STUDIES ON HYDRAULIC TRANSPORTATION OF THICKENED COPPER

TAILINGS SLURRIES

Ms. Soma Dalbehera

Department of Mechanical Engineering
E-mail ID: soma_2k4@yahoo.co.in
Keywords: Shear stress, shear rate, particles
size distribution, coefficient of viscosity,
rheology, headloss, friction factor
Abstract
The studies aim at establishing the feasibility
of technology of pipeline transportation of
copper tailings slurry at high concentrations.
The disposal systems are highly uneconomical
& create pollution all around the disposal area
through seepage and flooding of waste slurry
water. The solids concentration of these tailing
slurry is as low as 15-25%. Hence the
deposition rate of solids is very low at the pond
and a lot of power is consumed in pumping 75-
85% water only. A recent developed
technology i.e. Thickened Tailing Disposal
(TTD) system is gaining importance
worldwide & is most adaptable for the
purpose.Deposition of tailings in steeper slope
or beach slope makes the reduction of
consumption of power by pump& makes the
process highly economical and cost-effective.
It has good application for back filling the
mine cavities & reduces environmental
pollution.The summary of paper presents the
characterization studies of copper tailings
sample, mixing & determination of pH of high
concentration copper tailings
rheological measurements and to predict the
head loss/ pressure drop of thickened copper
tailings slurry at concentrations of 70-72% by
weight for possible use in a commercial scale
pipeline for a various pipe diameters. A model
(Bingham model) incorporating shear stress
(), shear rate ()&viscosity () has been
developed to correlate the data for evaluating
the hydraulic parameters for design
commercial high concentration copper tailings
slurry pipelines.
1. Introduction:
A slurry is a two-phase flow system and is a
mixture of solids and liquid. It is defined as the
dispersion of colloidal particles in fine
chemical industries & mud in oil drilling
industry. Slurries are fluids & can be
transported in pipes & flumes in contrast to
other wet solids that cant readily be pumped
and are not perceived to flow under the
influence of gravity. The flow of slurries
according to transport conditions is classified
as homogenous Newtonian fluid flow,
heterogeneous Newtonian fluid flow,
heterogeneous non-Newtonian fluid flow &
energy slurries.
Hydraulic transportation is defined as an
industrial process or technology moving the
process forward between the different stages of
solid/ liquid mixing, solid/solid separation and
solid/liquid separation by means of pump or
slurry transportation. The hydraulic
transportation system is used for industrial
application of vertical transportation of solid-
liquid mixture in a pipe & the operating
velocity is sufficient to maintain a continuous
flow of solids at the discharge end. It is cost
slurry,
effective method for transporting waste
/slurries. It is used for pumping of tailings
flotation slurry & coal ashes. It has extensive
power application in process engineering &
refinery industry. It is used for delivery of raw
ones to metallurgical plants & for waste
removal (ashes, slag) from power plants &
metallurgical plants.
Tailings are defined as the finely ground
of
residues or wastes resulting from ore
extraction and processing. It refers to high
concentration solids. Tailings are usually

1
mixed withy water to from a slurry. Copper a slurry ceases to occur. It was found after
tailings are finely ground residues or wastes allowing a slurry of given concentration to
resulting from the ore extraction and settle for a longtime (> 24 hours) until the
processing of copper minerals. It is discharged equilibrium condition is reached. The value of
from the copper ore & minerals. maximum settled concentration is found to be
70%. The pH of copper tailings slurries was
Khetri copper complex of Hindustan Copper
determined by using a pH meter (Model:
Limited produces about 31,000 tones of copper
ELICO, LI613) and the pH data were taken at
per year resulting a huge quantity of tailings
an interval of 15 minutes. The value of pH of
from extraction which is disposed off in a
the sample was found to be 7.66. The graph of
tailing pond that is 1.1km away from plant site.
pH & maximum settled concentration is shown
The different copper tailings slurry
in fig. 2a & 2 b.
transportation pipelines are OK Tedi copper
concentrate pipeline, Bougainville copper
concentrate pipeline, West Irina copper
concentrate pipeline and Southern Peru copper
corporation pipeline etc.

