Rheology of Slurry A Review

10 X October 2022
https://doi.org/10.22214/ijraset.2022.46955
International Journal for Research in Applied Science & Engineering Technology (IJRASET)
ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 7.538
Volume 10 Issue X Oct 2022- Available at www.ijraset.com
Rheology of Slurry: A Review

Sai Swapnesh Mishra1, Ashish Kumar Parida2, Anurag Das3, Shrutam Saha4, Tushar Kumar5
1
JSW Steel Ltd., Barbil, Odisha, India
2, 3, 4, 5
Department of Mechanical Engineering, Institute of Technical Education & Research, S’O’A Deemed To Be University,
Bhubaneswar, Odisha-751030, India
Abstract: In this paper, the rheological parameters, characterisation, and the rheological behaviour of mineral ore slurry are
reviewed and discussed in detail. Rheology is a study of flow phenomenon of matter, parameters like viscosity and the
relationship between stress, strain, and time for the matter are helpful in defining rheology, these parameters have helped in
classification of fluids into two broad categories - Newtonian and Non-Newtonian fluids. The rheological characteristics have a
great impact in design and operation of the pipelines. This paper has a special emphasis on the iron ore slurry and its
rheological behaviors which are highly affected by several physical and chemical properties (particle shape, particle size
distribution, shear rate, pH value, solid concentration, viscosity, and slurry temperature) which also have been explained in
particulars. The importance of rheology in slurry transportation makes it really important to define ways for controlling
rheology that have proven to be helpful in stabilizing the slurry thus making the operation more efficient. Rheology is a major
factor that affects the process of pipeline transportation of slurry which makes it such an important topic of study and research.
Keywords: Rheology, Viscosity, Iron-ore slurry, Newtonian & Non-Newtonian fluids
I. INTRODUCTION
Rheology is a rather young branch of science, that came into repute only after the conclusion of World War - II. Yet, in a sense, it is
also considered as a really old branch of science, with roots in olden times. Greek philosopher Heraclitus and the Jewish prophetess
Deborah Notable are amongst those who have (inadvertently) popularized a number of concepts which are now recognized as
“rheological”. Various crucial rheological postulations were studied through the centuries and long before the conventional
introduction of the term rheology in 1929. This coincided with the founding of the American Society of Rheology in Washington
DC and the formal definition of rheology is invariably associated with Professor Eugene Bingham, department of chemistry,
Lafayette College, Easton, Pennsylvania. Professor Bingham, G. W. Scott Blair and Marcus Reiner of Israel of the U.K were the
three organizers of the meeting held in 1929 C.E. An appropriate description of rheology, which is generally acknowledged, is: “The
science of the deformation and flow of matter” [1].
Rheology is defined as the science of deformation and its root lies in the Greek word for flow. The term ‘Rheology’ was coined by
Eugene Bingham who also founded the society of rheology in the USA.
Rheological categorization and sorting of materials give an all-inclusive idea about the viscoelastic flow behavior of system.
Rheology is paramount to every material because the rheological feedbacks are closely related to the final designing and modeling
of systems. Now, rheology is an effective tool which has been in use for years now, to link physical properties of the concerned
material with its various other properties.
Using accustomed and standard rheometric procedures, various other behaviors like yield stress, flow profiles and fractural
behaviors can be easily regulated, and the slurry transportation process can be enhanced [2,3].
Slurry is a suspension of solid particles in a carrier liquid and transportation of these raw materials in the form of slurry through
pipelines is an environment friendly method. When raw materials are suspended in water, it is a hydraulic transport or conveying
[4]. Nowadays slurry transportation is widely used all over the world due to its benefits over other means of transport and for
designing an accurate and well-organized slurry pipeline we must have a great understanding of the Rheology of slurries which is
used to describe the fluid flow properties. While developing a slurry pipeline system, compiling good rheological data is crucial as it
will help largely in choosing pipes and pumps for the pipeline, and as a result, it's a contributing element in failure or success of a
project. Rheological studies help in determining shear stress, shear strain and yield stress which are further used in knowing the
viscosity, design velocity and as a result of which rheology ultimately tells us about best pumping conditions for transportation of
slurry [5,6].The transportation of slurry is defined by its rheology. This paper primarily focuses on rheological properties,
characteristics, and behavior of slurry systems and also the industrial applications related to iron ore slurry [47,49].
©IJRASET: All Rights are Reserved | SJ Impact Factor 7.538 | ISRA Journal Impact Factor 7.894 | 139
II. BASICS OF RHEOLOGY

Rheology is defined as the study of flow phenomena of matter in response to applied forces and stresses. It can also be defined as
the science of deformation and flow phenomena. The flow process can be described via parameters like viscosity and the
relationship between stress, strain, and time for the matter [47].
A. Rheological Parameters
1) Viscosity (η): Viscosity of a fluid is defined as the estimate of its resistance to flow. It occurs when one layer of fluid is caused
to move with respect to another layer of the same fluid. The S.I unit of viscosity is Pascal seconds (Pa.s) or kg.m-1.s-1 [7]
.Change in temperature causes change in viscosity but it does not change considerably when there is a difference in pressure. In
the case of a liquid, an increase in temperature causes the viscosity to decrease because of the rise in the molecular spacing but
whereas in terms of gases viscosity increases with the rise in temperature [8].
Viscosity (η) =
2) Shear Stress (σ): The force per unit area which acts coplanar to the infinitesimal small element/part of the fluid to cause
shearing action is called shear stress. The S.I unit of shear stress is N/m2. The following equation is used to calculate shear
stress [4,7]:
( )( )
Shear Stress (σ) = ( )( )
3) Shear Strain (ϒ): It is defined as a tangent of the change in angle that occurs between two-line segments which were mutually
perpendicular to each other initially. It is denoted by gamma and measured in radiance. It is a dimensionless quantity [7,9].
( )( )
Shear Strain (ϒ) =
( )( )
4) Shear Rate (ẙ): Velocity gradient are defined as the speed at which the intermediate layers of a fluid move relatively to one
another. This causes a shearing effect in the liquid and thus is defined as shear rate. The S.I unit of shear rate is reciprocal of
second (s-1) [7].
( ϒ) ( )
Shear Rate (ẙ) =
( )( )
B. Characterization On The Basis Of Rheological Parameters

