Classifications

• • C—CHEMISTRY; METALLURGY
  • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F1/00—Treatment of water, waste water, or sewage
  • C02F1/52—Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities
  • C02F1/54—Treatment of water, waste water, or sewage by flocculation or precipitation of suspended impurities using organic material
  • C02F1/56—Macromolecular compounds
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
  • B01D—SEPARATION
  • B01D21/00—Separation of suspended solid particles from liquids by sedimentation
  • B01D21/01—Separation of suspended solid particles from liquids by sedimentation using flocculating agents
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
  • C01F7/00—Compounds of aluminium
  • C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
  • C01F7/04—Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom
  • C01F7/06—Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom by treating aluminous minerals or waste-like raw materials with alkali hydroxide, e.g. leaching of bauxite according to the Bayer process
  • C01F7/0646—Separation of the insoluble residue, e.g. of red mud
  • C01F7/0653—Separation of the insoluble residue, e.g. of red mud characterised by the flocculant added to the slurry
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
  • C01F7/00—Compounds of aluminium
  • C01F7/02—Aluminium oxide; Aluminium hydroxide; Aluminates
  • C01F7/04—Preparation of alkali metal aluminates; Aluminium oxide or hydroxide therefrom
  • C01F7/14—Aluminium oxide or hydroxide from alkali metal aluminates
  • C01F7/144—Aluminium oxide or hydroxide from alkali metal aluminates from aqueous aluminate solutions by precipitation due to cooling, e.g. as part of the Bayer process
  • C01F7/148—Separation of the obtained hydroxide, e.g. by filtration or dewatering
• • C—CHEMISTRY; METALLURGY
  • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F2101/00—Nature of the contaminant
  • C02F2101/10—Inorganic compounds
  • C02F2101/20—Heavy metals or heavy metal compounds
• • C—CHEMISTRY; METALLURGY
  • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
  • C02F2103/16—Nature of the water, waste water, sewage or sludge to be treated from metallurgical processes, i.e. from the production, refining or treatment of metals, e.g. galvanic wastes
• • C—CHEMISTRY; METALLURGY
  • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
  • C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
  • C02F2103/26—Nature of the water, waste water, sewage or sludge to be treated from the processing of plants or parts thereof
  • C02F2103/28—Nature of the water, waste water, sewage or sludge to be treated from the processing of plants or parts thereof from the paper or cellulose industry
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B21/00—Obtaining aluminium
  • C22B21/0015—Obtaining aluminium by wet processes
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
  • C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
  • C22B3/20—Treatment or purification of solutions, e.g. obtained by leaching
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
  • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
  • Y02P10/00—Technologies related to metal processing
  • Y02P10/20—Recycling

Definitions

• the present invention relates to flocculants and methods for using them and more particularly to hydroxamated polymer emulsion flocculants and methods for flocculating process solids in industrial process streams.
• the flocculants and methods of the present invention find use in such industrial processes as the Bayer process for the recovery of alumina from bauxite ore.
• the Bayer process is almost universally used to manufacture alumina from bauxite.
• raw bauxite ore is first heated with caustic soda solution at temperatures in the range of 140 to 250° C.
• caustic soda solution at temperatures in the range of 140 to 250° C.
• Resulting concentrations of dissolved materials are very high, with sodium hydroxide concentrations being greater than 150 grams/liter and dissolved alumina being greater than 120 g/l.
• any undissolved solids usually oxides of iron which are known as red muds, are then physically separated from the aluminate solution.
• a polymeric flocculent is used to enhance the settling and removal of the fine solid particles.
• Residual suspended solids are removed by a filtration step.
• the filtered clear solution or liquor is cooled and seeded with alumina trihydrate to precipitate a portion of the dissolved alumina. After alumina precipitation, this depleted or spent liquor is reheated and reused to dissolve more fresh bauxite.
• the clarified sodium aluminate liquor is seeded with alumina trihydrate crystals to induce precipitation of alumina in the form of alumina trihydrate, Al(OH) 3 .
• the alumina trihydrate particles or crystals are then separated from the concentrated caustic liquor.
• the alumina trihydrate crystals are generally separated from the liquor in which they are formed by settling and/or filtration. Coarse particles settle easily, but fine particles settle slowly resulting in yield losses. Fine particles can also blind the filters. The fine particles of alumina trihydrate which do not settle easily, are most often recycled back to digestion with the spent liquor.
