties that make handling and dewatering difficult. It is estimated that, under the action of gravity alone, this component of tailings could take decades to centuries to consolidate and settle and, thus, allow the land to recover. The tailings from phosphate mining in Florida form a gel-like structure. Below a superficial crust, these tailings have a solids content of about 25% with a fluid type consistency.

[0006] The so-called capture reservoirs are used to store two types of waste from the handling and combustion of coal. Carbon ash, which is a combustion residue, is one of these materials and includes several components (fly ash, bottom ash, etc.). The EPA estimated that 100 million tonnes of coal ash was generated in the USA in 2012. There are dry methods of disposal and coal ash can also be recycled in construction materials, but for economic reasons the wet disposal of ash in ash reservoirs has been common practice. The EPA estimated that there are more than 500 units, presumably, ash reservoirs in more than 200 plants. There are growing

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4/49 environmental concerns regarding leachate from these reservoirs.

[0007] The second type of capture reservoir for coal processing residues stores material that is a product of coal preparation plants, where soil and rock are removed from the coal in the mine to reduce its ash content and increase its value. This is done by washing. However, this coal cleaning process produces a waste stream in the form of slurry or slurry. This slurry contains very fine particles of coal together with other material (such as clays) and, as with the aforementioned waste streams, it is very difficult to drain it economically using standard methods. There are now about 600 slurry dams in the USA, where this residual material is stored, mainly in the Appalachian coal mining region. The dams can be up to 50 acres (202343 m ² ) in size and contain billions of gallons of toxic sludge. This material represents an economic cost in terms of the loss of a valuable resource (in the form of fine coal particles) and a great environmental risk. The Washington Post (April 24, 2013) reported that a study by the Surface Mining Recovery and Inspection Office found that many sludge dam walls are weak and are known to leak. Historically, a number of catastrophic failures of ash and mud reservoirs have occurred, resulting in significant loss of life and environmental devastation. With the coal industry in decline and mining companies going bankrupt, damming reservoirs, both those that remain

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5/49 in use and those that have been abandoned are a significant and growing problem.

[0008] The production of alumina from bauxite also results in the generation of a large flow of tailings. Approximately 77 million tons of a highly alkaline residue product composed mainly of iron oxide and known as red sludge or red sludge is generated each year. This represents a significant disposal problem and a failure at the tailings dam has led to catastrophic consequences, as described above.

[0009] There is a continuing need for management and treatment of fine aqueous particles, for example, tailings, to reduce the volume of such tailings and / or to empty and consolidate solids in such tailings and in a preferred way for land reclamation and remediation. .

SUMMARY OF THE INVENTION [0010] Advantages of the present invention include processes for pouring aqueous compositions including fine particles, for example, tailings, to produce materials with a high solids content.

[0011] These and other advantages are satisfied, at least in part, by a process of consolidating solids in the aqueous composition. The process comprises treating the composition, which includes fine particles and process water, with a highly water-soluble salt. Advantageously, the process can include treating the composition with at least one highly water-soluble salt or solution of the same and can optionally include one or both of (i) at least one flocculating polymer or solution of the same and / or (ii ) optionally coarse particles, eg sand, for

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6/49 form a treated composition. The treated composition can include a material consolidated in the process water, which can then be advantageously separated from the consolidated material.

[0012] Implementations of the process of the present invention include, for example, (i) treating the composition with at least one highly water-soluble salt to form a treated composition including material consolidated in the process water, (ii) treating the composition with at least one highly water-soluble salt and at least one flocculating polymer to form a treated composition including material consolidated in the process water, (iii) treating the composition with at least one highly soluble salt in water and coarse particles to form a treated composition including a material consolidated in the process water, and (iv) treating the composition with at least one highly water-soluble salt, at least one flocculating polymer and coarse particles to form a treated composition including a material consolidated in the process water. Each of these implementations can include aqueous solutions of the salt and / or flocculant polymer to treat the composition. Each of these implementations may include separating process water from consolidated material. Advantageously, the consolidated material has a higher density than process water.

[0013] The modalities of the processes include one or more of the following characteristics individually or in combination. For example, the aqueous composition including fine particle may be discarded. In some embodiments, at least one highly water-soluble salt may have a solubility in

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7/49 water (a salt / water solubility) of at least about 5 g / 100 g at 20 ° C, for example, at least about 10 g / 100 g at 20 ° C. In other embodiments, the at least one highly water-soluble salt is a non-hydrolyzing salt. In yet other embodiments, the at least one highly water-soluble salt may have a monovalent cation and may include an ammonium-based salt, a phosphate-based salt, or a sulfate-based salt or combinations thereof.

[0014] In certain embodiments, the treated composition may have a concentration of the saline composition of at least 0.5% by weight of at least one highly water-soluble salt and preferably not less than 1% by weight. weight, such as at least about 2% by weight and still greater than about 3% by weight, 4% by weight, 5% by weight, etc. at least one highly water-soluble salt. In some embodiments, the at least one flocculating polymer is a polyacrylamide or copolymer thereof. The treated composition may have a polymer composition concentration of at least one flocculating polymer of not less than about 0.001% by weight, for example, not less than about 0.003% by weight, 0.005% by weight, 0 , 01% by weight or 0.04% by weight. In other embodiments, the composition is treated with coarse particles, for example, sand, in a ratio of sand to fine particles of less than 4: 1, for example, between about 2.5: 1.0 to about 0.5 : 1 or between about 2.25: 1 to about 0.75: 1. Advantageously, the flocculant polymer forms high-density flakes, for example, having a higher density than process water, which facilitates the separation and dewatering of the consolidated solids.

[0015] In various modalities, the treatment of the composition

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8/49 may include combining the composition with a solution including at least one highly water-soluble salt and at least one flocculating polymer. In some embodiments, treatment of the composition may include combining a flow of the composition, for example, tailings, with a flow of a solution including at least one highly water-soluble salt and a separate flow of a solution including the at least one flocculating polymer.

Alternatively, or in combination, O treatment gives composition can include the combination in one flow gives composition, per example, tailings, with one flow of an solution including both the , at least, one salt highly

water-soluble with at least one flocculating polymer. Coarse particles (e.g., sand) can also be added to the composition or flow of the same and / or to any or all of the solution flows. Advantageously, the flows can be mixed in-line and / or with the aid of an in-line mixer. In certain embodiments, treatment of the composition can be carried out at a temperature of not more than about 50 ° C, for example, not more than about 40 ° C or about 30 ° C. In other embodiments, treatment of the composition includes the use of a solution of one or more highly soluble salts from a natural or existing source, such as sea water or a body of hypersaline water.

[0016] In still other modalities, the process water can be separated from the consolidated material by any one or more of decantation, filtration, aspiration, gravity drainage, electrofiltration, etc. or combinations thereof. In several modalities, the separation of process water from the

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9/49 consolidated material may include the mechanical dewatering of the consolidated material, for example, the mechanical dewatering of the consolidated material by a dewatering screw. Once separated, the consolidated material can be transferred for further dewatering or disposal.

[0017] In practical aspects of the processes of the present invention and the various modalities thereof, the separate process water may include at least one highly water-soluble salt and the process may further comprise recovering at least a portion of the separate process water. In some embodiments, the process may further comprise recycling at least a portion of the separate process water recovered to treat additional waste. In other embodiments, the process may also include purifying at least a portion of the recovered process water.

[0018] Yet, another aspect of the present invention includes the recovery of valuable materials from the aqueous composition of fine particles, for example, tailings. Valuable materials may include rare earth elements (REE) associated with solids, such as clays in tailings of various types of fine aqueous particles, such as the flow of tailings. Therefore, in the practice of certain aspects of the processes of the present invention and the various modalities thereof, the aqueous compositions may further include materials from rare earth elements that can be recovered by treating the composition with at least one highly water-soluble salt. , for example, an ammonium based salt such as ammonium sulfate, to form a treated composition including REE in the process water and / or materials

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10/49 consolidated. In some embodiments, the process also includes separating process water from consolidated material and recovering the REE from separate process water and / or from consolidated materials.