According to scientific data and observations, a fluid provides more resistance when it is thick/thickened, and it has a lower
resistance to flow if it is thinner. Viscosity, as mentioned earlier, is defined as the property of a fluid to resist its flow and based on
the formula of viscosity, fluids are categorized into two types: (i) Newtonian fluids, in which η (Viscosity) is constant, and (ii) Non-
Newtonian fluids, in which η (Viscosity) is variable.
1) Newtonian Fluid: These are the type of fluids which exhibit constant viscosity for a comprehensive range of shear rates and at a
constant temperature and pressure [4]. They have a zero-shear rate at zero shear stress thus having a linear relationship between
shear stress and shear rate. These fluids obey Newton’s law of viscosity [7, 8].
τ =μ
where, μ = Viscosity, τ = Shear stress (F/A), and = Rate of shear deformation
Fig. 1 –Rheogram for flow of (a) shear stress vs shear rate, and (b) viscosity vs shear rate [4].
2) Non-Newtonian Fluids: These are the type of fluids that don’t follow Newton’s law of viscosity and their viscosity does not
remain constant as it changes according to the force applied. The various non-Newtonian fluids are Bingham plastics, dilatants,
pseudoplastics and yield pseudoplastics [9,10].
Shear stress, σ
Shear rate, ẙ
Fig. 2 - Flow behavior outline of non-Newtonian Fluids (Shear Stress vs Shear Rate) [14]
C. Types Of Flow
Flow regimes can be categorized into three distinct types, namely, laminar, turbulent, and transitional flow. Reynolds number is
used to determine if the concerned fluid flow falls into either of the aforementioned categories, to determine if the fluid flow is
laminar, transitional, or turbulent. The flow is said to be: Laminar, if Reynolds number is less than 2300 (i.e., if
Re<2300);Transitional, if Reynolds number lies in the range 2300–4000 (i.e., if 2300< Re <4000);or, Turbulent, if Reynolds
number is greater than 4000 (i.e., if Re>4000).
1) Laminar Flow: It is a type of flow in which the motion of the fluid particles is smooth and orderly, the particles are in a well-
ordered arrangement and the fluid moves in infinitesimal parallel layers with no disorganization between them. Properties like
pressure and velocity remain constant at every point [10, 11,12]
.
Fig. 3 - Laminar Flow [12]
2) Turbulent Flow: Turbulent flow is the type of flow in which the motion of the fluid is irregular, and the magnitude and the
direction of velocity is inconsistent at any given point, therefore the flow speed of the fluid keeps changing constantly. Blood
flow in arteries and flow of wind and water in river are the common examples of turbulent flow [10, 11,12].
Fig. 4 - Turbulent flow [12]
3) Transitional Flow: Transitional flow is the fusion between laminar and the turbulent flow and it is an arduous task to recognize
this type of flow. Transition region is used to determine the conditions of the flow of the fluid when it changes from laminar to
turbulent[4,12,13,14].
Fig. 5 – Transitional flow [12]
All fluids could be categorized into 2 fundamental types, namely, Newtonian fluids, and non-Newtonian fluids on the basis of
change in viscosity with applied shear stress. A flow can either be laminar, turbulent, or transitional depending on its nature and
Reynolds number is used to classify and determine the type of flow. These parameters help us to understand the rheology and flow
pattern in a more effective and efficient way [45].
III. RHEOLOGICAL CHARACTERISTICS

While numerous important factors are considered while designing a pipeline, characteristics of the slurry have the most influence on
its design and operation. The ore with a density higher than that of water is kept in a suspension mode for transportation.
Thenceforth, all the parameters have to be kept in check for free flow of the stream without any impediments.
A. Rheological Characteristics Of Minerals

Minerals have several rheological characteristics which affect the rheology and hence the flow of the slurry. These points are kept in
mind while designing pipelines. Several research activities have been carried out to determine the effect of these by research persons
from all around the globe. Some of their findings are listed in the table below.
Table 1 – Literature review of rheological characteristics of minerals.