• the un-recovered alumina trihydrate is then redigested and reprecipitated in a second cycle through the Bayer process, unnecessarily expending energy and reducing the alumina extraction capacity of the spent liquor. It is therefore highly desirable to settle as much of the trihydrate as possible so as to limit the adverse consequences of these problems.
• Dextran has however proved to be a poor flocculant for trihydrate crystals resulting in poor supernatant clarifies.
• U.S. Pat. No. 6,608,137 describes water-in-oil emulsions of hydroxamated polymers. These polymers must firstly be dissolved and pre-diluted in an aqueous medium (often a Bayer process liquor) before they may be added to the Bayer process liquor to be settled/clarified.
• an aqueous medium often a Bayer process liquor
• water-in-oil-in-water dispersions of water-soluble polymers which can be added directly into industrial process streams such as Bayer process steams without predilution thus eliminating the need for expensive storage vessels and associated pumping and dilution equipment.
• the water-in-oil-in-water emulsions of a hydroxamated polymer of the current invention also exhibit enhanced storage stability over prior art solution and water-in-oil emulsion polymers particularly when subject to extremes of low temperature.
• the present invention provides a composition of a water-in-oil-in-water emulsion of a water-soluble polymer in which the continuous aqueous or water phase is comprised of an aqueous solution of water-soluble salt.
• the water-in-oil-in-water emulsion of a water-soluble polymer is a water-in-oil-in-water emulsion of a hydroxamated polymer
• the discontinuous phase is a water-in-oil emulsion of a water-soluble polymer preferably a water-soluble hydroxamated polymer.
• emulsion, microemulsion or dispersion are used synonymously to indicate that the polymer is present in the form of small particles or droplets dispersed in a continuous oil phase of the oil-in-water emulsion.
• the particle size can range from 0.01 microns to 50 microns and can be in the form of a microemulsion or microdispersion.
• the particles may also contain little or some water ranging from 0-90% the remainder being polymer.
• the particle size range is 0.05 to 10 microns.
• the hydroxamated water-in-oil-in-water emulsions of the present invention can be prepared by mixing a water-in-oil emulsion or dispersion of a hydroxamated polymer with water or an aqueous solution of water-soluble salt.
• the water soluble salt can be any salt which prevents the polymer from dissolving.
• the salt is a salt containing aluminum or calcium.
• an improved method for the flocculation, clarification and separation of solids from an industrial process stream comprising adding to the process stream a water-in-oil-in-water emulsion or dispersion of a water-soluble polymer.
• the process stream is a Bayer process stream
• the solids consist of as red mud (waste) or alumina trihydrate solids (product).
• the water-in-oil-in-water emulsion or dispersion of the water-soluble polymer is added in an amount effective to improve the clarification of said process stream by reducing the amount of suspended solids present in the supernatant.
• the preferred flocculent is a water-in-oil-in-water emulsion of a hydroxamated polymer but can include other flocculants such as polymers of acrylic acid.
• Hydroxamated polymers are well known to those skilled in the art and are specifically disclosed, as are methods for their production, in U.K. Patent Application 2171127 and U.S. Pat. Nos. 3,345,344; 4,480,067; 4,532,046; 4,536,296 and 4,587,306, 4767540, and 6,608,137 which are hereby incorporated herein by reference.
• these hydroxamated polymers may be produced by reacting a pendant reactive group, in solution, with a hydroxylamine or its salt at a temperature ranging from about 50 C. to 100 C. From about 1-90% of the available pendant reactive groups of the polymer may be replaced by hydroxamic groups in accordance with said procedures.
• the water-in-oil-in-water emulsions of polymers of this invention may be prepared by adding to an aqueous solution of water-soluble salt a water-in-oil emulsion of a polymer most preferably a hydroxamated polymer.
• aqueous solution of water-soluble salt may be added to the water-in-oil emulsion of a polymer which is most preferably a hydroxamated polymer.
• the order of addition may be reversed i.e. the aqueous solution of water-soluble salt may be added to the water-in-oil emulsion of a hydroxamated polymer.
• the polymer is a hydroxamated polymer when the substrate to be treated is a Bayer process stream.
• Methods of preparation of water-in-oil emulsion of a hydroxamated polymers are described in U.S. Pat. No. 6,608,137 which is hereby incorporated herein by reference.