[0019] Advantageously, the processes of the present invention can consolidate the solids of the composition to produce a consolidated material with a solids content in excess of about 45% by weight, for example, a solids content greater than about 50% and greater than about 60%, 65%, 70% and 75% by weight.

[0020] When practicing certain aspects of the processes of the present invention and the various modalities thereof, the consolidated material formed in the treated composition, according to certain modalities, can result in a high content of solids after mixing and / or dewatering the composition treated in a short period of time. In some embodiments, the consolidated material may have a solids content greater than about 50% and at least about 60%, 65%, 70%, 75% and 80% by weight after mixing and / or dewatering.

[0021] Another aspect of the present invention includes an aqueous solution for the treatment of aqueous fine particles. The aqueous solution includes a highly water-soluble ammonium-based salt and a flocculant polymer, for example, a water-soluble polymer. The embodiments include, together or individually, an aqueous solution of one or more salts highly soluble in water and having a concentration of not less than 1% by weight, for example, at least 2% by weight, 5% by weight, 10% by weight, 20% by weight, 30% by weight and even 40% by weight or as an aqueous salt slurry. The aqueous solution can also include one or more of the flocculating polymers and

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11/49 with a concentration of not less than about 0.005% by weight, for example, not less than about 0.01% by weight, 0.04% by weight, 0.05% by weight, 0.1 % by weight, 0.2% by weight, 0.4% by weight, for example.

[0022] Additional advantages of the present invention will become readily apparent to those skilled in the art from the following detailed description, in which only the preferred embodiment of the invention is shown and described, simply by way of illustration of the best way to carry out the invention. As will be noticed, the invention is capable of other and different modalities, and its various details are capable of modifications in several obvious aspects, all without departing from the invention. In this way, the drawings and the description should be considered as illustrative in nature and not as restrictive.

BRIEF DESCRIPTION OF THE DRAWINGS [0023] Reference is made to the accompanying drawings, in which the elements with the same numerical reference designations represent similar elements as a whole and in which:

Figure 1 schematically illustrates an exemplary embodiment of a process for consolidating an aqueous composition including fine particles and process water.

[0024] Figure 2 shows images of bottles containing waste coal slurry treated in accordance with an embodiment of the present invention. The images show coal slurry after adding an ionic solution (left), then centrifuging (medium) and after removing the supernatant solution (right).

[0025] Figure 3 shows images of the dewatered coal slurry in Figure 2 after removing the bottle

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12/49 (left) and subsequent manual pressing between paper towels.

[0026] Figure 4 shows images of flasks containing fine mature residues from processing bituminous sands treated with an ammonium saline solution, including a polyacrylamide flocculant in the concentrations indicated in the figure.

[0027] Figure 5 shows images of vials containing fine mature residues treated with an ammonium salt and a polyacrylamide flocculant and illustrates the effects of increasing the salt concentration and reducing the polymer concentration under the conditions tested.

[0028] Figure 6 shows an image of flasks containing fine mature residues from processing oil sands treated with sea water, which included varying amounts of a polyacrylamide flocculant.

DETAILED DESCRIPTION OF THE INVENTION [0029] The present invention relates to the treatment of aqueous composition including fine particles to consolidate and empty the composition. Aqueous fine particle compositions can be in the form of tailings, which are typically produced by mining and processing ores such as metallic ores, for example, aluminum, copper, zinc, lead, gold, silver, etc., phosphate ore, sands bituminous, etc. Aqueous compositions of fine particles can also be produced during coal processing. For example, certain processes finely grind coal before combustion to more readily release pyrite (a sulfur-based compound) and therefore reduce sulfur emissions after combustion of ground coal. Such processes

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13/49 can produce fine coal particles, as well as other fine mineral or mineral materials, in an aqueous composition, which are difficult to recapture and reuse.

[0030] The particulate solids in the aqueous compositions of the present invention can be mineral and mineral-type materials, that is, mineral matter, clays, crevices and in sizes ranging from fine particles to coarse solids. The term fines, as used here, is consistent with the Canadian tar sands classification system and means solid particles with sizes equal to or less than 44 microns (gm). Sand is considered to be solid particles larger than 44 μπι. The composition of the fine particles depends on the source of the materials, but generally the fine particles are composed mainly of mud and clay material and sometimes mineral or mineral materials, depending on the ore. Tailings can have varying solids content and varying amounts of fine particles as their solids content. Treated waste according to the modalities of the present invention can include a significant amount of fine particles by weight (> 5% by weight) as its solids content. Such tailings may include at least about 10% by weight, 20% by weight, 30% by weight, 40% by weight, 50% by weight, 60% by weight, 70% by weight or more fine particles such as its solids content.

[0031] Advantageously, the process of the present invention can consolidate solids from aqueous compositions including fine particles, for example, tailings, to produce consolidated material with a solids content in excess of about 45% by weight, for example, a content solids greater than about 70% by weight.

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14/49 [0032] The terms coagulation and flocculation are often used interchangeably in the literature. As used herein, however, coagulation means particle aggregation caused by the addition of hydrolyzing salts, while flocculation means particle aggregation induced by flocculating polymers. Hydrolyzing salts undergo hydrolysis when added to water to form metal hydroxides, which precipitate from the solution, trapping fine particles and other minerals in the coagulant mass. Hydrolyzing salts typically have low water solubility and are used as coagulants. Flocculation-induced aggregation, in contrast, is believed to be the result of binding the polymer to the particles, thus linking the particles together in the so-called flake, causing the aggregation of the particles.

[0033] In practical aspects of the present invention, an aqueous composition of fine particles and process water can be consolidated by treating the composition with one or more highly water-soluble salts or an aqueous solution thereof to destabilize and consolidate solids in the composition, for example example, to destabilize and consolidate fine particles in the composition. Aggregation induced by the addition of salts is believed to be the result of destabilizing the particles suspended in the fine particle by altering or protecting the surface electrical charge of the particles to reduce the repulsive forces of interparticues that prevent aggregation. In certain embodiments, the composition is discarded, for example, a suspension of particulate solids in an aqueous liquid that includes fine particles and process water such as flows

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15/49 of tailings from metal extraction or a coal slurry that includes fine coal particles and other materials. The process includes treating the composition with highly water-soluble salts or an aqueous solution thereof to form a treated composition including a consolidated material, for example, fine particles consolidated, in process water. The process water can then be separated from the consolidated material. Advantageously, the consolidated material has a solids content of at least 45% by weight, for example, a solids content greater than about 50% and greater than about 60%, 65%, 70% and 75% by weight.

[0034] Salts that are useful in the practice of the present invention include salts that are highly soluble in water. A highly water-soluble salt, as used herein, is one that has a water solubility of more than 2 g of salt per 100 g of water (ie a salt / water solubility of 2 g / 100 g) at 20 ° C. Preferably, the highly water-soluble salt has a water solubility of at least about 5 g / 100 g at 20 ° C, for example, at least about 10 g / 100 g of salt / water at 20 ° C .

[0035] In addition, the highly water-soluble salts used in the processes of the present invention are preferably non-hydrolysing. Hydrolyzing salts undergo hydrolysis when added to water to form metal hydroxides, which precipitate from the solution. These hydrolyzing salts are believed to form open flakes with a lower solids content and cannot be readily recycled for use with additional tailings in continuous or semi-continuous processes. In addition, hydrolyzing salts typically have low

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16/49 solubility in water and are used at high temperatures to ensure sufficient solubility for aggregation, which is an energy-intensive process. See US 4,225,433, which discloses the use of lime as a coagulation agent at a temperature of 75 ° C.

[0036] In addition, highly water-soluble salts are preferably non-carboxylated salts, since these salts of organic acids tend to be more expensive than inorganic salts and can be harmful to plant life and / or animal.