Serial Name of the Rheological Research Fields, Activities and Findings
Number Author characteristics
1. (i) Zengeni Particle size The particle size evaluation of mineral slurries is crucial due to
B.T etal. [7] distribution the probable impact of particle size allocation on various
(ii) KongasM. downstream processes.It is an attempt to emphasize the relative
et al [15]. properties ofthe varying particle sizes the concerned sample
comprises of.
2. Abro M. I Slurry pH and The pH testing method is used to determine the acidity or
et.al.[17] temperature basicity of the aqueous slurry. Change in pH causes a change in
viscosity. With rise in pH value the percentage entrapment of
fine particles decreases, and the settling rate escalates.
Temperature plays crucial role as viscosity was noticed to reduce
with a rise in temperature until a certain point after which it tends
to increase.
3 Zengeni B.T Particle A tiny total of the specimen was sprinkled on to aluminum
etal. [7] micrographs remnant overlaid with carbon glue. It was then covered with a
carbon film in the evaporation coater. It was then placed into the
electron micrograph and was observed at various magnifications.
This whole process was carried out to demonstrate the variance
in shape of the particles.
4 Zengeni B.T Solid density Solid density is calculated using a helium gas pycnometer.
etal. [7] and slurry Helium gas pycnometer is used to compute solid density of
mixture density particles. The slurry mixture density was estimated with the help
measurements of a 250 ml volumetric flask. Density of the water was taken as
1000kg/m3. The following equation is used to determine mixture
density of the specimens.
( ⁄ )
5 Zengeni B.T Mass solid The mass solid concentration (Cm) of the slurries is calculated
etal. [7] concentration using the oven drying method. The following equation is used to
determine mass solid concentration:
Cm =
Where, M = mass of solids, and M =mass of the mixture
6 Zengeni B.T Volumetric solid The volumetric solid concentration ( ) is the function of
etal.[7] concentration mixture density ( m ), mass solid concentration (Cm )and solid
density( ). It is calculated using the following equation: =
× Cm
7 Matoušek V. Freely settled The freely settled bed packing concentration by volume is
etal.[18] bed packing determined by a familiar volume of solids that form the freely
concentration settled bed. Then the volume of the freely settled bed is
calculated subsequently. It is carried out by allowing the slurry to
settle down which comprises of dried and pre-weighed solids.
The following equation is used to calculate the freely settled bed
concentration (Cb,free):
( )
=
( )
8 Assefa K. M Chemical Chemical additives can be categorized as dispersants,

etal. [19] additives flocculants, surfactants, and anti- settling agents on the basis of
their functionalities. They can enrich and amplify the fluidity of
slurries.
B. Rheological Characteristics Of Pipeline

1) Slope And Elevation Of Pipe: Kesely etal.have discussed in their paper that the slope and elevation of the pipeline are
influenced according to the measurement and proportions of the particles. More often than not, a high solid concentration and
an ascending slope are used to convey the finer particles for even flow through the pipelines [20].
2) Thickness Of Pipe: Miguez etal. reviewedthat while constructing a pipeline, factors like concentration of solids, solid
distribution, flow velocity, and cost are taken into consideration. Hence, the thickness and diameter of the pipe are selected
accordingly [21].
3) Corrosion And Erosion Of Pipe: Javaheri etal. talked through about the effects of corrosion and erosion on pipelines. Slurry
velocity and particle size affect the corrosion and erosion in the pipeline to a great extent. Corrosion and erosion rate are also
taken into consideration while designing the thickness of the pipeline. Chemicals are added accordingly to regulate the pH of
the slurry [22].
Table 2 – Some of the chemical additives and their functions on the iron ore slurries [19].
Name of the chemicals Functions/effects Parental solids
Tapioca, Potato and corn starch, Sodium silicate & SHMP [23] Flocculants, Iron ore tailings
Dispersants
Magnafloc and Rishfloc; Sodium petroleum and CTAB [24] Flocculants; Iron ore fines
Surfactants
Calcium lignosulphonate [25] Surfactants Ferrosilicon

and magnetite
Magnafloc-1011-anionic and Magnafloc – 333- non-ionic [26] Flocculants Iron ore tailings
Limestone [27] Increased Acid iron ore

reducibility pellets
C. Factors Affecting Rheology

1) Size And Shape: Kawatra etal. and Eisele etal. noticed that at a given concentration of solids, depletion inthe size of the particles
will lead to an increase slurry viscosity. Furthermore, density of slurry rises, with a descension in particle size, for a constant
volume of slurry. In addition to that, the settling velocity of the coarse particle is higher than that of the fine particles [28].
Table 3 Solids density of typical minerals [29]

Minerals Solid density Largest particle Diameter
(g/cm3)* (microns)**
Iron concentrate 4.9 149
Copper concentrate 4.1 212
Zinc concentrate 4.0 212
Phosphate concentrate 3.2 212
Bauxite concentrate 2.6 297
Kaolin concentrate 2.6 297
Coal 1.4 1190
* Typical densities
** Typical, but can vary depending on specific circumstances and pipeline length
2) Concentration Of Solid: Mangesana etal. discussed that the viscosity of a suspension increases with increase in solids
concentration. Solid concentration depends on the size of the solid and viscosity of the slurry. Moreover, maximum
concentration at which the viscosity of the slurry increases sharply after increasing a small concentration of the solid is defined
as the optimal solid concentration [30].
3) Viscosity Of Slurry: Sahoo et al. investigated on the basis of the ANOVA results procured, solid concentrations, particle
diameter, microwave exposure time and shear rate were discovered to have notable effects on the apparent viscosity of iron ore-
water slurry, with shear rate striking the most substantial effect on apparent viscosity of iron ore-water slurry, while on the
contrary, solid concentration had the least effect on the response [31].
4) Slurry Flow Rate: Silva et al. discussed that the slurry flow rate is dependent on the solid concentration and particle size
distribution. The slurry velocity varies from 1.60 m/s to 1.86 m/s depending on the size of the particles and the flow rate can
vary between 1,826 m³/h and 2,105 m³/h to minimize the solid particle bed deposition, which reduces the overall efficiency of
the pipeline [32].
There is no standard accessible technique that is referred to while designing slurry pipelines, each slurry and circumstance is distinct
and discrete. So consequently, nearly all the data available for the design aspect is centered on experience.
IV. RHEOLOGICAL BEHAVIOR OF IRON-ORE SLURRY

