CA1108319A - Disposal of thixotropic muds - Google Patents

Disposal of thixotropic muds

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Publication number
CA1108319A
CA1108319A CA314,959A CA314959A CA1108319A CA 1108319 A CA1108319 A CA 1108319A CA 314959 A CA314959 A CA 314959A CA 1108319 A CA1108319 A CA 1108319A
Authority
CA
Canada
Prior art keywords
mud
dump
water
weight
electrolyte
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired
Application number
CA314,959A
Other languages
French (fr)
Inventor
Horst Pohland
Manfred Haerter
Gerhard Bayer
Bernhard Schepers
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
BK Giulini Chemie GmbH
Original Assignee
Giulini Chemie GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Giulini Chemie GmbH filed Critical Giulini Chemie GmbH
Application granted granted Critical
Publication of CA1108319A publication Critical patent/CA1108319A/en
Expired legal-status Critical Current

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  • Treatment Of Sludge (AREA)

Abstract

ABSTRACT

The specification describes a method of depositing and solidifying thixotropic mud such as red mud, which comprises filtering, washing and mechanically liquefying the mud and then transferring it to a dump for solidification. The mechanical liquefaction is performed on moist mud having a solids content of over 30% by weight and in the presence of an electrolyte. The dump is provided with at least one retaining embankment for discharging meteoric water by hydraulic action.
The embankment contains at least one substance having cation exchanging properties whereby alkali metal ions absorbed by the water from the mud are removed from the water before it is dis-charged. With the same ground area and the same storage height, approximately 1.4 times as much red mud in the moist state can be stored by the above method as in conventional dumping.
Also the dump height can be increased to 3 to 4 times that of a conventional dump. Therefore, a storage capacity of 4 to 6 times the conventional methods is available by the above method.

Description

~L~ 3'~9
- 2 -The present invention relates to a method for :~
dumping thixotropic m~lds', especial'ly "red mud" ~hich ';
is formed when sodium aluminate is extracted by the Bayer ~:
~ process, S In the Bayer process', which ls a chernical extraction - process', al~minium oxide is made from bauxite. At temperatures between 90 and 300C, crushed bauxite is brought in contact with sodium aluminate solution in cir~ulation', the various aluminium hydrates contained in 10 the bauxike being dissolved with the formation of sodium aluminate', while impurities', such as iron oxides and titani~m oxides, as well as by-products fonmed during the . . ~::
e~tractlon opera~ion', e,g~ sodium aluminium silicates, ~' remain suspended in the decomposition solution : 15 Red mud (which is in most cases separate~ from the .
~: decomposition solution by sed'imentation with the aid'of . settling thickeners and', to remove the sodium and aluminium com-: pounds present, is washed with hot water in counter.-current manner in up to` 10 washîng thickener machines in ~ :
20 succession) is a troublesome waste product in the extraction of aluminium oxide by the Bayer process.
::; Depending on the quantity of the bc~uxite, between 002 and 1.3 tons of red mud, calculated as dry substance, have ~:
to be dumped or put to other use for each ton of~aluminium-
3 3~ 3.~

oxid~ produced, An analysis of the dried red mud occurring during the processing of lateritic bauxite shows, by way of example~ the following composition:
SiO2 - 14.03% by weight TiO2 - 7.20% by weight Na2~ ~ 10.20% by weight Loss on ignition9.04% by weight ...
2 3 29.56% by weight A1203 ~ ~3.90% by weight CaO _ .~6 30% by weigh~
Despite considerable effort it has not been possible hitherto to put red mud, approximately 25 million tons of which are at present produced annually throughout the world, to any useful purpose to the necessary extent. The major part of the red mud has~ therefore, even today5 still to be stored in dumps (e.gO in lakes or reservoirs) or pumped into the sea as diluted mud.
When red mud is dumped, the mud from the final washing stage, with a concentration of approximately 150 tc 360 g of solids per litre, is pumped into red-mud lakes where the solid substance set~les out~ Depending on the ~ . ~umber of washing stages used, the red mud still contains : 1.2 to 4% by weight of soluble Na20 relative to the~ dry : substance. After~sedimentation has taken place,~the supernatant liquid containing Na20 is fed back into the production process where it is used in the manufacture of alumina with 0.3 to O~S tons of C02 per ~on of A12o3.
Owing to the conversion of sodium aluminate into Na~C03 during storage in the red-mud lake causticisation : 30 of the soda with quicklime or removal thereof by separation of foreign salts ~separation of common salt) :
4 ~ 33~