[0037] Highly water-soluble salts that are not hydrolyzers and useful in the practice of processes of the present invention include salts that have a monovalent cation, for example, alkali halide salts such as sodium chloride, potassium chloride; also salts with monovalent cations, such as sodium nitrate, potassium nitrate, sodium and potassium phosphates, sodium and potassium sulphates, etc. are useful in the practice of the processes of the present invention. Other monovalent cationic salts useful in the practice of the processes of the present invention include ammonium based salts such as ammonium acetate (NH4C2H3O2), ammonium chloride (NH4CI), ammonium bromide (NI ^ Br), ammonium carbonate ((NIULCOs) , ammonium bicarbonate (NH4HCO3), ammonium nitrate (NH4NO3), ammonium sulfate ((NIULSCú), ammonium hydrogen sulfate (NH4HSO4), ammonium dihydrogen phosphate (NH4H2PO4), ammonium hydrogen phosphate ((NH4) 2HPO4), ((NIULPCú), etc. Mixtures of such salts can also be used.

[0038] Ammonium-based salts are useful for the practice of the present invention, since residual salts based on

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17/49 ammonium in the consolidated material after combining salt with fine aqueous particles, for example, tailings, can be beneficial for plant life. In fact, many of the ammonium-based salts are useful as fertilizers, for example, ammonium chloride, ammonium nitrate, ammonium sulfate, etc. Many of the monovalent sulfate and phosphate salts are also useful as fertilizers. In certain embodiments of the present invention, the highly water-soluble salt or salts used in the processes of the present invention can preferably be non-toxic and beneficial to the life of the plant to aid in environmental remediation and restoration of mine sites.

[0039] In one aspect of the present invention, treatment of the compositions of the present invention with a highly water-soluble salt destabilizes and consolidates solids in the composition. Such a process may include mixing the composition, which includes fine particles and process water, with a highly water-soluble salt to consolidate the fine particles, and separating the process water from the consolidated fine particles to produce a high solids content, for example. example, at least 45% weight. In certain embodiments, the highly water-soluble salt is an ammonium-based salt.

[0040] The highly water-soluble salts that can be used in the practice of the present process can also include salts having multivalent cations. Such salts include, for example, divalent cation salts, such as calcium and magnesium cation salts, such as calcium chloride (CaC2), calcium bromide (CaBr2), calcium nitrate (Ca (NOs) 2), chloride magnesium (MgC2), magnesium bromide (MgBr2), magnesium nitrate (Mg (NOs) 2), magnesium sulfate

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18/49 (MgSCU); and trivalent cation salts, such as aluminum and iron (III) cation salts, for example, aluminum chloride (AICI3), aluminum nitrate (Al (NOs) 3), aluminum sulfate (AÍ2 (SC> 4) 3), iron (III) chloride (FeCls), iron (III) nitrate (Fe (NOs) 3), iron (III) sulfate (Fe2 (804) 3), etc. As explained above, the highly water-soluble salts used in the processes of the present invention are preferably non-hydrolysing. Many of the multivalent cation salts are hydrolysing and therefore less preferred for the reasons given above. In addition, experimentation with multivalent salts showed increased encrustation of containers and formation of less cohesive consolidated materials compared to highly water-soluble salts with monovalent cations. In addition, some multivalent salts, such as FeCls and Fe2 (804) 3, are particularly corrosive and Fe2 (804) 3 is formed from oxidizing pyrite and results in acid mine escape, which makes these salts less preferable for use in processes of the present invention.

[0041] When a sufficiently high concentration of highly water-soluble salt is included in the treated composition, the salt can destabilize and consolidate solids in the composition. During relatively short process times with a relatively low energy input, the concentration of the saline composition of at least one highly water-soluble salt should preferably be at least 0.5% by weight and preferably not less than about 1% by weight, such as at least 2% by weight and even at least about 3% by weight, 4% by weight, 5% by weight, etc. The term concentration of the saline composition as used herein refers to the concentration of highly salts

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19/49 water soluble in the treated aqueous fine particles, for example, tailings, and is determined by performing the percentage of the mass of highly water-soluble salts divided by the combined mass of the salts plus the fine particles and any water used to dilute the salts. For example, the combination of 1 part of undiluted (i.e., pure) salt to 99 parts of tailings by weight results in a concentration of the saline composition of 1% by weight. Alternatively, the treatment of tailings with an equal weight of a solution of 2% by weight of the salt also results in a concentration of the saline composition of 1% by weight in the treated tailings.

[0042] The highly water-soluble salts can be used to treat compositions of the present invention as a solid, for example, by combining the salt as a powder with the composition. Alternatively, the salt can be used to treat as a solution, for example, by combining an aqueous saline solution with the compositions. In some aspects of the present invention, an aqueous solution of the highly water-soluble salt can be prepared having a concentration of not less than about 1% by weight, for example, greater than about 2% by weight, 5% by weight, 10% by weight, 20% by weight, 30% by weight and even 40% by weight or as an aqueous salt slurry. The composition and saline solution or semi-fluid must be mixed in a ratio sufficient to destabilize the composition to cause the consolidation of the solids in it. In one aspect of the present invention, the composition and saline are mixed in a ratio between 5.0: 1.0 and 1.0: 5.0, for example, mixed in a ratio between 1.5: 1.0 and 1.0: 1.5 of the composition for saline.

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20/49 [0043] In some embodiments of the present processes, it may be more advantageous to use a natural source of highly soluble salt or salts, such as in a natural body of water including these salts in sufficiently high concentration, such as at least about 2% by weight and up to at least about 3% by weight or more. For example, sea or ocean water can be used as a source of highly soluble salts, which can significantly improve the process economy under certain conditions. The vast majority of seawater has a salinity between 31 g / kg and 38 g / kg, that is, 3.1-3.8%. On average, seawater in the world's oceans has a salinity of about 3.5% (35 g / L, 599 mM). Sea water includes a mixture of salts, containing not only sodium cations and chlorine anions (together totaling about 85% of the dissolved salts present), but also sulfate and calcium anions, potassium and magnesium cations. There are other ions present (such as bicarbonate), but these are the main components. Another natural source of highly soluble salts that can be used as a source of highly soluble salts includes a hypersaline body of water, for example, a lake, reservoir or hypersaline reservoir. A hypersaline body of water is a body of water that has a high concentration of sodium chloride and other highly soluble salts with saline levels that exceed ocean water, for example, greater than 3.8% by weight and typically greater than about 10% by weight. Such hypersaline bodies of water are located on the earth's surface and also on the subsurface, which can be brought to the surface as a result of ore mining operations.

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21/49 [0044] After treating the fine aqueous particles with at least one highly water-soluble salt, the solids in the composition can be consolidated, such as by mixing followed by gravity sedimentation in a settling tank or by centrifugation to increase the rate of formation of a material consolidated in the treated composition. The consolidated material can be separated from the process water by decanting, filtration, electrofiltration, cross-flow filtration, aspiration and / or by mechanical dewatering, that is, applying an external force to the consolidated material. Once separated, the consolidated material can be transferred for further dewatering or disposal.

[0045] Although highly water-soluble salts can destabilize and solidify the fine aqueous particles, it was found that the process could be significantly improved by the addition of one or more flocculating polymers. The addition of a flocculating polymer to the highly water-soluble salt significantly reduced the time for consolidation of the fine particles. In addition, the processes of the present invention can also include the treatment of aqueous fine particles with coarse particles, for example, particles larger than 44 pm, such as sand, to significantly increase the solids content. The mixture with sand is suitable for fine aqueous particles that have solids mainly as fine particles, since fine particles can accumulate in the voids between the coarse particles, increasing the packaging and content of the solids. However, it has been found that for certain compositions such as coal slurry, the addition of

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22/49 sand was not necessary to achieve a high solids content, as there were sufficient coarse particles present in the stream of fine aqueous particles to provide a material with a high solids content.