Iron ore slurry being a solid liquid mixture undergoes plastic deformation when subjected to stress. Investigation and study of
rheological characteristics has been a topic of interest since years due to its industrial applications. Study of the rheology of the iron
ore suspension is highly complicated and no single parameter can solely explain it. Physical and chemical properties like solid
concentration, particle size distribution, particle shape, pH value, shear rate, viscosity, and slurry temperature highly affect the
rheology of iron ore slurry [23,58].
A. Effect Of Solid Concentration On Apparent Viscosity

Senapati et al. [27] investigated the non-Newtonian flow characteristics of the iron ore slurry and concluded the Bingham plastic
flow behavior from the rheogram (shear stress (Pa)) – ̇ (shear rate (s )) plotted in Figure 3 with observation that the increase in
mass concentration, shear stress values increase. At low concentrations of the iron ore, the flow pattern may be Newtonian with
viscosity η independent of the shear rate. With gradual increase in concentration, it advances to acquire non-Newtonian properties
with a steeply increasing viscosity as the shear rate decreases (Fig. 2) [8, 34,37].
Figure 6 – (a) Rheogram of iron ore at different solid concentrations by mass, (b) Variation of apparent viscosity with shear rate at
different solid [33].
B. Effect Of Particle Size And Particle Size Distribution

Senapati et al. [34] conducted a series of experiments blending fine particles in coarser slurry suspensions of iron ore in fixed blend
ratio of 4:1 thereby attaining a bidisperse suspension. The size ratio (λ) that is the ratio of larger diameter to smaller particles given
by, λ = highly affects the the viscosity of the slurry. So the apparent viscosity increases with the decrease in size ratio for
thethree particle size distribution depicted by Figure 4(a). Bingham yeild stress rapidly increases beyond a slurry concentration with
unimodal particle size distribution while with bimodal and multimodal particle size distribution lesser yield stress is indicated. A
high solid concentration with small inter-particle distance generates a high attractive force and a specific shear force is required to
break apart incoherent flocs and overcome internal friction between fine particles to intiate flow [35,36]. It is hence observed that
the bimodal and multimodal particle distribution of iron ore influence the apparent viscosity than the unimodal distribution from the
Figure 4(b) [34,37,50].
Figure 7 – (a) Effect of size ratio (λ) on the apparent viscosity for the three iron ore particle distributions, and (b) Effect of particle
size distribution on apparent viscosity of iron ore slurry at high solid concentration [34].
C. Effect Of Temperature On Iron Ore Slurry

Temperature is one the major factors that has a strong effect on yield stress and apparent viscosity of the slurry. Peforming rheology
experiments Kumar et al. [33] noticed the reduction in the apparent viscosity with the rise in temperature.The increase in
temperature of the iron ore suspensions results in the increase in the kinetic energy of the slurry particles and reduces the
intermolecular forces within the layers of the fluid and thereby leads to the decrease in viscosity. Temperature highly affects the
yield stress of the slurry as well as its apparent viscosity because of the variation in viscosity of the carrier fluid. In lower
temperature ranges the yield stress is decreased with increasing temperature and at higher temperatures an increase in yield stress is
observed. It is quite evident from Figure 5 [33], the yield stresss and viscosity dependancy on temperature that is necessary for
evaluating the slurry rheology [8,50,51,55].
Figure 8 - Effect of temperature on apparent viscosity of iron ore slurry [23].
D. Effects Of Chemical Additives On Rheological Properties Of Highly Concentrated Iron Ore Slurry
At an experiment conducted by Senapati et al. [34] it is observed that some selective additives can influence the flow behaviour and
acts as a stabilising agent of iron ore slurry. The fundamental role of chemical dispersants is to decrease or completely terminate the
yield stress of slurry. Aqueous suspension of mineral ores has inter-particle forces which consists of van der Waals forces and
electrostatic forces, use of a potent additive can alter the surface charge of the slurry thus making the inter-particle forces completely
repulsive which results in reduction of yield stress and stabilization the slurry.Having an elementary knowledge about the effects
and side effects of an additive on highly concentrated iron ore slurry is really important for selection of a suitable additive[8]. The
prominent additives selected for stabilization of iron ore slurry are hydrated lime, quick lime, Acti-Gel and Sodium
Hexametaphosphate (SHMP).
Figure 9 - Effect of chemical additives on yield stress of iron ore slurry [59]
Quick lime (CaO) and hydrated lime (CaOH) both used as flocculants and can also be frequently mixed with iron ore mixture to
enhance the output. Sodium Hexametaphosphate (SHMP) is generally used as a deflocculant agent; it reduces the particle-particle
interactions which prevents aggregations of particles and thus successfully reducing the yield stress of the iron ore slurry. Acti-Gel
which is highly purified Magnesium Alumino-Silicate according to the Active Minerals International LLC website is used for water
based industrial application, with a pH between 2 and 13. The Acti-gel being chemically inert acts as a rheology modifier and anti-
settling agent that yields a higher quality particle suspension, boosts the workableness, slurry performance and flowability by
stabilizing the mixture, [38,55].
E. Effects Of Velocity Of Iron Ore Slurry

For iron ore slurries where the solid particles are not properly suspended in the carrying liquid determining the operating velocity is
important. Operating velocity of the iron ore slurry should not be too high or low as it can have a negative impact on the slurry
transportation. It is important to determine the operating velocity that is higher than the superficial velocity to avoid settling and
sedimentation of solid particles thus preventing blockage of pipeline, but the determined velocity should not be much above the
superficial velocity as that leads to extreme wear and tear of the pipeline and pumps. For the iron ore slurry, the operating velocity is
normally kept around 1.7m/s [37,39].
The present study shows the influence of solid concentration, particle size distribution, surface characteristics, additives, and
temperature on the rheological behavior of iron-ore slurry. The non-Newtonian flow behavior of the solid-liquid suspension
integrates quite well with the Bingham plastic model. The specific multimodal iron ore samples with a broad size distribution
indicates a considerable reduction in slurry viscosity, yield stress and improved solid loading compared to monomodal ones.
Recently, it was found that microwave pre-treatment of iron ore reduces the slurry viscosity and yield stress exhibiting shear-
thinning or pseudo-plastic behavior. The viscosity and density of microwave treated ore is always lower than that of untreated
[31,37,52].
V. METHODS TO CONTROL RHEOLOGY

