In mining and processing operations where minerals, high in pyrite and low in calcite/dolomite are processed, acid is generated, which needs to be neutralised. Ticor at Empangeni in South Africa (SA) produces rutile (TiO2), leucoxene (TiO2 plus iron compounds), titanium (Ti), zircon (Zi) and ilmenite (TiO2 plus iron compounds). Neutralisation is required in the processing plant where acid is leached into the wash water. This water needs to be treated to a quality suitable for re-use in the metallurgical process or to a higher quality to make it suitable for discharge into the Empangeni sewage system (SA). For re-use the water needs to be neutral and under-saturated with respect to gypsum while for discharge into the sewage system the sulfate concentration needs to be reduced to less than 500 mg/L (as SO4)._x000D_
Acid mine water is generally neutralised with lime. Disadvantages associated with lime are the costs and maintenance of the slaking equipment as well as hazards, associated with handling of the alkali. The cost of powdered limestone (CaCO3) in South Africa, a by-product, is 50 - 60 per cent cheaper than lime. A technology has been developed where limestone is used for neutralisation of acid mine water instead of lime. This development includes: Limestone handling and dosing system. A novel, robust system has been developed where waste CaCO3 from the paper industry is slurried to a constant density. A full-scale plant was constructed to evaluate its performance (Figure 4). The dosing system consists of an inclined slab onto which the limestone is stored and from where it is slurried into a make-up tank. The density of the slurry in the make-up tank is controlled via a loadcell that measures the weight of the tank (operated at constant volume) and activates/deactivates the spray of the recycle slurry onto the slab. Integrated limestone neutralisation/lime treatment process. In this process powdered CaCO3 is used for neutralisation and partial sulfate removal of acid leached from the coal washing plant. The sulfate concentration can be further reduced to below the saturation level of gypsum (ie 1200 mg/L) through gypsum crystallisation by means of lime treatment, resulting in metal precipitation (eg Fe3+ and Al3+). CO2- treatment for CaCO3 precipitation. The pH of the lime treated water can be adjusted to pH levels of 8.5 and lower using CO2. The CO2, generated during limestone neutralisation (Equation 2), can be captured and used in this stage of the process._x000D_
The first two stages (limestone- and lime neutralisation) of this technology have been implemented on full-scale at Ticor to treat the effluent of the process. The constructed plant is 80 m3/hr and differs from coal processing plants by way of not containing Fe(II) and Fe(III) in the water. The CO2-treatment stage (Stage 3) will soon be implemented at IHM as part of a program to optimise the technology for maximum benefits.