[0046] Thus, implementations of the process of the present invention include, for example, (i) treating the composition with at least one highly water-soluble salt to form a treated composition including a material consolidated in the process water, (ii ) treating the composition with at least one highly water-soluble salt and at least one flocculating polymer to form a treated composition including a material consolidated in the process water, (iii) treating the composition with at least one salt highly soluble in water and coarse particles to form a treated composition including a material consolidated in the process water, and (iv) treating the composition with at least one highly water-soluble salt, at least one flocculating polymer and coarse particles for form a treated composition including a material consolidated in the process water. Each of these implementations can include aqueous solutions of the salt and / or the flocculant polymer to treat the composition. Each of these implementations may include separating process water from consolidated material. Advantageously, the consolidated material has a higher density than process water. The process water can then be readily separated from the consolidated material, for example, by one or more settling, filtration, gravity drainage, electrofiltration, cross-flow filtration, aspiration and other evaporation techniques, etc. and / or by one or more of a device to

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23/49 the dewatering of consolidated material, such as centrifuge, settling centrifuge, dewatering screw, hydrocyclone, vacuum belt filter, filter press or pressing devices, etc. In addition, the separate consolidated material can be disposed of or deposited in a containment structure that allows the removal of water released from the consolidated material.

[0047] Polymers that are useful in the practice of the present invention include water-soluble flocculating polymers such as polyacrylamides or copolymers thereof such as nonionic polyacrylamide, an anionic polyacrylamide (APAM) such as a polyacrylamide-co-acrylic acid and a polyacrylamide cationic (CPAM) which may contain comonomers such as acryloxyethyltrimethylammonium chloride, methacryloxyethyltrimethylammonium chloride, dimethyldiallylammonium chloride (DMDAAC), etc. Other water-soluble flocculating polymers useful for practicing the present invention include a polyamine, such as a polyamine or quaternized form thereof, for example, polyacrylamide-codimethylaminoethylacrylate in quaternized form, a polyethyleneimine, a polydialldimethyl ammonium chloride, a polydiciandiamide, or its copolymers, a polyamide-co-amine, polyelectrolytes such as a sulfonated polystyrene can also be used. Other water-soluble polymers, such as polyethylene oxide and its copolymers, can also be used. Flocculating polymers can be synthesized in the form of a variety of molecular weights (MW), types of electrical charge and charge density to meet specific requirements. Advantageously, the flocculant polymer used in processes in the practice of this

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The invention does not include the use of activated polysaccharides or activated starches, that is, polysaccharides and starches that have been heat treated, in amounts sufficient to decrease the flake density to lower the process water density from which they are separated. . Such activated polysaccharides and activated starches when used in sufficiently high dosages tend to form low density flakes that rise to the surface of an aqueous composition, which can prevent the removal of solids in large scale operations involving high solids content and can also prevent the dewatering of consolidated material.

[0048] The amount of polymers used to treat fine aqueous particles should preferably be sufficient to flocculate the solids in the composition and any coarse particles added, for example, sand. The amount of polymers used to treat an aqueous composition that includes fine particles and processes such as tailings can be characterized as a concentration based on the total weight of the composition or as a dosage based on the weight percentage of the solids in the composition.

[0049] In some embodiments of the present invention, the

concentration of one or more polymers flocculants in treated composition have an concentration in polymer- composition no less of that about 0.001 % in weight, by example, not less than what fence of 0.003% in Weight, 0.005% in

weight or not less than about 0.01% by weight. For relatively short processing times, consolidation of the fine particle / sand mixture can be achieved at polymer-composition concentrations of not less than about 0.04% by weight. The term polymer concentration

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The composition as used herein refers to the concentration of the flocculating polymers in the treated composition and is determined by taking the percentage of the mass of the polymers divided by the combined mass of the polymers plus the composition and any water used to dissolve the polymers. For example, the combination of 1 part of undiluted (i.e., pure) polymer to 9999 parts of tailings by weight results in a polymer-composition concentration of 0.01% by weight. Alternatively, the treatment of tailings with an equal weight of a solution of 0.02% by weight of the polymer also results in a polymer-composition concentration of 0.01% by weight. In certain embodiments, the aqueous fine particles are treated with at least one flocculating polymer to produce a polymer-composition concentration of not less than about 0.02% by weight, such as not less than about 0, 03% by weight, 0.04% by weight, 0.05% by weight, and even at least about 0.07% by weight, 0.09% by weight, 0.1% by weight, 0.2 % by weight, etc. The amount of flocculant polymer can be used in higher concentrations. However, after certain high concentrations, it becomes difficult to dissolve the flocculant, the solution becomes very viscous and the process is less economical.

[0050] In some embodiments of the present invention, the concentration of one or more flocculant polymers in the treated composition, for example, tailings, has a dosage (weight of the flocculant for weight of the solids in the composition, for example).

example, tailings), not any less of what fence in 0.005% in weight, for example, of not any less of what fence in 0.01% in weight and preferably not any less of what fence in 0.015% in

weight, 0.020% by weight, 0.025% by weight, 0.03% by weight or 0.04%

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26/49 by weight.

[0051] The amount of flocculant polymer can be reduced if the concentration of the saline composition is increased. Although the reason for this effect is not clear, a very low polymeric composition concentration of not less than about 0.001% by weight, for example, not less than about 0.003% by weight, 0.005% by weight, 0, 01% by weight, 0.02% by weight, 0.03% by weight, 0.04% by weight, 0.05% by weight, for example, can achieve reasonably rapid consolidation of solids in the composition, for example, tailings if the concentration of the saline composition is increased.

[0052] Coarse particles useful for the practice of certain processes, according to the present invention, are preferably sand and when used in the treatment of compositions the amount of such particles is preferably in a sand-to-particle ratio fines (SFR ratio) less than 4: 1, for example, between about 2.5: 1.0 and about 0.5: 1 or between about 2.25: 1 and about 0.75: 1 . The SFR ratio is calculated by determining the amount of sand added to an estimated amount of solid fine particles in the aqueous fine particles based on weight. It is believed that the use of coarse particles facilitates the packaging of the consolidated fine particles which advantageously increases the solids content and may even form a congested structure of consolidated solids, that is, a structure in which individual particles of the consolidated solid generally can no longer move freely to other particles.

[0053] The treatment of an aqueous composition including

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27/49 fine particles and process water, for example, tailings, with at least one highly water-soluble salt and optionally with one or both of at least one flocculating polymer and / or optionally sand can be carried out in a number of ways. In certain embodiments, treatment of the composition includes combining and / or mixing the various components. In addition, at least one salt can be added directly to the composition as an undiluted powdered solid or as a solution; the at least one flocculant polymer can be added directly to the composition as an undiluted material or as a solution, and the sand can be added to the composition directly or with the salt and / or polymer or solutions thereof. The salt and the polymer can be combined in a single solution, with or without sand, and combined with the composition. The order of combining salt, polymer and sand to the composition can provide equivalent results and the optimization of the process will depend on the type of composition and the scale and equipment used in the process.

[0054] However, it tends to be more convenient to prepare one or more solutions first, including one or more highly water-soluble salts and one or more flocculant polymers followed by the combination of one or more solutions with the composition and sand. In certain embodiments, an aqueous solution of one or more highly water-soluble salts can be prepared having a concentration of not less than about 0.5% by weight or 1% by weight, for example, at least 2% by weight, 3% by weight, 4% by weight, 5% by weight, 6% by weight, 7% by weight, 10% by weight, 20% by weight, 30% by weight and even 40% by weight or as a slurry of aqueous salt for use in the treatment of the composition. The one or more flocculating polymers

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28/49 may also be included in the aqueous salt solution and may have a concentration of not less than about 0.005% by weight, for example, not less than about 0.01% by weight, 0.04% by weight. weight, 0.05% by weight, 0.1% by weight, 0.2% by weight, 0.4% by weight, for example. The aqueous solution of the highly water-soluble salt and the flocculating polymer can be used to treat the composition and can be combined with such compositions in a ratio of 5.0: 1.0 to 1.0: 5.0, for example, at a ratio of 1.5: 1.0 to 1.0: 1.5 of the composition for aqueous solution. The sand can be combined with the composition before, during or after combining the composition with the solutions.