Pipelines have been the major conveyance to transport solids on large scale than the conventional modes of transportation since the
last decades. Pipelines are used for long distance transportation of different solid materials such as coal, fly ash, limestone, zinc
tailings, rock phosphate Gilsonite, copper concentrate and iron concentrate. Rheology control is of paramount importance for
designing the slurry pipeline system. Rheology of slurry is controlled by mechanical means that includes maintenance of high-
pressure gradient and ultra-sonication, adding chemical additives or Nano-stabilizers. [5,53]
A. Mechanical Methods For Controlling Rheology

After conducting a large number of experiments scientists have discovered some mechanical methods for controlling rheology.
Maintaining high pressure gradient and ultra-sonication are one the best mechanical methods for rheology control.
(i)Maintenance of high-pressure gradient –Gillies et al. [40] predicted the pressure drop in slurry pipelines and his Saskatchewan
Research Council (SRC) two-layer model predicts that the pressure gradient and deposition velocity as a function of the particle
diameter, pipe diameter, particle concentration and the mixture velocity based on his experimental correlations [49]. The pressure
gradient (∆ ), where ∆ is the pressure drop for pipeline flow of solid-liquid suspension and is the length of the pipe - of the
solid–liquid slurry is generally higher than that of an equal flow rate of pure liquid because the particles produce additional
dissipation. The pressure gradient has its dependency on the four distinct flow regimes of particle conveyance as per the
experiments carried out by Newitt et al. [41] and Durand [42] predicting the critical deposition velocity of slurry.
Figure 10 – Variation of slurry performance characteristics for slurry of iron oxide with solid concentration 1% by volume and
particle diameter = 1 mm. versus mean mixture velocity.[44]
The pressure gradient variation is shown as the non-dimensional variable expresses the pressure drop divided by the mixture weight
[43]:
= ⁄( )
where, is the pressure gradient in height of mixture / length of pipe, is the differential axial distance, is the mean density
and g is the specific gravity of the mixture. Hence, Aziz et al. [44] concluded that the increase in the input concentration and
specific gravity leads to the increase in pressure gradient and as the mixture velocity increases, the efficiency of the transport
increases [37,57].
(ii)Ultrasonic Treatment – Ultrasonic treatment in solid-liquid system is an economic approach that is capable of producing a high
transient temperature and pressure at the place of its application. Li et al. [45] studied the ultrasonic irradiation on coal water slurry
that effectively improved the static stability of the slurry. It favors the pseudo plastic flow of the non-Newtonian fluid and decreases
the apparent viscosity with increasing shear rate. For a sufficient period of treatment promotes a sharp decrease in apparent viscosity
and highly improves the static stability [36,46].
B. Chemical Means For Controlling Rheology

Addition of chemical additives, viscosity modifiers and Nano stabilizers are some well-known methods that can be used to control
slurry rheology by chemical means.
1) Addition Of Chemical Additives: The fundamental role of chemical dispersants is to decrease or completely terminate the yield
stress of slurry. Aqueous suspension of mineral ores has interparticle forces which consists of van der Waals forces and
electrostatic forces, the use of a potent additives can alter the surface nature of the slurry thus making the interparticle forces
completely repulsive which results in reduction of yield stress thus the slurry rheology is improved[8]. Most of the potent
additives are water soluble polymers with low molecular weights along with other prominent additives such as lime, sodium
silicate, sodium Hexametaphosphate (SHMP), sodium phosphate, NaOH or KOH, etc. [38]. Determining a proper dosage of a
potent chemical additives is important as an insufficient amount will lead to flocculation which will increase the viscosity of
slurry and an excessive amount can cause slurry destabilization [8].
2) Addition Of Viscosity Modifiers: This method is used for decreasing viscosity of the mineral ore slurries by the addition of a
viscosity modification agents. The viscosity of highly concentrated mineral ore slurry is often troublesome in operations
involving transportation, pumping and agitation. In an experiment conducted by Perez et al. [47] it was observed that the
mineral ores are primarily, made of gangue or the waste particles, they are the largest component of the mineral ore slurry
therefore the selection of favourable viscosity modification agents can be based upon the type of gangue particles present in the
mineral ore.
.
Figure 11- Effect of Viscosity modifiers on apparent viscosity of iron ore slurry.[59]
Viscosity modifiers are anionic surfactants mostly sodium salts of inorganic and organic sulphonates the addition of one or more
viscosity modifiers in an effective amount can decrease the viscosity thus reducing the cost and problems related to transport
pumping and agitation thus improving the slurry rheology [47].
C. Adding Nano-Stabilizers To Control The Rheology Of The Slurry