• a backbone polymer is prepared by forming a water-in-oil emulsion of a water-soluble monomer such as acrylamide by dispersing the monomer phase within an oil and surfactant phase and conducting the polymerization in the absence of oxygen by conventional polymerization techniques e.g. by the addition of redox, thermal e.g. azo initiators or by the application of UV irradiation in the presence of UV initiators.
• the polymeric backbone is then reacted with hydroxylamine to form the hydroxamated polymer.
• concentration of hydroxamated polymer present in the water-in-oil emulsion of hydroxamated polymer can range from 1-60% usually in the range from 10-30%.
• concentration of salt present in the aqueous solution should be such as to prevent dissolution of the water-in-oil dispersion of a hydroxamated polymer.
• a preferred range for the concentration of water-soluble salt is from 0.1-10% based on the water-in-oil-in-water emulsion. Most preferably the range is 1-5%.
• Suitable water-soluble salts include sodium aluminate, aluminum sulfate, sodium chloride, potassium chloride and the like.
• the ratio of water-in-oil emulsion of a hydroxamated polymer to aqueous solution of water-soluble salt that is used to prepare the water-in-oil-in-water dispersion of a hydroxamated polymer can range from 1:99 to 99:1, preferably 10:90 to 90:10 most preferably 20-50%.
• hydroxamic polymers Any water-in-oil emulsion of hydroxamic polymer may be used.
• the hydroxamic polymers, or hydroxamated polymers are well known in the art and can be prepared by post-polymerization derivatization from polymers containing pendant reactive groups, such as pendant ester, amide, anhydride and nitrile groups and the like by the reaction thereof with hydroxylamine or its salt at a temperature within the range of from about 20 degrees C. to about 100 degrees C. for several hours.
• Monomers suitable for the preparation of precursor polymers include acrylamide and esters of (meth)acrylic acid such as methyl acrylate.
• From about 1 to about 90 mole percent of the available pendant reactive groups of the precursor polymer may be replaced by hydroxamic groups in accordance with such procedures.
• Such post-polymerization derivatization may be carried out in water-in-oil emulsion or dispersion form as described in U.S. Pat. No. 6,608,137.
• the molecular weight of the hydroxamated polymer can range from 1000 to 50 ⁇ 10 6 .
• the hydroxamated polymer preferably has a weight average molecular weight of at least about 0.1 million, preferably with an IV of from about 0.5 to about 40 dl/g when measured in M NaCl at 30 degrees C.
• the degree of hydroxamation may vary from about 1 to about 90 mole percent, and preferably is within the range of from about 5 to about 75 mole percent, and most preferably from about 10 to about 50 mole percent.
• the hydroxamated polymer in the preferred embodiment is predominantly anionic, although it can also contain nonionic or cationic units.
• Anionic monomer units other than the hydroxamic monomer units can be incorporated into the polymer and are generally carboxylic acids or sulphonic acids and are usually derived from (meth)acrylic acids, sulfoalkyl acrylamides, such as 2-sulfopropylacrylamide or acrylamidodimethylpropylsulfonic acid.
• the polymers used in the present invention are employed by adding them, either directly to the process stream as water-in-oil-in-water emulsion of a hydroxamated polymer or in the form of pre-diluted aqueous solutions.
• the process stream can be any industrial process stream from which solids need to be separated. These processes may include mineral beneficiation processes such as is used in the extraction of alumina, phosphate, and other industrial minerals, copper, zinc, lead, and precious metals, in the production of pulp and paper, for the treatment of paper wastes as well as for the treatment of industrial and municipal wastes.
• the process stream is a Bayer process steam e.g., one containing red mud or alumina trihydrate solids.
• the water-in-oil-in-water emulsion of a hydroxamated polymer is added to the process stream containing red mud or alumina trihydrate solids in an amount at least sufficient to settle said suspended solids.
• at least about 0.1 mg of the hydroxamated polymer, per liter of the process stream should be employed. More preferably, at least 1.0 mg of the hydroxamated polymer is added. It is understood, that higher amounts than those just stated may be employed without departing from the scope of the invention, although generally a point is reached in which additional amounts of hydroxamated polymer do not improve the separation rate over already achieved maximum rates, Thus, it is uneconomical to use excessive amounts when this point is reached.
• hydroxamated polymer clarification aid will improve the alumina-caustic liquor separation on a vacuum filter by forming a more porous filter cake.
• the process stream is a red mud stream
• superior settling rates and supernatant clarifies are achieved compared to prior art polymers.
