Investigating the influence of total electrolyte concentration and sodium–calcium ion competition on controlled dispersion of swelling clays

The influence of clay dispersion method on dewatering behaviour of a run-of-mine bentonite was examined to better understand the roles of calcium–sodium ion exchange and overall electrolyte concentration on the suppression of swelling and subsequent stabilisation of the clay. As with previous work, controlled dispersion of the clay directly into a swelling suppressing environment was observed to yield order of magnitude improvements in dewatering behaviour [de Kretser, R.G., Scales, P.J. and Boger, D.V., 1997. Improving clay-based tailings disposal: a case study on coal tailings. AIChE Journal. 43 (7), 1894–1903.]. The calcium ion, even after normalisation for its valence, yielded significantly better clay stabilisation performance than the sodium ion indicating the greater benefit afforded via divalent ion-exchange driven controlled dispersion. However the results also highlighted a synergistic effect of the double layer suppression effect on the efficacy of ion-exchange mediated controlled dispersion through simultaneous swelling suppression and structure preservation during the transient process of ion exchange on hydration. Studies of controlled dispersion in dual ion, Na+ and Ca2+, systems illustrated that although the efficacy of controlled dispersion deteriorated with an increase in the Na+ to Ca2+ ratio, even small amounts of calcium character could generate significant improvements in dewaterability over the pure sodium case. This result was relevant in terms of defining an operational window for the commonly used, but sparingly soluble calcium source, gypsum where the low deliverable calcium level could be more than offset by the controlled dispersion benefits of maintaining a higher overall salinity level. Based on the results presented, the potential impact of practical implementation of a controlled dispersion framework within a mineral processing operation was illustrated via numerical modelling of the operation of a steady state thickener.