2. Materials and Methods

2.1 Characterization

The copper tailings samples used in the study

were obtained from the Khetri copper complex
of Hindusthan Copper Limited (HCL) located
at Rajsthan. The material density of the bulk Fig.1a:Particle Size Distribution of Copper
samples determined by laboratory tests was tailings samples S1

found to be 2.81gm/cc. Two representative

sample was collected and the particle size
distribution of the sample was determined by
using Malvern Particle size analyzer. The
samples were first added & dispersed in
distilled water to indicate the Obscuration
value of 12%. To avoid formation of any
agglomerates of copper tailing particles, ultra-
sonication of the samples was carried out for
about 1 minute. The particle size distribution
of all samples are plotted in Fig. 1a & 1b. The
d50 (median size) of sample were found to be
63.006m & 73.031m for S-1(Sample-1) &
S-2(Sample-2). The maximum settled
Fig.1b:Particle Size Distribution
concentration of slurry indicates the limiting of Copper tailings samples S2
concentration beyond which the flow ability of

2

Fig.2a:Maximum settled concentration at
different slurry concentration by wt.
Fig.2b: variation of pH with mixing time
of Copper Tailings Sample in
distilled water (pH=7.6)
2.2. Rheological studies
The rheological studies are very important for
determining the viscous characteristics of any
slurry with respect to the material properties
and slurry concentration. Rheology is defined
as the relationship between the shear stress and
the corresponding rate of shear in a slurry
under laminar flow conditions. The head loss
in a pipeline depends on the rheology of the
slurry in homogenous and intermediate flow
regions. Reheology of a Newtonian fluid is
3
expressed by its viscosity which is the ratio of
shear stress () to the corresponding rate of
shear().
For this study, several slurry samples were
prepared by mixing known amount of solids
and liquid. The samples were adequately
stirred and the time of stirring was varied
between 5-10 minutes. The amount of solids
required for a given concentration was
computed as follows :
Vs
(1)
Vs VL
WhereVs Ms
Ps
Vl s
Therefore Ms (2)
1
Where the subscripts s and l denotes solid and
liquid respectively and the symbols V, M,
and denote volume, mass, density and
volume fraction of solids respectively.
Therefore, knowing the density of solids, the
required amount of solids for a given volume
fraction can be readily calculated.
The rheological experiments were conducted
using HAAKE rotational viscometers (Model
RV30) supplied by M/s. Haake Mess
Technick,Germany. A sensor system MVI was
chosen for the rheological measurements. The
sensor and the cup were cleaned and air dried.
The copper tailings samples having d50 of
63.006m & 73.031m were used for the
rheological experiments. About 100ml of
slurry was prepared for each sample as
mentioned above and the rheological
measurements of slurries at 70%, 71% & 72%
wt concentration were carried out. The shear
rate was applied from 10 to 200s-1 for a period
of 2 minutes to measure the corresponding
viscosity and shear stress under controlling
shear rate. Steady shear measurements were
performed at room temp (around 300C). The & shear rate () indicates the behaviour of
variation in temperature was 0.10C which slurry which is desired in the rheology study of
was ensured by passing the slurry through a copper tailings slurry sample.
constant temperature circulating bath Table 1: Rheology of copper tailings slurry
connected to the viscometer. All rheological
Material : Copper tailings
measurements were repeated thrice for each Wt. Concentration : 70%
suspension to minimize & avoid experimental Specific Gravity : 2.81
Slurry Temperature : 300C
error during rheological tests.
Slurry pH : 7.6
3. Results and Discussions Shear Shear Apparent
Sl.No. Stress Rate (), Viscosity (a),
3.1 Rheological behaviour of the copper (), Pa Sec-1 Pas
tailings slurry 1. 3.153 9.359 0.3368