• the water-in-oil-in-water hydroxamated polymer emulsions of the instant invention are more effective flocculants for treating red muds which are contaminated with silicon containing minerals commonly known as desilication products or DSP.
• Superfloc® HF80 is a commercially available water-in-oil emulsion containing polymer having about 60 mole % of hydroxamate groups. It is manufactured by Cytec Industries Inc. of Garret Mountain, N.J.
• Stable water-in-oil-in-water emulsions of hydroxamated polymers are prepared by using the following procedure.
• a solution of 250 grams/liter of aluminum sulfate hydrate (Al 2 (SO 4 ) 3 .18H 2 O) and 100% sodium hydroxide are dissolved in deionized water.
• Example A is then added rapidly to the vigorously stirred caustic aluminum sulfate solution.
• Table 2 lists several water-in-oil-in water formulations that are prepared by this procedure. TABLE 2 Parts 250 g/l Parts Parts Parts % Aluminum Al 2 (SO 4 ) 3 . % Al 2 (SO 4 ) 3 .
• a stable water-in-oil-in-water hydroxamated polymer emulsion is prepared by using the following procedure. One hundred fifty (150) parts of a solution of aluminum sulfate is added with vigorous stirring and at a constant rate over 30 to 40 minutes to 150 parts of Example A. The aluminum sulfate solution is prepared using 18.6 parts of 48% aluminum sulfate hydrate (Al 2 (SO 4 ) 3 .14H 2 O) and 131.4 parts of deionized-water. The concentration of Example A in the final product is 50%, and the concentration of Al 2 (SO 4 ) 3 .14H 2 0 is 2.97%. The final product bulk viscosity is 780 cps and the pH is 10.1. This example demonstrates that the aqueous phase can be added to the water-in-oil hydroxamated polymer emulsion to produce a stable water-in-oil-in-water hydroxamated polymer emulsion.
• a stable water-in-oil-in-water hydroxamated polymer emulsion is prepared by using the following procedure. One hundred fifty (150) parts of a 2.2% solution of calcium chloride (CaCl 2 ) in DI-water is added with vigorous stirring and at a constant rate over 43 minutes, to 150 parts Example A. The concentration of Example A in the final product is 50%, and the concentration of CaCl 2 is 1.1%. The final product, stable water-in-oil-in-water hydroxamated polymer emulsion had a bulk viscosity of 10,750 cps and pH of 10.1.
• CaCl 2 calcium chloride
• Example 15 is thermally cycled for 4 cycles from room temperature to a temperature of between ⁇ 20° C. and ⁇ 30° C. to simulate freeze-cycles to which the product could be subjected to when used in extreme climates. After thawing to room temperature the product is remixed to form of stable water-in-oil-in water emulsion of hydroxamated polymer.
• the solubility of water-in-oil-in-water hydroxamated polymer emulsions of Examples 8 and 15 is compared to the solubility of Example A in 150 g/l sodium hydroxide in Dl water at 60° C. These conditions are similar to the conditions found in the tertiary tray feed in an alumina refinery where precipitated alumina trihydrate is flocculated, settled and separated from the liquor.
• the torque/viscosity build up of the solution is measured by using a mixing motor capable of increasing torque to maintain the stirring speed as the viscosity increased.
• Example 20 did not dissolve in the simulated tertiary tray feed liquor whereas the water-in-oil-in-water hydroxamated polymer emulsions of the instant invention rapidly dissolved (Examples 19, 21). Therefore the water-in-oil-in-water hydroxamated polymer emulsions can be added directly to the Bayer process stream without the use of an additional dilution step.
• TABLE 3 Examples Sample Time to maximum torque 19 Example 15 Maximum torque in 50 seconds 20 Example A No torque increase in 5 minutes 21 Example 8 Maximum torque in 100 seconds
• Example 1 The flocculation performance of Example 1 is compared to that of two commercial prior art alumina hydrate flocculants, dextran and Example A, in simulated tertiary tray feed as shown in table 4.
• the slurry is prepared using spent liquor from an alumina refinery.
• the spent liquor is saturated with 74.8 g/l of alumina at its boiling point.
• the solution is then cooled and held at 70° C. and then 34 g/l of alumina is suspended in the liquor.
• the flocculants are diluted to 0.01 % polymer concentration to aid in delivering very low doses.
• a 200 milliliter aliquot of the slurry is then treated with the flocculants.
