Abstract
The mining industry produces substantial tailings, which present environmental challenges. This necessitates the adoption of efficient solid–liquid separation technologies to convert these tailings into a dewatered and environmentally manageable dry stack form. This work aims to investigate the transformative potential of ultrasonic treatment in the context of flocculation filtration for kaolinite dewatering and to elucidate the underlying mechanism. Through Uniform Design optimization, we determined the optimal conditions: 40 W ultrasound power, 12 min duration, and 40 kHz frequency. Experimental validation emphasized the effectiveness of these parameters, revealing a 2.02 % reduction in filter cake water content alongside a significant 2.5-fold enhancement in filtration rate. Furthermore, this combined treatment surpassed the performance of flocculation alone, resulting in the formation of smaller, more desirable flocs. The 3D structural analysis of the filter cake using micro-CT revealed that the synergistic application of ultrasound and flocculation led to a notable decrease in overall porosity. More significantly, there was a substantial reduction of isolated pores (down to 9.32 %). This phenomenon remarkably improved pore connectivity, enlarged pore and channel radii, and effectively mitigated capillary resistance during water transport. Additionally, the filter cake subjected to ultrasound and flocculation treatment showcased a uniform distribution of pore space, indicative of a promising trend towards homogenization across different sections. Ultrasound plays a role in refining flocs and suppressing segregation during tailings flocculation and filtration processes, primarily attributed to the cavitation and acoustic streaming effects of ultrasound. This comprehensive investigation sheds light on the transformative role of ultrasonic treatment in advancing the efficiency and performance of kaolinite dewatering processes.
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