The slurry concentration for viscosity 2. 3.997 20.32 0.197

measurements ranged from 70% to 72% by
3. 5.844 30.59 0.191
Wt. The shear stress () shear rate () data for
the above range of concentration were 4. 6.888 40.96 0.168

obtained for each copper tailings sample. The 5. 7.46 52.51 0.142
Bingham plastic model that fitted the
6. 7.643 62.35 0.1225
experimental data at this range of solids
concentration is given by 7. 9.013 73.79 0.122

= 0 + ..(3) 8. 8.189 84.1 0.097

Where (Pa),is the shear stress, (s-1) is the 9. 9.238 94.43 0.0978
shear rate,(Pas) is the Bingham viscosity or
10. 8.357 105.5 0.079
coefficient of rigidity, and 0 (Pa) is the yield
stress. Yield stress (0) is defined as the 11. 10.69 114.9 0.093
minimum stress required to initiate the flow 12. 10.58 125.2 0.084
before the flow stars and is an internal property
that enables a fluid to resist deformation upto a 13. 10.38 136.3 0.076
certain point, effectively enabling it to behave
14. 10.79 146.4 0.074
as solid.The rheological data were obtained on
a computer screen and are given in table 1, 2 & 15. 11.32 157.3 0.072
3. The rheograms of copper tailings slurry at
16. 11.13 167.7 0.066
different solids weight concentration are
plotted in Fig. 3a, 3b & 3c. The Bingham 17. 11.58 177.8 0.065
plastic model was found to provide the best fit
18. 10.79 188.7 0.057
for the data given. The nature of variation of
shear stress with shear rate for the copper 19. 11.45 199 0.057
tailings slurries indicates that the yield stress is
present for different concentration and Model fit: Bingham Model, = 0 +
variation is non-linear. The flow pattern is 0=4.7328 Pa = 0.0395 Pas=39.5 cp
non-Newtonian exhibit linear relationship where = Shear Stress, Pa 0 = Yield Stress,Pa
between shear stress and shear rate with = Shear rate, Sec-1 =Coefficient of Rigidity
intercept of yield stress (0). As the or Bingham Viscosity, Pas.
concentration increases, it will become
progressively more strongly Non-Newtonian
with a steeply increasing viscosity as yield
stress increases. The graph of shear stress ()

4
Table 2: Rheology of copper tailings slurry Table 3: Rheology of copper tailings slurry

Material : Copper tailings Material : Copper tailings

Wt. Concentration : 71% Wt. Concentration : 72%
Specific Gravity : 2.81 Specific Gravity : 2.81
Slurry Temperature : 300C Slurry Temperature : 300C
Slurry pH : 7.6 Slurry pH : 7.6
Shear Shear Apparent Shear Shear Apparent
Sl.No. Stress Rate (), Viscosity Sl.No. Stress Rate (), Viscosity
(), Pa Sec-1 (a), Pas (), Pa Sec-1 (a), Pas
1. 3.695 9.397 0.392 1. 3.937 9.397 0.419

2. 5.006 20.8 0.246 2. 5.967 20.32 0.294

3. 5.704 30.61 0.186 3. 6.324 30.69 0.206

4. 6.554 40.98 0.16 4. 6.744 40.87 0.165

5. 7.766 52.42 0.147 5. 9.797 52.44 0.186

6. 8.626 62.9 0.138 6. 10.48 62.37 0.168

7. 11.74 73.62 0.159

7. 9.276 73.81 0.126
8. 11.86 84.2 0.141
8. 9.822 84.12 0.116
9. 12.26 94.56 0.13
9. 9.686 94.55 0.102
10. 14.65 105.4 0.139
10. 10.06 105.4 0.095
11. 13.87 114.9 0.12
11. 11.15 114.9 0.097
12. 14.6 125.2 0.116
12. 11.55 125.2 0.092
13. 15.35 136.1 0.113
13. 11.74 136.1 0.086
14. 16.25 146.6 0.111
14. 12.51 146.4 0.085
15. 16.23 157.3 0.103
15. 12.81 157.3 0.081
16. 16.1 167.6 0.096
16. 12.71 167.6 0.076
17. 17.03 178 0.096
17. 12.93 177.8 0.073
18. 17.81 188.7 0.094
18. 13.34 188.7 0.071
19. 17.14 199 0.086
19. 13.07 199 0.066