Nano stabilizers have gain importance as a rheology controlling agent in recent times. Addition of nano-stabilisers to the iron ore
slurry increases the stability of the slurry and efficiency of the operation. Stabilisation of slurry will make it easy to transport it to
longer distances with greater ease [48]. Discoveries of the mechanical and chemical methods for controlling and manipulating the
rheology of slurry has made transportation through slurry pipelines easier over the years. Research is going on to find ways to make
these methods more efficient. As chemical dispersants have a great effect on the slurry rheology, research is going as we need a bit
more understanding on the effect of molecular weight of the dispersants and the methods for determining the proper dosages of
potent dispersants also need refinement [36].
VI. CONCLUSION
The slurry flow mannerism is governed by its rheology, which elucidates its deformation and flow behavior. Rheology is also
authoritative to fluids with complex microstructures that are used in various other industries. Numerous factors such as solid
concentration, slurry viscosity, slurry flow rate etc. condition of the rheology of the slurry. The most crucial rheological
characteristic is the slurry viscosity and fluids may further be categorized into two categories namely, Newtonian fluids, and non-
Newtonian fluids, in accordance with it. Rheology has a pivotal role in the designing and construction aspect of pipeline and cost
optimization is a top priority in the course of construction and manufacturing. Alterations involving length and inclination of the
pipe can be carried out to curtail pressure losses. Petroleum coke oil slurry was made to undergo ultrasonic treatment to evaluate its
effects. Experiments are being carried out by taking two petroleum cokes and mixed with paraffin to prepare the slurry fuel, and
then investigations are also being carried to study the effect of ultrasonic treatment on slurry, where the results showed that the
petroleum coke oil slurry fuel not only decreased the viscosity but also aided their static stability. Similarly, several other research
activities, investigations, and projects on the rheology of slurry are currently in process to make the slurry transportation process
through pipelines more effective and efficient. Slurry transportation through pipelines is an emerging sector, and as mentioned
earlier in this paper, almost all data available for design and construction through pipelines is experience based, so research work in
more depth on rheology must be carried out to enhance the transportation system [51]. Nevertheless, lots of scope for further
research in the field of rheology still remains with the ever-growing need to investigate and to have appropriate relations between
the rheology and mineralogy of iron-ore slurry.
REFERENCES
[1] Walters K. ‘History of Rheology’, Rheology Vol.-1, Institute of Mathematical and Physical Sciences, Aberystwyth University, Aberystwyth, UK.
[2] Abraham J., Sharika T., Mishra R.K., Thomas S., ‘Rheological Characteristics of Nanomaterials and Nanocomposites’.Woodhead Publishing Series in
Composites Science and Engineering, Elsevier BV, 2017, Pages 327–350.
[3] Wilson D.I., “What is Rheology?’, Cambridge Ophthalmology Symposium, Eye. 2017. Pages 179-183.
[4] Kumawat N. Kumar S., Mohapatra S.K., ‘Rheological Characterization of Minerals’. Department of Mechanical Engineering, Thapar University, Patiala, July
2015.
[5] Rao N.D., Thatoi D.N., Biswal S.K.'Rheological study and numerical analysis of high concentration iron ore slurry pipeline transportation. Materials Today:
Proceedings. Volume 22. Part 4. 2020. Pages 3197-3202.
[6] https://www.sgsgroup.in/en-gb/mining/metallurgy-and-process-design/pilot-plants/rheology-and-slurry-flow
[7] ZengeniB.T.,Oliver G.J., ‘Bingham yield stress and Bingham plastic viscosity of homogeneous non-Newtonianslurries’MTech thesis paper Cape Peninsula
University of Technology, October 2016.
[8] He M., Wang Y., Forssberg E., ‘Slurry Rheology in wet ultrafine grinding of industrial minerals: a review’. Powder Technology, 2004, Pages 94-112.
[9] Poloski A.P., Adkins H.E, Bonebrake M.L, Chun J., Casella A.M, Denslow K.M., Johnson M.D, Luna M.L, MacFarlan P.J, Tingey J.M, Toth J.J., ‘Deposition
Velocities of Non-Newtonian Slurries in Pipelines: Complex Simulant Testing’. U.S. Department of Energy. July 2009.
[10] Krishnan A., Radhakrishnan T., Poelma C., Lier J.V. & Clemens F., ‘Laminar-turbulent transition of a non-Newtonian fluid flow’, Journal of Hydraulic
Research, Volume 59 issue 2, Page -235-249,2020
[11] Özahi E., Çarpinlioğlu M., ‘A Brief Review On Laminar to Turbulent Transition in Time-Dependent Pipe Flows’. ResearchGate. November 2008.
[12] Lesher M.,‘Up, Down, or Sideways: Emplacement of Magmatic Ni-Cu-(PGE) Sulfide Melts in Large Igneous Provinces’. Canadian Journal of Earth
Sciences. Volume 56, March 2019.
[13] Rapp B.E, ‘Fluids, In Micro and Nano Technologies, Microfluidics: Modelling, Mechanics and Mathematics’. Elsevier, Pages 243-263, 2017.
[14] Nakayama Y., ‘Characteristics of a Fluid, Introduction to Fluid Mechanics (Second Edition)’, Butterworth-Heinemann, Pages 9-24, 2018.
[15] Pinto F., &MeoM., ‘Design and Manufacturing of a Novel Shear Thickening Fluid Composite (STFC) with Enhanced out-of-Plane Properties and Damage
Suppression’. Applied Composite Materials. Volume 24, June 2017.
[16] Kongas M., ‘Mineral Slurry On-Stream Particle Size Analysis, Filtration& Separation,’ ScienceDirect,Volume 40, Issue 7,Pages 36-37,2003.
[17] Abro M. I., Pathan A. G., Andreas B,Mallah A. H., ‘Effect of Various Parameters on the Dispersion of Ultra Fine Iron Ore Slurry’. Pakistan journal of
analytical & environmental chemistry. Volume 10, Pages 18 -22,2010.
[18] Matoušek V., Krupička J., Kesely M., ‘A layered model for inclined pipe flow of settling slurry.’ Powder Technology, Volume 333, Pages 317-326, June 2018.
[19] Assefa K.M., Kaushal D. R., ‘The Influence of Chemical Additives on the Flow Behaviors of Solid-Liquid Suspensions: A Review’, International journal of
engineering research & technology. , Volume 4, Issue 3, 2015.
[20] Matoušek V., Kesely M., Konfršt J., Vlasak P., ‘Effect of Pipe Inclination on Settling Slurry Flow Near Deposition Velocity’, Researchgate, July 2018.
[21] Beltran J.P., Ceci P., Miguez P., Casali P.' Construction of slurry pipelines.' Procedia Engineering. Volume 138.2016. Pages 127 – 130
[22] Javaheri V., Porter D., Kuokkala V. T., ‘Slurry erosion of steel – Review of tests, mechanisms and materials’ ScienceDirect, Volumes 408–409, Pages 248-273,
2018.
[23] Rao K.H., Narasimhan K. S., ‘Selective flocculation applied to Barsuan iron ore tailings’, International Journal of Mineral Processing, Volume 14, Issue 1,
Pages 67-75, 1985.
[24] Singh B.P., Besra L., ‘The effect of flocculamts and surfactants on the filtration dewatering of iron ore fines’, Separation Science and Technology, Volume 32,
Issue 13 , Pages 2201-2219, August 1996.