is necessary. However, other inorganic salts, such as sulphates and phosphates, as well as organic substances', also are trapped in the liquor circulation system during the above-mentioned feedback o the dumped ' ~-liquid, contaminate the decomposition liquor and con- ;
sequently increase the costs.o~;purifying the liquor.
It is known that when red-mud lakes are established many factors must be taken into account. Thus'l to prevent alkaline water from ~ntering the ground water', the dikes are sealed with suitable building material. Where necessary the tanks are also lined with a rubber film or with a thick layer of compressed silt4 Neither proposal has'~ however'~ yet assumed any ;mportance'9 as', on the one ~ hand', plastic films undergo ageing and become penmeable ~ '~
in time and', on the other'~ very high layers of silt are required for sealing purposes.
In red-mud lakes the height of the dike is kept below 10 m for reasons of cost and the risk of a breach in the dike~ These lakes are~rarely made deeper than 6 m', so that large areas of land are necessary ~or depositing the red mud~
To increase the solids content of the red-mud lake',' :
: a system has~been~developed whereby the bed of the dumping site is p~ovided with a~sand filter layer~and a network of drainpipes. This method', also-9 is ~ howe~er', considered by many red~mud operators to be uneconomical ~:
and laborious. Also', it can be applied only in regions ~:
which have a subsoil impervious to water.
A need exists', therefore', for an improved method 30 for dumpin~ thixotropic muds, especi;~lIy red mud as ~-a by-product of the manufacture of aluminium oxide, ~ ;

' ' ~

. , .
5 ~ 3~-~

wherein the above-mentioned disadvantages are eliminated and storage heights depths up to at least lS m can be achieved.
This invention provides a method of depositing and solidiying thixotropic mud', which comprises filtering', washing and mechanically liquefying the mud and then transerring it to a d~mp for solidi~ication; the mechanical liquefaction being performed on moist m~d having a solids content of over 30% by weight and in the presence of an electrolyte; the dump being provided with at least one retaining embankment or discharging meteoric water by hydraulic action', the embankment containing at lea~t one substance having cation exchanging properties whereby alkali metal ions absorbed by the water from the mud are removed ~rom the water before it is discharged The mechanical liquefaction may be effected by :: means of apparatus applying shearing forces to the mud.
The electrolyte is generally used in an amount of 0.2 ¦
to Go6% by weight', especially 0~25 to 0.4% by weight', rela~ive to the dry weight of the mud', and may or ~ :
example be sulphite waste liquor', NaOH', Na2C03', or a polyphosphate or polyacrylate or other polyelectrolyte~ ~ ' : The d~mp may for example be in the form of a ; reservoir', at least one of whose banks possesses the necessary cation-exchanging capabilityO Other parts of the dump may, if desired, also contain a ca~ion exchanging material.
:~- As indicated above9 at least one of the retaining emban~-ments must be capable of hydraulically discharging water It is prefered that this embankment should achieve this by being : water-permeable; mechanical arrangements are unnecessary It has been shown, surprisingly, that with red mud dumped ~
with a solids content of over 30% by weight ~e g ' 30-70%), ;
~ preferably over 45% by weight (e g 45-55%), there is : _ 5 _ :
; , . , : '' ' '' ' 33~
~ .
- 6 -obtained within a few days due to the thixotropic properties7a clay-like mass which is impervious to rainwater and from which the alkali metal ions cannot therefore be washed into the subsoil or into the ground waterO If the red mud is dumped conventionally with concentrations under 30% by weight by the usual method', it is certainly concentrated'~ aEter standing ~or a long time, as a result of sedimentation'~ but it remains soft~
impossible to walk on and permeable to water', so that on porous subsoils the alkali metal ions contained in the red mud penetrate the subsoil and thé ground water. The combination of the above-mentioned measures in accordance with the invention has enabled red mud to be dumped in a way which does not adversely affect the environment.
It has been proven by X-ray analyses that due to a chemical reaction of the constituents contained in the red mud it is possible to achieve further solidi~ication ~ ~
in course of time~, which leads to an increase ;n shearing -force (storage height or depth3 and even better sealing '~
against rainwater', consequently further reducing the 20 risk that alkali metal ions'will be washed out. ' ;
According to the preerred proce~s of the invention the liquefied mud is conveyed at pressures from 10 to 200 atmospheres', more preferably 30 to 100 atmospheres. Positive-displacement pumps have proved most successful in this case. The liquefied mud can be p~mped without difficulty over dis~ances of up to 15 km ;~
or beyond, if necessary.
The viscosi~y of the filter moist mud introduced ' ~-into the reactor (by screw conveyors or other conveying ~ ' systems) is usually between 30~000 and 130,000 c.p. It ~;
ran be reduced by mechanical liquefaction down to - approximately 10900Q c.p. and a minimum of SjO00 c.p.
~-- 6 ~
~., ,~ , .