• the seftling time and supernatant clarity are measured as a function of dose.
• Table 1 shows that water-in-oil-in-water hydroxamated polymer emulsions are effective trihydrate flocculants.
• TABLE 4 Polymer Dose Settling Supernatant Example Polymer (ppm) time (sec) clarity (NTU)
• Example 22 Example A 0.75 58 286
• Example 23 Dextran 0.75 160 >1000
• Example 24 Example 1 0.75 84 861
• Example 25 Example A 1.5 37 236
• Example 26 Dextran 1.5 81 >1000
• Example 27 Example 1 1.5 62 388
• Example 29 Example 1 2.25 55 271
• the flocculation performance of water-in-oil-in-water hydroxamated polymer emulsions, Example 11 and 15 are compared to that of two commercial prior art hydrate flocculants, dextran and Example A, in tertiary tray feed obtained from an alumina refinery.
• the tray feed temperature is measured at 70° C. and had a caustic content 228 gram/liter.
• the flocculants are all added to the tertiary tray feed without pre-dilution.
• the flocculants are added to 1 liter of tertiary tray slurry in a 1 liter graduated cylinder.
• the flocculant and slurry are thoroughly mixed with 10 up and down strokes of a plunger (perforated disk of slightly smaller diameter than that of the cylinder with a 1 ⁇ 8 inch rod attached to the center of one side of the disk).
• the interface of the settling hydrate is timed from the 900 to 700 milliliter graduations.
• the supernatant clarity is also measured 1 minute after the mixing stopped. Table 5 lists the results of these experiments and shows that the water-in-oil-in-water hydroxamated polymer emulsions of the instant invention perform much better than the prior art flocculants.
• Example 30 Dextran 0.8 800 24 383
• Example 31 Example 15 0.8 800 4 303
• Example 32 Example 11 0.8 800 11 265
• Example 33 (1)
• Example 34 Dextran 0.4 400 20 300
• Example 35 Example 15 0.4 400 3 323
• Example 36 Example 11 0.4 400 13 287
• Example 37 Example A 0.4 400 93 650 Comparative Example 38 No polymer 0 0 129 806
• Example 11 and 15 The flocculation of red mud obtained from an alumina refinery digester blow-off with water-in-oil-in-water hydroxamated polymer emulsions (Example 11 and 15) is demonstrated in Table 6.
• the blow-off solids is 39.3 grams/liter, blow-off temperature is >100° C., caustic concentration is 204 grams/liter and the alumina to caustic ratio (A/C) is 0.675.
• Example 11 and 15 are all added to the blow-off process stream without pre-dilution.
• the flocculants are added to 1 liter samples of digester blow-off in a 1 liter graduated cylinder.
• the flocculant and slurry are thoroughly mixed with 5 or 10 up and down strokes of a plunger (perforated disk of slightly smaller diameter than that of the cylinder with a 1/8 inch rod attached to the center of one side of the disk).
• the interface of the settling hydrate is timed from the 900 to 700 milliliter graduations.
• Table 6 shows that water-in-oil-in-water hydroxamated polymer emulsions can be added directly to a Bayer process steam containing red mud solids without the need for a predilution step.
• Example 15 0.2 200 37.2 22.85 Example 15 0.4 400 15.1 56.29
• Example 15 0.6 600 14.8 57.43 Example 15 1 1000 5.8 146.55
• Example 40 Example 11 0.2 200 22.4 37.95
• Example 11 0.6 600 11.1 76.58 Example 11 1 1000 8.8 96.59
• a stable water-in-oil-in-water hydroxamated polymer emulsion was prepared by using the following procedure. 150 parts of aluminum sulfate hydrate (Al 2 (SO 4 ) 3 .14H 2 O) was dissolved in 177.5 parts of DI water. This was added with vigorous stirring to 105 parts Example A.
• Example 42 a stable water-in-oil-in-water hydroxamated polymer emulsion was prepared from a water-in-oil emulsion of a commercially available water-in-oil emulsion of a hydroxamated polyacrylamide similar to Example A except that the degree of hydroxamation was about 25 mole %. This is designated Comparative Example B.
• Table 7 shows the results of red mud settling tests comparing the performance of Examples 42 and 43 water-in-oil-in-water hydroxamated polymer emulsions of the present invention with that of prior art products. The data clearly show that the polymers of the instant invention yield superior settling rates and clarifies (lower NTU).

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