[0055] Since highly water-soluble salts and flocculating polymers are preferably water-soluble are used in the process of the present invention, the temperature of the treated aqueous fine particles need not be raised above room temperature to practice the process . In certain embodiments, the treatment of the composition according to the various embodiments of the present invention can be carried out at a temperature of not more than about 50 ° C, for example, not more than about 40 ° C or about 30 ° Ç. In other modalities, such as tar sands, consolidation of foam tailings, the tailings flow may already be warm or hot as a result of previous processing. The processes of the present invention can be applied directly to these waste streams.

[0056] In practical aspects of the present invention, compositions, for example, a suspension of particulate solids in an aqueous liquid that includes fine particles and process water, can be consolidated by treating such compositions with at least one highly soluble salt in

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29/49 water or aqueous solutions thereof and may optionally include one or both of at least one flocculating polymer, for example, a water-soluble flocculating polymer, or aqueous solutions thereof, and / or optionally coarse particles, for example , sand to form a treated composition. The treatment of compositions, for example, tailings, in this way, can cause destabilization and consolidation of solids, for example, fine particles and sand, in the composition treated to form a consolidated material, which can settle under gravity relatively quickly, in the water of process.

[0057] Treated compositions and / or consolidated material can be further dewatered to further separate process water from consolidated material and, in some cases, further consolidate solids. In some embodiments, the consolidated material formed in the treated compositions can be separated from the process water by any one or more of decantation, filtration, for example, electrofiltration, cross flow filtration, gravity drainage, aspiration and other evaporation techniques, etc. . and / or by any one or more of a mechanical dewatering, that is, applying an external force to the consolidated material, with a device for dewatering the consolidated material, such as applying a centrifuge, settling centrifuge, dewatering screw, hydrocyclone, press filters, pressing devices, etc. or combinations thereof. In one aspect of the processes of the present invention, process water can be separated from the consolidated material by passing a stream of the treated composition through a cross-flow filter, for example, a porous or grooved tube, which filters

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30/49 and dehumidifies the flow of treated composition to separate process water from consolidated material. The process water can then be easily separated from the consolidated material. In another aspect of the processes of the present invention, process water can be separated from the consolidated material by draining gravity to achieve a solids content of at least about 70% within about one month after treatment of the tailings, for example. example, within about two weeks or within about a week after draining gravity after treatment of the tailings. In yet another aspect of the processes of the present invention, the consolidated material can be further dehydrated after separation of the treated composition by depositing the separated consolidated material in a fine elevation deposition.

[0058] The consolidated material formed in the treated compositions can advantageously have a high solids content, for example, a solids content greater than about 50% and at least about 60%, 65%, 70% and 75% in weight. In addition, the consolidated material formed in the treated compositions, according to certain modalities, can result in a high solids content after mixing and / or dewatering the treated compositions in a short period. In embodiments of the present invention, the consolidated material can have a solids content greater than about 50% and at least about 60%, 65%, 70%, 75% and 80% by weight after mixing and / or dewatering . In certain embodiments, a solids content of at least about 70% is obtained within a month of gravity drainage after treatment of the composition, for example, within about two weeks or within about a week. gravity drainage after treatment of the composition.

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[0059] In one embodiment of the present invention, the process includes mixing the composition with a highly water-soluble salt, for example, an ammonium-based salt, a water-soluble polymer, for example, a polyacrylamide and optionally sand, such as sand for fine particle ratio between about 2.25: 1 to about 0.75: 1 to form a treated composition including a consolidated material with a high solids content, for example, a solids greater than about 50% by weight, for example, at least about 60%, 65%, 70% by weight or more in less than 10 minutes, depending on the dewatering method used.

[0060] Another advantage of the processes of the present invention is the recovery of waste materials that include rare earth elements. For example, certain tailings can include valuable minerals that include rare earth elements. A rare earth element (REE), as defined by IUPAC, is a set of seventeen chemical elements in the periodic table, specifically the fifteen lanthanides, in addition to scandium and yttrium. Scandium and yttrium are considered rare earth elements because they tend to occur in the same ore deposits as lanthanides and exhibit similar chemical properties. Many of the REE are used in electronic devices, magnets, high performance coatings. Such REE include cerium (Ce), dysprosium (Dy), erbium (Er), europium (Eu), gadolinium (Gd), holmium (Ho), lanthanum (La), lutetium (Lu), neodymium (Nd), praseodymium ( Pr), Promethium (Pm), Samarium (Sm), Scandium (Sc), Terbium (Tb), Thulium (Tm), Ytterbium (Yb) and Yttrium (Y).

[0061] WEE in fine aqueous particles are

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32/49 typically in the form of an ion or oxide. For example, zirconium may be present as zirconium, ZrSiCú, titanium may be present as the minerals ilmenite, leukoxen and rutile. Coal ash and coal cleaning residues contain rare earth elements. The coal ash from the fire clay has extraordinarily high concentrations of yttrium and zirconium. Tar sands tailings also contain REE.

[0062] The processes of the present invention are useful in the recovery of REE. In some tailings, REEs are believed to absorb the clay surface in the tailings. In other tailings, REEs are predominantly included among the tailings solids, but they can also be in the process water. The absorbed REEs can be exchanged with the highly water-soluble salts of the present invention, for example, ammonium-based salts due to an exchange of ammonium ions for REE ions. REEs from tailings solids can be obtained by leaching the solids with acid followed by extraction and precipitation or by caustic decomposition followed by acid leaching.

[0063] Another aspect of the processes of the present invention includes the consolidation of an aqueous composition including fine particles and process water, for example, tailings, which include REE materials by treating the composition with at least one highly water-soluble salt. , for example, an ammonium-based salt such as ammonium sulfate, to form a treated composition including a material consolidated in the process water that includes the REE materials in the process water and / or among the consolidated materials. In one aspect of the present invention, the treated composition

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33/49 consolidates fine particles and also separates REE materials from solids and process water. The process water can then be separated from the consolidated material and the REE materials can be recovered from the separate process water. REE materials can be recovered from the process water by precipitation, for example, using oxalic acid, or extraction. Other methods for recovering REE from process water include mineral processing and physical processing, extraction of deep eutectic solvents / ionic liquids, acid dissolution, high temperature phase separations, use of selective REE absorbents, photophoresis, injection and brine extraction in -situ, reactive grinding, etc. In another aspect of the present invention, the treated composition consolidates the fine particles and the REEs are among the consolidated materials. The process water can then be separated from the consolidated material. The consolidated material can then be leached with acid, for example, nitric acid, sulfuric acid, etc., followed by extraction with solvent and / or ion exchange resins and precipitate. Alternatively, the consolidated material can then be treated with a caustic reagent, such as sodium hydroxide, to decompose some of the materials to form hydroxides from the REEs, followed by acid leaching, for example, HCl.

[0064] In addition, the composition that includes REE materials can be treated with at least one flocculating polymer and optionally sand to form the treated composition. The treated composition may have a concentration of the saline composition of at least 0.5% by weight of at least one highly water-soluble salt, and preferably not less than

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34/49 than about 1% by weight, such as at least about 2% by weight and even greater than about 3% by weight, 4% by weight, 5% by weight, etc. of at least one highly water-soluble salt.

[0065] The process of the present invention allows large-scale treatment of fine aqueous particles in a continuous or semi-continuous process with subsequent recovery, recycling and purification of at least a portion of the process water in the fine aqueous particles and, optionally, recovery of REE materials. When not hydrolyzed, highly water-soluble salts are used in the processes of the present invention, process water separated from an initially treated composition can advantageously include a significant amount of one or more highly water-soluble salts initially used to treat the composition. In certain embodiments, the separate process water includes at least one highly water-soluble salt and the process includes recovering at least a portion of the separate process water; recycling at least a portion of the separate process water recovered to treat additional aqueous fine particles; and / or purify at least a portion of the recovered process water. In other embodiments, the separate process water includes salt from REE materials and the process further includes recovering at least a portion of the separate process water; recycle at least a portion of the recovered separate process water to treat fine particles

additional aqueous; recover the materials in REE and / or purify at least one portion of water in process recovered. [0066] Figure 1 illustrates schematically such process

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Exemplary continuous or semi-continuous 35/49. As shown in the figure, aqueous compositions including fine particles and process water are treated with one or more highly water-soluble salts, and optionally one or more flocculating polymers and optionally coarse particles (sand) combining a flow of salt (101a), which it can be an aqueous solution with a flow of the composition (103a). For this embodiment, the composition is a waste composition, but other fine aqueous compositions can be processed in the same way. Optionally, the composition can also be treated with one or more flocculating polymers by combining a flow of the flocculants (102a), which can be as an aqueous solution, with the composition flow (103a). Alternatively, the salts and flocculant can be combined together as a solution to treat the waste as a stream of it. Coarse particles (sand) can also be added to the composition or flow of the same and / or to any or all flows of the solution.