Model fit: Bingham Model, = 0 + ,

Model fit: Bingham Model, = 0 + ,
0=5.2356 Pa = 0.0698 Pas=69.8 cp
0=4.8053 Pa = 0.0487 Pas=48.7 cp
where = Shear Stress, Pa, 0 = Yield Stress,Pa
where = Shear Stress, Pa, 0 = Yield Stress,Pa
= Shear rate, Sec-1
= Shear rate, Sec -1
= Coefficient of Rigidity or Bingham
= Coefficient of Rigidity or Bingham
Viscosity, Pas.
Viscosity, Pas.

5
 Fig.3c: Rheogram of copper tailings sample at
Fig.3a : Rheogram of copper tailings sample at Cw = 72%
Cw=70% 4. Prediction of Pressure Drop
Characteristics

4.1 Experimental Setup

For this purpose pilot plant studies were taken

up to establish the actual conditions of copper
tailings slurry flow in the pipeline. The
experiment were conducted in 200mm (8),
250mm (10 ) & 300mm (12) diameter
pipeline test loops to determine the head loss
& pressure drop characteristics and the
deposition behaviour.

The pilot plant test rig used for the studies is

shown in Fig. 4a. The test set up has been
Fig.3b: Rheogram of copper designed as an open loop system with a fairly
tailings sample at Cw=71% large slurry tank & the slurry pumped through
the pipeline, retunes in the loop and freely
discharged into the slurry tank which holds
large quantity of slurry compared to that in
pipeline. A centrifugal rubber lined slurry
pump having through put of 260m3/hr at
maximum discharge pressure of 4kg/cm2
enters to the 200mm, 250mm and 300mm
diameter loops. The control of pipeline
velocity is obtained through the use of variable

6
speed drive for the centrifugal pumps & the s m 1000
Cw -----------(5)
continuous variation of speed (r.p.m.) of the m s 1000
D.C. motor are executed through the thyristor Where Cw = Wt. concentration in %
control system. The volume flow rate of slurry
s = density of solid in gm/cc or kg /m3
in the pipeline was measured with the help of a
Bingham modified Reynold number is
magnetic flow meter mounted vertically in the
calculated as follows
pipeline. A water pump of 300m3/hr capacity
with maximum discharge pressure of 6 kg/cm2 mVD
ReB -------------(6)
is provided to prevent any blockage in the
lines. Where V= Velocity of fluid in pipe in m/s.

N =Coefficient of viscosity or rigidity of fluid

Friction factor of is calculated by

f =16/ReB ------------------- - (7)

f is directly calculated from the plot of

Bingham Reynold number (ReB) and
Headstrome No.(NHe ) of [9] or from the graph
of (NHe) & critical Reynold number (R ec) of
[13].
Head loss or pressure drop is determined from
Darey-weisbach equation given by

Fig.4a:Pilot Plant Test Set-up 4 fLV 2 m

H m of water (8)
2 gD w
4.2 Calculation
Where f = friction factor of piple
The prediction of pressure drop and head loss
L= Length of pipe in m (1.1km)
of copper tailings samples is derived
V= velocity of fluid in pipe in m/s.
theoretically from Bingham Model. Headstrom
D= Diameter of pipeline in m
Numbers (NHe ) is calculated for determination
of head loss & is given by formula Head loss (H) is converted into kg/cm2 by
mathematically by the given formula
0 xm xD 2
NH e . (4) 10 x m of water = kg/cm2
2
4.3 Results & Discussions
where 0= yield stress
From the above calculation the head loss or
D=Diameter of pipe in mm
pressure drop of copper tailings slurry at
m = density of slurry mixture in gm/cc or
different concentrations of 70%, 71% & 72%
kg/m3 for a given length of pipe (1.1km) and
Solid Wt. concentration is given by relation diameter such as (200mm, 250mm & 300mm)
loop was calculated with a computer