[25] Mabuza N., Pocock J., Loveday, Brian., ‘The use of surface active chemicals in heavy medium viscosity reduction’. Minerals Engineering. Volume-18, Pages
25-31, January 2005.
[26] Dash M., Dwari R.K., Biswal S. K., Reddy P.S.R., Chattopadhyay P., Mishra B.K., ‘Studies on the effect of flocculant adsorption on the dewatering of iron ore
tailings’, Chemical Engineering Journal, Volume 173, Issue 2, Pages 318-325, 2011.
[27] Iljana M., Kemppainen A., Paananen T., Mattila T., Pisilä E. Kondrakov M., Fabritius T., ‘Effect of adding limestone on the metallurgical properties of iron
ore pellets’, nternational Journal of Mineral Processing, Volume 141, Pages 34-43, 2015.
[28] Kawatra S.K., and Eisele T.C., ‘Rheological Effects in grinding circuit’ ScienceDirect. volume 22, Issue 1-4, Pages 251–259, April 1988.
[29] Chapman J.P, Lima R., Pinto D., Vidal A., ‘Slurry Pipeline Technology – An Overview’, Rio Pipeline Conference and Exposition 2009, September 2009.
[30] Mangesana N., Aubrey A., Govender I., Van der Westhuizen A., Mangadoddy N., ‘The effect of particle sizes and solids concentration on the rheology of
silica sand-based suspensions’Journal of the Southern African Institute of Mining and Metallurgy, Volume 108, 2008.
[31] Sahoo B.K., Das T.K., Gupta A., De S., Carsky M., Meikap B.C., ‘Application of response surface analysis to iron ore slurry rheology using microwave pre-
treatment.’, South African Journal of Chemical Engineering, Volume 23, Pages 81-90, June 2017.
[32] Silva A.M., Passos A.C, Santos D., Orban E.M., Lisboa H.D., Gonçalves N., Guimarães R.C., ‘Overview of the long-distance iron ore slurry pipeline from
anglo ferrous brazil.’, Rio Pipeline Conference Proceedings., September 2009.
[33] Kumar S, Kumar S, ‘Investigation of flow characteristics of iron-ore and water slurry.’ Department of Mechanical Engineering, Thapar Institute of
Engineering and Technology, Patiala, 2018.
[34] Senapati P. K, PothalJ. K, Barik R, Kumar R, Bhatnagar S. K, 'Effect of particle size, blend ratio and some selective bio-additives on rheological behavior of
high-concentration iron ore slurry.’, Proceedings of the 21st International Seminar on Paste and Thickened Tailings, Australian Centre for Geomechanics,
Perth, 2018.Pages 227-238.
[35] Abro M.I, Pathan A.G, Andreas B, Mallah A.H, ‘Effect of various parameters on the dispersion of ultra fine iron ore slurry. Part-1.’, Pakistan Journal of
Analytical & Environmental Chemistry. Volume 10 No. 1, 2009. Pages 34-38.
[36] Chang C, Powell R.L, ‘Effect of particle size distributions on the rheology of concentrated bimodal suspensions.’, Journal of Rheology. Volume 38 No. 1,
1994. Pages 85–98.
[37] Sahoo B.K, De S, Meikap B.C, ‘An investigation into the influence of microwave energy on iron ore-water slurry rheology.’, Journal of Industrial and
Engineering Chemistry. Volume 25, 2015. Pages 122-130.
[38] Melorie A.K, Kaushal D.R, ‘Experimental Investigation of the effect of Chemical additives on Rheological Properties of highly concentrated iron ore slurry’,
KONA and particle Journal No.35 2018. Pages 186-199.
[39] Roitto V.,‘Slurry flows in metallurgical process engineering-Developmesnt of tools and guidelines’. Department of Plant Engineering of Outotec, Finland,
2014. Pages 40-50.
[40] Gillies R.G, Shook C.A, Wilson K.C, ‘An improved two layer model for horizontal slurry pipeline flow’, The Canadian Journal of Chemical Engineering.
Volume 69 Issue 1, 1991. Pages 173-178.
[41] Newitt M, Richardson J.F, Abbot M, Tur-tle R.B, ‘Hydraulic Conveying of Solids in Horizontal Pipes’, Transactions of the Institution of Chemical Engineers,
Volume 33, 1955. Pages 93-113.
[42] Durand R, ‘The Hydraulic Transport of Coal and Solid Materials in Pipes’, Proceedings of Colloquium on the Hydraulic Transport of Coal, National Coal
Board, London, 1952. Pages 39-55.
[43] Li M.Z, He Y.P, Liu Y.D, Huang C, ‘Effect of interaction of particleswith different sizes on particle kinetics in multi-sized slurry transport by pipeline’, Powder
Technology, Volume 338, 2018. Pages 915-930.
[44] Abd Al Aziz A.I, Mohamed H.I, ‘A Study of the Factors Affecting Transporting Solid-Liquid Suspension through Pipelines’, Open Journal of Fluid Dynamics,
2013. Volume 3. Pages 152-162.
[45] Li Y.X, Li B.Q, ‘Study on the ultrasonic irradiation of coal water slurry’, Fuel. Volume 79,Issues 3-4, 2000. Pages 234-241.
[46] Wang Z,Wang H, Guo Q, ‘Effect of Ultasonic treatment on the Properties of petroleum Coke Oil Slurry’, Energy & Fuels, Volume 20, 2006. Pages 1959-1964.
[47] Perez L, Polizzotti D.M, Johnson I.D, ‘Mineral ore slurry viscosity modification method’, United states patent application publication, 2004.
[48] Lin M, Wey M, Tseng H, Lin Y, ‘Charateristics of two types of stabilizers’, Department of enviromental engineering , Natinal Chung-Hsing University ,
Taicung ,Taiwan, 2010. Pages 2260-2267.
[49] Capecelatro J.,Desjardins O., ‘Eulerian–Lagrangian modeling of turbulent liquid–solid slurries in horizontal pipes,International Journal of Multiphase
Flow,Volume 55,2013,Pages 64-79.
[50] Kumar S., Singh M., Singh J., ‘Rheological Characteristics of Uni/Bi-Variant Particulate Iron Ore Slurry: Artificial Neural Network Approach’. Journal of
mining science. Volume 55, 2019, Pages 201–212.
[51] Messa G.V., Malin M., Malavasi S., ‘Numerical prediction of fully-suspended slurry flow in horizontal pipes’. Powder Technology, Volume 256, 2014, Pages
61-70.
[52] Das S.N., Biswal S.K., Mohapatra R.K., ‘Recent advances on stabilization and rheological behaviour of iron ore slurry for economic pipeline transportation’.
Materials Today: Proceedings, Volume 33, Part 8, 2020,Pages 5093-5097.
[53] Nayak B.B., Gupta S.K., Chatterjee D., Mullick A.N., ‘Numerical Analysis of Convective Transport of Fly Ash-water Slurry Through a Horizontal Pipe’.
Multiphase Science and Technology, Volume 7, Number 2, 2015, Pages 79 – 96.
[54] Strivens T.A., ‘Rheometry’. In ullmann’s Encyclopedia of industrial chemistry. 2000.
[55] Hong E., Herbert C.M., Yeneneh A.M., Sen T.K., ‘Rheological characteristics of mixed kaolin- sand slurry, impacts of ph, temperature, solid concentration and
Kaolin – sand mixing ratio’. International journal of environmental science and technology, Volume 13, 2016, Pages 2629 – 2638.
[56] Dash A.K., Agarwalla D.K., Das H.C., Pradhan M.K., Bhuyan S.K., ‘Application of genetic algorithm for fault detection in cracked composite structure’.
Proceedings of the ASME 2014 Gas turbine India conference, 2014.
[57] Uzi A., Levy A., ‘Flow characteristics of coarse particles in horizontal hydraulic conveying’. Powder Technology, Volume 326, 2018, Pages 302-321.
[58] He M., Wang Y., Forssberg E., ‘Parameter studies on the rheology of limestone slurries’. International Journal of Mineral Processing, Volume 78, Issue 2,
2006, Pages 63-77.
[59] Leong Yee-Kwong, ‘Controlling the rheology of iron ore slurries and tailings with surface chemistry for enhanced beneficiation performance and output,
reduced pumping cost and safer tailings storage in dam’, Minerals Engineering, Volume 166, 2021.