[0067] The fluxes of the salts and polymers solution can come from the retention reservoirs 101 and 102 and the flows of fine aqueous particles and sand can come from the retention reservoirs 103 and 105, respectively. Alternatively, the tailings may come from an oil sands extraction operation.

[0068] For this modality, the salt flow (101a) and polymer (102a) and tailings flow (103a) are transported to the mixing device 107, where a sand flow (105a) is added and the combination mixed. The mixing device 107 can be an in-line mixer, a mixing tank

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36/49 mixing, ribbon mixer or other mixing device that can mix streams 101a, 102a, 103a and 105a. For this modality, the fine aqueous particles are combined with the salts and polymers as solutions followed by the addition of sand to treat the fine aqueous particles. However, the order can be changed, for example, the sand can be combined with the fine aqueous particles (105b) followed by mixing with the salt and polymer solutions. Sand can be added as a wet or dry stream. In some embodiments, the combination of flows in a line can cause sufficient mixing to eliminate the need for a separate mixing device, for example, in-line mixing, and the combined flows can be transported directly to a mechanical dewatering device to separate the consolidated material from the process water and, in some cases, to further consolidate the solids in the consolidated material.

[0069] As shown in the embodiment of Figure 1, after the mixer 107, the treated aqueous fine particles, which include a consolidated material and process water, are transferred to the dewatering device 109 to separate the process water from the consolidated material. Such dewatering devices include, for example, one or more devices for settling, filtration, electrofiltration, cross-flow filtration, gravity or suction drainage or combination thereof and / or for one or more devices for dewatering consolidated materials, such as centrifuge, settling centrifuge, dewatering screw, hydrocyclone, vacuum belt filter, filter press or pressing devices, etc. or

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37/49 combinations thereof.

[0070] Separate process water can be recovered and collected in reservoir 111 and separate consolidated material can be recovered and collected in container 113. For this modality, the process water recovered in reservoir 111 includes the process water of fine aqueous particles, for example, tailings, diluted with flow 101a and thus includes residual salts of one or more highly water-soluble salts and may possibly include residual polymers of one or more flocculating polymers, as well as contaminants of the fine aqueous particles. If the fine aqueous particles include REE materials, the process water recovered in reservoir 111 and / or the material consolidated in 113 can also include REE materials. There are also highly water-soluble salts that are constituents of the original aqueous fine particles and these become part of the recovered process water. The process water recovered in reservoir 111 can then be transferred to a water purification system 115 to purify at least a portion of the recovered process water which is transferred to reservoir 117. Water purification systems that can be used for modalities of the processes of the present disclosure include reverse osmosis systems, vacuum distillation systems, electrodialysis, filtration systems, etc. The remaining unpurified, recovered process water is transferred to reservoir 119 to recover the process water including one or more highly water-soluble salts and highly water-soluble salts that are constituents of the original aqueous fine particles. This recovered, unpurified, remaining process water can be recycled

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38/49 returns to the treatment process. For this modality, at least a portion of the recovered, non-purified process water can be recycled back to the retention reservoir 101 and the deficiency in the concentration of salts or polymers can be corrected by adding additional water-soluble salts or flocculating polymers from one or more replacement reservoirs, such as replacement containers 121 and 122.

[0071] The process of the present invention may also include recovering REE materials from separate recycled process water or consolidated solids. REE materials can be recovered from the process water by precipitation, for example, using oxalic acid or extraction. Other methods for recovering REE from process water include mineral processing and physical processing, extraction of deep eutectic solvents / ionic liquids, acid dissolution, high temperature phase separations, use of selective REE absorbents, photophoresis, injection and brine extraction in -situ, reactive grinding, etc. The process of the present invention can also include recovering REE materials from consolidated solids by acid leaching or caustic decomposition.

[0072] The process of the present invention can include the addition of an organic solvent (for example, naphtha, kerosene or a C5-8 hydrocarbon, such as pentane, hexane, heptane, benzene, toluene, etc. or mixtures thereof) dilute the organic material included with the fine aqueous particles, for example, tailings such as residual hydrocarbons, organic solvents, oil, bitumen. The addition of an organic solvent forms an organic mixture with the organic material

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39/49 that can be removed.

[0073] In addition, consolidated solids can be recovered. The recovered consolidated solids may include highly water-soluble residual salt (s) from waste treatment. When the salt used in the treatment of tailings is beneficial for the life of the plant, such as ammonium-based salt or sulfate-based salt or phosphate-based salt, the residual salt can act as a fertilizer with the consolidated solids. The recovered consolidated solids may include REE materials that can be separated from the consolidated solids, as explained elsewhere.

EXAMPLES [0074] The following examples are intended to further illustrate certain preferred embodiments of the invention and are not limiting in nature. Those skilled in the art will recognize, or be able to determine, using no more than routine experimentation, numerous equivalents to the specific substances and procedures described herein.

Coal Ash Slurry Consolidation [0075] An initial sample of a coal ash slurry was analyzed by infrared spectroscopy to determine the solids content. In addition, the sample was estimated to have 30% or more fine coal particles present, i.e., a mixture of fine coal particles and fine mineral particles. Approximately 5 g of the coal slurry was placed in a flask and an equal weight of an aqueous ionic solution was added and the diluted slurry was stirred to mix the components. The ionic liquid was composed of water, 10% by weight of ammonium sulfate and 0.1% by weight of polyacrylamide

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40/49 (PAM). The settlement started immediately, as can be seen in the figure on the left in Figure 2. The flask was then centrifuged for 30 seconds at 3000 rpm and the particles consolidated into a compact mass, as shown in the figure in the center of Figure 2. The supernatant liquid appeared clear, with no visible suspended particles. After removing the liquid, it was found that the compacted solids have sufficient cohesive strength to maintain their shape when the flask was inverted, as can be seen in the figure on the right in Figure 2.

[0076] The material was removed from the bottle (Figure 3, left) and a portion was dried. The consolidated material had an initial solids content of 54%. Part of the rest was pressed (by hand) between paper towels (Figure 3, right). This pressed material had a solids content of 74%.

Variation of Salt and Salt Concentration in the Treatment of Bituminous Sand Tailings [0077] Additional experiments were carried out with various salts highly soluble in water and in different concentrations and with and without sand to treat bituminous sand tailings. A number of saline / polymer solutions were prepared. All saline / polymer solutions included 0.1% by weight of polyacrylamide (PAM) but the type and concentration of the salt varied. For example, a series of calcium chloride solutions of 10% by weight, 5% by weight and 2% by weight, each with 0.1% by weight of PAM, was prepared and used to treat MFT. Other saline solutions of 10% by weight, 5% by weight and 2% by weight of ammonium sulfate, potassium chloride, etc. were prepared, each, with 0.1% by weight

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41/49 of PAM. An equal weight of a particular saline / polymer solution was then combined with MFT, with or without sand, in a flask followed by vigorous mixing. The vials were then centrifuged at 3000 rpm in a LW Scientific laboratory centrifuge for 30 seconds to form a consolidated material in the form of a slurry. After centrifugation, the supernatant liquid was separated from the consolidated material by a pipette. The consolidated material was then weighed, dried and weighed again to determine a solid content of the consolidated material. The various salts and their concentrations that were used to treat MFT and the resulting solids content data are summarized in Tables 1 and 2 below.