-.
;. . . . .

3:~
. .

By the simultaneous use of small quantities o~ electrolytethe viscosity can even be lowered to 1,200 c.p.
It was not previously known and must be considered as surprising that thixotropic m~lds in a liquefied state S can be pumped over distances up to several kilometers in a pipeline on to dumps which have at least one hydra~lically acting embankment contai~ing a ca~ion-exchangeable substance through which the meteoric water is discharged. Sedimentation of the solids either in the pipeline or in the dump has not been o~served. It has been observed, on the other hand, that mud spreading like lava in t~e dump has solidified after ~nly 3 to 5 weeks to the extent tha~ it is possible to walk and driye o~er it, By the addition ~f chemical additives [e,g, Ca ~ ~ the solidi-f,icatiun oper~tion can be accelerated still urther, Solidiied red mud treated in this way can be used to seal the s~lbsoil for -~he ~stallation of a new dump, There is consequently no need to feed back nd recover supernatant water containing alkali metal,ions.
The particle size of the mud should be between 0.1 and 150 ~m, preferably between 0.3 and 10 ~m, although these particle ranges do not represent critical valuesO
It has been shownj ~urther~ that it is especially advantageous to build the dump in stages,~ For this purpose, the dum? is divided into several sectors which are supplied alternately with liquefied mud. In this way, there is always suficient time for the red mud to solidify and dry out in layers. Also, cracks due to shrinkage occurring after solidification are filled up with fresh red mud, Continuous Gompression and packing of the deposited mass are thereby achievedO The
- 7 -, ~ . .
,~ ' ' , ' ~ ' ' - `'``` - 8 ~ 3~3 intermedlate dams required to divide the dump into :' sectors can be made from already hardened red mud.
The method of the invention will 710W be described in detail by reference to the accompanying diagrammatic drawing Reference number 1 denotes th~ inlet of the mud from the preliminary thickener into the washing thickener 2 and 3 designates the washing liquor discharged from the thickener. The red mud is conve~éd from the washing thickener 2 into the filter 4', e g. a d~m-type vacuum filter', washed with washing water from the pipe 5 and then supplied to the reactor 6 where mechanical liquefaction is efected by means of the agitator 7 in the presence.of an elec- .
trolyte By the pump 8 the liquefied mud is conveyed into the ~.
dump according to the invention where the embanking.material : with cation exchange capacity is designated by 9 an~ the deposited mud by 10. Clay or silt',:for example, can be :
used as embanking material'J'although especially mixtures of clay 9 silt', sand and rubble can also be used. Pre-20 treatment of the bed of the dump is not necessary. The ' red mud can be conveyed directly into the dump where it solidifies and, consequently', forms a bed impervious ;~
to water.
The height of the deposited red-mud can be', for `~
example', up to 20 m over a gro~md area of 90',000 m and ~.
can be increased considerably still further.
The advantage of the dumping method according to the invention is', finally9 seen in the fact that with the same ground area and the same storage height 30 approximately 1.4 times as much red mud in the moist `:~
state can be stored as.i~ conventional dumping~ Also, . . .
.,.. . . . . ........... . .......... , - ~ . ~ ., : -, " :., - ~ , _ 9 ~

tlle clump hei,ght can be increased to 3 to 4 times the height of a conventional dump, so that there results a storage capability o~ 4 to 6 times the quantity of red mud.