7
 programme at slurry velocities of 1.5m/s, 2m/s,
& 2.5m/s for the given pipe diameter loop and
tabulated in table 4, 5 & 6.
Table -4
5. CONCLUSION
The characterization, rheological analysis,
viscosity and computation of head loss using
theoretical model for the copper tailings

Sl. Wt. conce Length Diameter Slurry Head

sample of M/s. HCL, Khetri indicates the
No. ntration of the of Velocity loss ( following. The rheological analysis of
(CW) in pipeline Pipeline in m/s H) in
% (L) in (D) in kg/cm2 thickened slurry (CW = 70%-72%) indicates
m mm
1. 70 1100 200 1.5 50.5 that the flow behaviour can be characterized by
2. 71 1100 200 1.5 65.15 Bingham plastic model. The viscosity of
3. 72 1100 200 1.5 89.48
tailings slurry of solid weight concentrations of
4. 70 1100 250 1.5 33.11
5. 71 1100 250 1.5 40.95 70%, 71% & 72% were found to be 39.54 cp,
6. 72 1100 250 1.5 56.51 48.7 cp & 69.8 cp respectively. Using this
7. 70 1100 300 1.5 21.44
8. 71 1100 300 1.5 27.92
model the prediction of pressure drop was
9. 72 1100 300 1.5 40.81 carried out for the copper tailings slurry by
means of a computer programme. The pressure
drop data for 200mm, 250mm & 300mm
Table -5
diameter pipelines were determined which will
Sl. Wt. conce Length Diameter Slurry Headloss
No. ntration of the of Velocity ( H) in be quite useful in selecting the pump power
(CW) in pipeline Pipeline in m/s kg/cm2
% (L) in m (D)in mm capacity for commercial application. The
1. 70 1100 200 2 65.41
disposal of thickened copper tailings slurry at
2. 71 1100 200 2 82.73
3. 72 1100 200 2 117.2 higher concentration will have the additional
4. 70 1100 250 2 39.24 advantage of occupying lesser space, there by
5. 71 1100 250 2 52.95
6. 72 1100 250 2 73.68 reducing the cost for construction of huge pond
7. 70 1100 300 2 27.25 for storage purpose & reduces environmental
8. 71 1100 300 2 38.6
9. 72 1100 300 2 50.23 pollution. The study will have immense help
Table -6 for the mineral processing industries to adopt
the higher concentration pipeline disposal
Sl. Wt. conce Length Diameter Slurry Headloss
No. ntration of the of Velocity ( H) in system.
(CW) in pipeline Pipeline in m/s kg/cm2
% (L) in m (D)in mm
1. 70 1100 200 2.5 76.65
Nomenclature
2. 71 1100 200 2.5 103.41 Cw Weight concentration in %.
3. 72 1100 200 2.5 143.9 Cwmax Maximum settled concentration by
4. 70 1100 250 2.5 51.10
2.5
weight in %
5. 71 1100 250 62.05
6. 72 1100 250 2.5 94.19 d50 Median size of sample in m
7. 70 1100 300 2.5 34.068 D Diameter of pipe in m
8. 71 1100 300 2.5 43.09
9. 72 1100 300 2.5 61.05 f Friction factor of pipe
g Acceleration due to gravity = 9.81m/s2
H Head loss or pressure drop in kg/cm2
L Length of pipe in m
NHe Headstrom Number
ReB Bingham modified Reynold number