Table 1: Content of MFT solids treated with an equal weight of a saline / PAM solution without the addition of sand and after centrifugation.

salt (+ 0.1% by weight of MAP) Without sand 10% Concentration ¹ 5% Concentration ² 2% Concentration ³ Ferric chloride (FeCla) 34.9% - 35.6% Aluminum sulphate (AÍ2 (S0 ₄ ) 3) 33, 1% - 34.1% Calcium chloride (CaCÍ2> 36, 8% 37, 1% 35.8% Ammonium sulfate (NH4SO4) 33, 1% 31, 8% 31.4% Potassium chloride (KC1) 35.4% 32, 4% 33.5%

Table 2: Content of MFT solids treated with an equal weight of saline / PAM with the addition of sand (ratio of

SFR 1: 1) after centrifugation.

salt (+ 0.1% by weight of MAP) With sand 10% Concentration ¹ 5% Concentration ² 2% Concentration ³ Chloride 45.7% - 52.8%

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42/49

ferric (FeCl ₃ ) Aluminum sulfate (Alz (S0 ₄ ) 3) 51.4% - 53.7% Calcium chloride (CaCl ₂ ) 58% 56.8% 56, 1% Ammonium sulfate (NH4SO4) 53.6% 52.3% 53.5% Potassium chloride (KC1) 53.4% 52.5% 53.9%

of salt tailings was about 5%

1. Concentration by weight.

2. The concentration of salt tailings was about 2.5% by weight.

3. The concentration of salt tailings was about 1% by weight.

[0078] Table 1 reports the solid content of the consolidated dry material after the treatment of MFT with the various salt solutions / polymer without sand. After centrifugation for only 30 seconds, the highly water-soluble salts provided solid contents for the consolidated materials in a range between about 31% - 37%. However, the use of highly water-soluble salts with a multivalent cation, such as aluminum and ferric cations, appeared to cause clogging of the flask walls and provided a less cohesive consolidated material compared to highly water-soluble salts with a monovalent cation under the conditions tested. In some tests using 10% salt concentrations, the clarified water over the top of the consolidated materials was removed using a pipette and the wet solids pressed between paper towels. It was found that salts with multivalent cations, aluminum chloride (AICI3), ferric chloride

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43/49 (FeCls) and calcium chloride (CaCl ₂ ), which provided significant deposits of viscous material on the walls of the flask, were less cohesive than the pressed solids obtained using salts with monovalent cations, such as NH ₄ ammonium salts C1 and (NH ₄ ) ₂ SO ₄ .

[0079] Table 2 reports the solid content of consolidated dry material after the treatment of MFT with the various saline / polymer solutions and sand. Sand with a 1: 1 sand to fine particle ratio (that is, 1.5 g of sand was added to 5 g of MFT with 30% solids to provide a 1: 1 ratio of the weight of the sand to that of solids in the MFT). After centrifugation for only 30 seconds, the highly water-soluble salts provided solids content for the consolidated materials in a range between about 46% -58%, which was significantly greater than the range of solids without using sand . Although the solids content of flasks containing added sand is double those without sand, the volume of the centrifuged slurry is approximately the same.

[0080] The data in Tables 1 and 2 show that the addition of 2% by weight saline to treat MFT was as effective as a 10% by weight saline. That is, a concentration of salt rejects at 1% by weight was as effective as a concentration of salt rejects at 5% by weight. Since an equal weight of the saline / polymer was used to treat MFT, the salt concentration of the added salt in the treated wastes is half that of the saline / polymer, that is, the added 2% by weight saline provided a concentration of salt wastes of 1% by weight and the saline solution of 10% by weight provided

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44/49 a salt wastes concentration of 5% by weight. The concentration of salt tailings in the treated MFT can be achieved in several ways. To facilitate handling in previous flask tests, it was convenient to combine equal weights of saline / polymer solutions for MFT. However, smaller amounts of saline / polymer solutions with higher concentrations of them provided the same concentration of salt tailings providing equivalent results for consolidated materials.

[0081] Centrifugation in flat bottom flasks is not as effective in terms of producing a material with a high solids content as using centrifuge tubes. It should be borne in mind that, for all sets of laboratory flasks and test tubes, there is always solution remaining in the voids between the particles. It will be shown later that the solid content of the consolidated material can be easily increased from the range of 46% -58% by simple drainage or the use of mechanical dewatering methods known in the art, such as filter presses, belt filters, filtration cross flow, sand dewatering screws, settling centrifuges, hydrocyclones, etc.

Variation of Salt Concentration and Polymer Concentration in the Treatment of Bituminous Sand Tailings [0082] When salt, polymer and sand are used together, salt tailings concentrations in excess of 0.5% by weight and, preferably, not less than about 1% should be used to achieve reasonably rapid consolidation of the solids in the tailings. In addition, although a degree of consolidation of the fine particle / sand mixture is obtained at

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45/49 polymers as low as 0.01% by weight for relatively short processing times, superior results are obtained at polymer tailings concentrations of 0.05% and higher. These preferences were determined by a set of flask experiments. The upper set of flasks in Figure 4 shows the results obtained by adding 5 g of a 2% by weight ammonium sulfate solution ((NH4) 2SC> 4) containing PAM to 5 g of MFT. The sand was also added to provide a fine particle sand ratio of 1: 1 (i.e., 1.5 g of sand was added). The amount of PAM in the solutions was varied between 0.1% (by weight) and 0.02% (by weight). The bottom set of vials shows what is observed when 1% by weight of ammonium sulphate was used. The vials were centrifuged at 3000 rpm for 30 seconds to accelerate sedimentation.

[0083] It can be seen that for all vials treated with 1% by weight (NH4) 2SO4 solutions there is a degree of sedimentation of fine particles and sand, but the supernatant liquid contains a significant amount of suspended particles. In addition, visually there appears to be a degree of segregation of sand and fine particles. In contrast, the MFT treated with a solution of (NH4) 2SO4 at 2% by weight containing 0.1% by weight of PAM showed solids settled and compacted in contact with a clear supernatant. As the amount of polymer in the solution is reduced from bottle A4 to E4, the clarity of the supernatant decreases as more suspended particles remain in the liquid phase. Greater clarity of the supernatant liquid should be achieved in longer centrifugation times, but for short processing times, MFT treatment

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46/49 to result in a salt tailing concentration of not less than about 0.5% by weight and a polymer tailing concentration of not less than about 0.04% by weight is preferable.

[0084] The solid content of the consolidated materials in each of the flasks shown in Figure 4 was determined by drying, that is, the consolidated, centrifuged material was separated from its supernatant liquid, the wet mass was weighed, dried and weighed again to determine a solids content. The solids content of the consolidated materials for the bottle sets is summarized in Table 3.

Table 3: The solids content of the MFT treated with centrifuged ammonium sulfate / PAM, as determined by separation and drying of the consolidated material.

0.1% of WFP % solids 0.08% of WFP % solids 0.06% of WFP % solids 0.04% of WFP % solids 0.02% of WFP % solids 2% 60.3% 58.8% 58.1% 52, 0% 48.5% (NH ₄ ) ₂ SO ₄ 1% 54.4% 57.2% 58.1% 56.3% 44.6% (NH4) 2SO4

[0085] It can be seen that for the solution of (NH4) 2SC> 4 to 2% by weight containing 0.1% by weight of PAM, a solids content of just over 60% was achieved. This decreased only slightly when treating MFT with solutions including PAM concentrations of 0.08% by weight and 0.06% by weight, but significantly in lower concentrated PAM solutions. The treatment of MFT with an equal weight of (NH ₄ ) 2SC> 4 / polymer solutions resulted in a concentration of salt rejects of about 1% by weight for each of the A4-E4 flasks, and for the A4 flask, a concentration of polymer waste of about 0.05% by weight of PAM, for bottle B4 a concentration of polymer residues of about

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47/49 of 0.04% by weight of PAM, for bottle C4 a concentration of polymer tailings of about 0.03% by weight of PAM, for bottle D4 a concentration of polymer tailings of about 0, 02% by weight of PAM, and for flask E4 a concentration of polymer waste of about 0.01% of PAM. For the solutions of (NHéUSCU of 1% by weight, the solids content was very variable, reflecting the problems with the segregation of coarse and fine particles in the materials consolidated in these experiments.