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Claims (9)

What we claim is:
1. A method of depositing and solidifying thixotropic mud, which comprises filtering, washing and mechanically liquefying the mud and then transferring it to a dump for solidification; the mechanical liquefaction being performed on moist mud having a solids content of over 30% by weight and in the presence of an electrolyte; the dump being provided with at least one retaining embankment for discharging meteoric water by hydraulic action, the embankment containing at least one substance having cation exchanging properties whereby alkali metal ions absorbed by the water from the mud are removed from the water before it is discharged.
2. A method as claimed in Claim 1 wherein the mud is red mud.
3. A method as claimed in Claim 1 wherein the solids content of the mud for liquefaction is 45 to 55% by weight.
4. A method as claimed in Claim 1, 2 or 3 wherein the electrolyte is present during liquefaction in an amount of 0 2 to 0.6% by weight.
5. A method as claimed in Claim l, 2 or 3 wherein the electrolyte is sulphite waste liquor, NaOH, Na2C03, a polyphosphate or a polyacrylate.
6. A method as claimed in Claim 1, 2 or 3 wherein the particle size of the mud pumped to the dump is from 0.3 to 10µm.
7. A method as claimed in Claim 1 wherein the substance possessing cation exchanging properties is clay, silt, sand or rubble.
8. A method as claimed in Claim 7 wherein the dump is a reservoir at least one of whose banks is made of clay, silt, sand or rubble or mixtures thereof;
9. A method as claimed in Claim 1, 2 or 7 wherein the dump is divided into sectors which can be supplied alternately with mud.
CA314,959A 1977-11-18 1978-10-30 Disposal of thixotropic muds Expired CA1108319A (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
HUGI000262 1977-11-18
HUGI-262 1977-11-18

Publications (1)

Publication Number Publication Date
CA1108319A true CA1108319A (en) 1981-09-01

Family

ID=10996610

Family Applications (1)

Application Number Title Priority Date Filing Date
CA314,959A Expired CA1108319A (en) 1977-11-18 1978-10-30 Disposal of thixotropic muds

Country Status (1)

Country Link
CA (1) CA1108319A (en)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1994002417A2 (en) * 1992-07-21 1994-02-03 Davy Mckee (Stockton) Limited Process for the removal of sodium values from sodium contaminated solids
FR2746786A1 (en) * 1996-04-01 1997-10-03 Pechiney Aluminium PROCESS FOR RECOVERING SODIUM CONTAINED IN INDUSTRIAL ALKALINE RESIDUES
WO2009009824A1 (en) * 2007-07-13 2009-01-22 Alcoa Of Australia Limited Method for controlling the precipitation of alumina
CN101845817A (en) * 2010-06-23 2010-09-29 贵阳铝镁设计研究院 Method for increasing capacity of flat type wet-method red mud disposal site by dry method
CN102409684A (en) * 2011-08-04 2012-04-11 中国铝业股份有限公司 Storage-yard damming method of red mud by mixed self-solidifying dry process

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO1994002417A2 (en) * 1992-07-21 1994-02-03 Davy Mckee (Stockton) Limited Process for the removal of sodium values from sodium contaminated solids
WO1994002417A3 (en) * 1992-07-21 1994-04-28 Davy Mckee Stockton Process for the removal of sodium values from sodium contaminated solids
FR2746786A1 (en) * 1996-04-01 1997-10-03 Pechiney Aluminium PROCESS FOR RECOVERING SODIUM CONTAINED IN INDUSTRIAL ALKALINE RESIDUES
WO1997036823A1 (en) * 1996-04-01 1997-10-09 Aluminium Pechiney Method for recovering sodium from alkaline industrial waste
US6110377A (en) * 1996-04-01 2000-08-29 Aluminum Pechiney Process for recovering the sodium contained in industrial alkaline waste
WO2009009824A1 (en) * 2007-07-13 2009-01-22 Alcoa Of Australia Limited Method for controlling the precipitation of alumina
CN101845817A (en) * 2010-06-23 2010-09-29 贵阳铝镁设计研究院 Method for increasing capacity of flat type wet-method red mud disposal site by dry method
CN102409684A (en) * 2011-08-04 2012-04-11 中国铝业股份有限公司 Storage-yard damming method of red mud by mixed self-solidifying dry process

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