Rheology of Slurry A Review

Uploaded by

Copyright:

Available Formats

Rheology of Slurry A Review

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rheology of Slurry A Review

Uploaded by

Copyright:

Available Formats

10 X October 2022

Rheology of Slurry: A Review

II. BASICS OF RHEOLOGY

B. Characterization On The Basis Of Rheological Parameters

Fig. 4 - Turbulent flow [12]

Fig. 5 – Transitional flow [12]

III. RHEOLOGICAL CHARACTERISTICS

A. Rheological Characteristics Of Minerals

Table 1 – Literature review of rheological characteristics of minerals.

8 Assefa K. M Chemical Chemical additives can be categorized as dispersants,

B. Rheological Characteristics Of Pipeline

Calcium lignosulphonate [25] Surfactants Ferrosilicon

Limestone [27] Increased Acid iron ore

C. Factors Affecting Rheology

Table 3 Solids density of typical minerals [29]

IV. RHEOLOGICAL BEHAVIOR OF IRON-ORE SLURRY

A. Effect Of Solid Concentration On Apparent Viscosity

B. Effect Of Particle Size And Particle Size Distribution

C. Effect Of Temperature On Iron Ore Slurry

Figure 8 - Effect of temperature on apparent viscosity of iron ore slurry [23].

E. Effects Of Velocity Of Iron Ore Slurry

V. METHODS TO CONTROL RHEOLOGY

A. Mechanical Methods For Controlling Rheology

B. Chemical Means For Controlling Rheology

C. Adding Nano-Stabilizers To Control The Rheology Of The Slurry

You might also like