Increased Salt Concentration Enables Less Polymer Concentration [0086] When salt, polymer and sand are used together to treat tailings, it has been observed that the concentration of polymer tailings can be reduced if the concentration of salt tailings is increased under certain circumstances. Thus, a very low concentration of polymer tailings can achieve reasonably rapid consolidation of solids in the tailings if the concentration of salt tailings is increased. Figure 5 illustrates that as the salt concentration increases, less flocculant polymer is needed to obtain clear supernatant solutions. For these tests, the concentration of polymer tailings increases from 0.01% to 0.05% in increments of 0.01% from right to left while the concentration of salt tailings increases from 1% to 2% from top to bottom. low.

Variation of Polymer Concentration in the Treatment of Bituminous Sand Tailings with Seawater [0087] For these experiments, seawater solutions (from the eastern US coast of the Atlantic Ocean)

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48/49 were prepared with various concentrations of a nonionic polyacrylamide (available from SNF as FA920) between 0.1% (by weight) and 0.02% (by weight). The concentration of highly soluble salts in sea water is believed to be greater than 3% by weight. Seawater polymer solutions were used to treat MFT from oil sands processing. An equal amount of the seawater - polymer solution was used to treat MFT (about 5 g of seawater - polymer solution to about 5 g of MFT) in a bottle. The treated mixtures were first stirred and then the flasks were centrifuged at 3000 rpm for 30 seconds to accelerate sedimentation. The results are shown in the figure in Figure 6. From left to right, the seawater used to treat MFT included about 0.1% by weight, 0.08% by weight, 0.06% by weight, 0, 04% by weight and 0.02% by weight of the flocculant polymer, respectively. These experiments show that a mixture of highly soluble salts from an ocean can be used in the process of the present invention.

[0088] Only the preferred embodiment of the present invention and examples of its versatility are shown and described in the present disclosure. It is to be understood that the present invention is capable of being used in various other combinations and environments and is capable of alterations or modifications within the scope of the inventive concept as expressed herein. Thus, for example, those skilled in the art will recognize, or be able to determine, using no more than routine experimentation, numerous equivalents to the specific substances, procedures and provisions described herein. Such equivalents are considered within the

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49/49 scope of this invention, and are covered by the following claims.

Claims (6)

1. Process of consolidation of an aqueous composition that includes fine particles and process water, the process characterized by the fact that it comprises: treating the composition with at least a highly water-soluble salt to form a treated composition including a material consolidated in the process water; and separating process water from consolidated material. 2. Process of consolidation of an aqueous composition that includes fine particles and process water, the process characterized by the fact that it comprises: treating the composition with at least a highly water-soluble salt and at least one flocculating polymer to form a treated composition including a material consolidated in the process water; and separating process water from consolidated material. 3. Process of consolidation of an aqueous composition that includes fine particles and process water, the process characterized by the fact that it comprises: treating the composition with at least a highly water-soluble salt and coarse particles to form a treated composition including a material consolidated in the process water; and separating process water from consolidated material. 4. Process of consolidation of an aqueous composition that includes fine particles and process water, the process characterized by the fact that it comprises: treating the composition with at least one highly water-soluble salt, at least one flocculating polymer and coarse particles to form a treated composition Petition 870190072623, of 7/29/2019, p. 124/130 2/6 including material consolidated in the process water; and separating process water from consolidated material. Process according to any one of claims 1 to characterized by the fact that the composition is discarded. 6. Process according to any one of claims 1 to 4, characterized in that the at least one highly water-soluble salt is a non-hydrolyzing salt. Process according to any one of claims 1 to 4, characterized in that the at least one highly water-soluble salt has a water solubility greater than 10 g / 100 g at 20 ° C. Process according to any one of claims 1 to 4, characterized in that the at least one highly water-soluble salt has a monovalent cation. 9. Process according to any one of claims 1 to 4, characterized in that the treated composition has a concentration of the saline composition of at least one highly water-soluble salt of at least 0.5% by weight. Process according to any one of claims 1 to 4, characterized in that the at least one highly water-soluble salt is an ammonium-based salt. 11. Process according to claim 10 characterized by the fact that the ammonium-based salt is selected from ammonium chloride ammonium bromide ammonium carbonate, ammonium bicarbonate, nitrate Petition 870190072623, of 7/29/2019, p. 125/130 3/6 ammonium, ammonium sulfate, ammonium phosphate or a combination thereof. Process according to claim 2 or 4, characterized by the fact that the at least one flocculating polymer is a polyacrylamide or copolymer thereof. Process according to claim 2 or 4, characterized in that the treated composition has a polymer-composition concentration of at least one flocculating polymer of not less than about 0.04% by weight. 14. Process according to claim 3 or 4, characterized in that the composition is treated with sand in a ratio between sand and fine particles between 2.5: 1.0 and 0.5: 1. Process according to any one of claims 1 to 4, characterized in that the treatment of the composition includes combining a flow of the composition with a flow of an aqueous solution including at least one highly soluble salt in water to produce a flow of the treated composition. 16. Process according to claim 2 or 4, characterized in that the treatment of the composition includes combining a flow of the composition with a solution including at least one highly water-soluble salt and at least , a flocculating polymer to produce a flow of the treated composition. 17. Process according to claim 2 or 4, characterized in that the treatment of the composition includes combining a flow of the composition with a flow of an aqueous solution including at least one highly water-soluble salt and a flow of an aqueous solution Petition 870190072623, of 7/29/2019, p. 126/130 4/6 including at least one flocculating polymer to produce a flow of the treated composition. 18. Process according to claim 4, characterized in that the treatment of the composition includes combining a flow of the composition with a flow of an aqueous solution including at least one highly water-soluble salt and a flow of an aqueous solution including at least one flocculating polymer and adding sand to the composition and / or at least one of the streams to produce a stream of the treated composition. 19. Process according to claim 15, characterized in that the flows are mixed in line and optionally with an in-line mixer to produce the flow of the treated composition. 20. Process according to claim 15, characterized by the fact that the flow of the treated composition is passed through a cross flow filter to separate the process water from the consolidated material. 21. Process according to any one of claims 1 to 4, characterized by the fact that it comprises the separation of process water from the consolidated material by any one or more of decantation, filtration, aspiration, gravity drainage, or combinations thereof . 22. Process according to any one of claims 1 to 4, characterized by the fact that the separation of process water from the consolidated material includes the mechanical dewatering of the consolidated material. 23. Process according to any one of claims 1 to 4, characterized by the fact that the Petition 870190072623, of 7/29/2019, p. 127/130 5/6 separation of process water from the consolidated material includes gravity drainage to further dehydrate the consolidated material. 24. Process according to any of claims 1 to 4, characterized in that the consolidated material has a solids content of at least 45% by weight. 25. Process according to any one of claims 1 to 4, characterized in that it further comprises recovering at least a portion of the separate process water. 26. Process according to claim 25, characterized in that it further comprises recycling at least a portion of the separate process water recovered to treat additional compositions. 27. Process according to claim 25, characterized by the fact that it still comprises the purification of at least a portion of the recovered process water. 28. Process according to any one of claims 1 to 4, characterized in that the composition includes rare earth elements (REE) and the treatment of the composition with at least one highly water-soluble salt forms a composition treated including REE in process water and / or consolidated material. 29. Process, according to claim 28, characterized by the fact that it still comprises the separation of process water from the consolidated material; and REE recovery from separate process water. 30. Process, according to claim 28, characterized by the fact that it still comprises separation of the Petition 870190072623, of 7/29/2019, p. 128/130 6/6 process water of the consolidated material; and recovery of the REE from consolidated materials. 31. Process, according to claim 28, characterized by the fact that it still comprises separation of process water from the consolidated material; and recovery of the REE from separate process water and consolidated materials. 32. Consolidated material, characterized by the fact that it is obtained as defined in any one of claims 1 to 4. 33. Consolidated material, characterized by the fact that it is obtained as defined in claim 28.