8
Vs Velocity of slurry in m/s.
m Density of mixture in kg/m3
w Density of water in kg/m3
Shear stress in Pa
0 Yield stress in Pa
Shear rate of velocity gradient
Coefficient of viscosity or rigidity
Acknowledgement
The author would like to thank Mr.P.K.
Senapati, Sr. Scientist of IMMT for his
assistance during the preparation of this project
paper.
References
[1]Venton and Cowper, N.T. the overview
of recent slurry systems, a case studies of
some major projects of copper concentrate
pipeline, 1988, pp. 642-43.
[2]Snoek, P.E. and Gandhi, R.L. the
Bougainville Copper Concentrate pipeline
of book Slurry handling & transportation,
1972, pp.313-14.
[3]Denson, D. West Irian slurried copper
concentrate pipe line industry, of book
solid-liquid flow, 1972, pp.567-68.
[4]Nguyen, V.T. and Saez, F., Design of
pipeline for highly abrasive and corrosive
slurry proc. 6th International Conference
on the hydraulic transport of solids in pipes,
Hydrotransport6, PAPERH2, 1979,
September 26-28, pp.367-77.
[5] Thornton. W.A., Hydraulic Transport of
Solids in Pipes, in proc.Hydrotransport3,
PAPERH3, BHRA Fluid Engineering,
cranfield, Bedford, England, Denver, 1974,
Sept.1-4, pp.245-50.
[6] Borns, R.andStoodley, F.R. and Crost, J.F.,
A Major Tailings disposal system at
Chingola, Zambia in proc. 6th International
Conference on the hydraulic transport of
solids in pipes, Hydrotransport6,
PAPERH3; Zambia Engineering Service
Ltd. U.K., 1979, September 26th-28th,
pp.447-57.
[7]Bain,A.G and Bonnington, S.T.,The
Hydraulic Transport of solids by pipeline,
9
proc 1st international conference on the
hydraulic transport of solids of BHRA fluid
engineering, Oxford, U.K.,1979, October,
pp.300-310.
[8]Brown, Nigel.P. and Heywood, Nigel.I.,
Slurry handling & design of solid-liquid
system, pp.516.
[9]Govier, G.W. & Aziz, K., The Flow of
complex mixtures in pipes, Van Nostrand
Reinhold Co.New York, USA.
[10]Thornton, W.A. Hydraulics Transport of
Solids in Pipes:A Bibliography. 1970,
BHRA, The Fluid Engineering Centre,
Cranfield, UK.
[11]Hydrotransport Conferences(International
Conferences on the Hydraulic transport of
Solids in Pipes),BHRA, Cranfield, UK. 1-4
Sept.1970.
[12]Baker, P.J. & Jacobs, B.E.A.A guide to
slurry pipeline systems, BHRA, The Fluid
Engineering Centre, Cranfield, UK, 1979.
[13] Edward, J.wasp, Solid liquid Flow slurry
pipeline transportation, pp.700
[14]Gandhi, L.Ramesh, Slurry and sludge
piping of piping handbook, pp.
c.567-616
[15]Wasp, E.J., Kenny, J.P. & Gandhi, R.L.,
Solid-Liquid Flow Slurry Pipeline
Transportation. & Design of slurry
systems,Transtech Publications, Clausthal-
Zellerfeld, Germany, 1979, pp.465-79.
[16]Pablo Kleiman, Hydraulic Transport of
copper tailings,Journal of Hydraulic
division, vol.102, No.10, 1976, October24-
29, pp.1589-1594.
[17]B.E.A. Jacobs, Design of slurry Transport
systems, by Elsevier applied science.
[18]Hydraulic Transport of Solids (Conference
and Workshop), Institute of Mechanical
Engineers, London, UK, 2 Dec.1980.
[19]Cheremisin off, N.P. (ed.) (1986).
Rheology and Non-Newtonian Flows
(Vol.7 of Encyclopedia of Fluid
Mechanics). Gulf Publishing Co., Houston,
TX, USA.
[20] Books on slurry transportation of copper
tailing at higher concentration,
wikianswers.com.
10