La qualité de la récupération des minéraux et métaux de valeur contenus dans les minerais est fortement liée à la granulométrie des particules soumises au procédé d'enrichissement. La granulométrie est généralement contrôlée par les hydrocyclones du circuit de broyage. Une inspection détaillée de ces équipements n'est pas évidente; ce qui entraîne souvent une classification inefficace. L'objectif du projet est d'évaluer l'opération d'un hydrocyclone dans différentes situations anormales de fonctionnement causées par des bris mécaniques ou encore des conditions de surcharge. Les travaux avec un hydrocyclone en usine pilote ont fourni les données pour évaluer l'impact des anomalies sur la classification et permis de calibrer un modèle qui est capable de détecter un problème d'opération de l'hydrocyclone.

La séparation gravimétrique est probablement le plus ancien procédé utilisé pour la séparation des minéraux. Le type de séparateur gravimétrique analysé dans le cadre de cette étude est un classificateur hydraulique à lit dense. Ces appareils séparent les minéraux en fonction de leur dimension et de leur densité à l'aide d'un courant d'eau ascendant. L'objectif principal de la présente étude est de développer un modèle phénoménologique qui prend en compte les variables opératoires du classificateur et les dimensions de l'appareil. Le modèle mathématique développé a comme objectif d'aider les opérateurs à améliorer les procédés utilisant des classificateurs hydrauliques, en permettant la simulation de différentes stratégies de régulation et la conception des équipements pour des applications particulières. De plus, l'outil de simulation permet de prédire les états de variables non mesurées et/ou non mesurables comme la densité locale, la composition de la surverse, l'emplacement des interfaces, permettant ainsi d'être utilisé comme capteur virtuel. Toutefois, les montages industriels sont complexes à simuler, parce qu'ils opèrent à des régimes d'écoulement très turbulent tandis que certains des modèles mathématiques existants ne peuvent pas supporter de grandes variations de la concentration solide en fonction de la hauteur, en plus de généralement nécessiter des coefficients qui doivent être déterminés par des essais conduits en laboratoire, dans des conditions contrôlées. Or, pour que l'algorithme de simulation soit utilisable, peu importe les contraintes, il aura fallu introduire de nouveaux concepts pour la modélisation et la résolution du bilan de masse. Il est question, entre autres, de l'ajout de la vitesse de la pulpe, plutôt que celle du fluide, de l'estimation de la concentration solide maximale dans le lit fluidisé, de la prise en compte des caractéristiques de l'alimentation, et de l'estimation de la diffusion turbulente. L'algorithme développé dans nos travaux a été mis à l'épreuve en simulant et comparant les opérations d'appareils installés à l'usine de bouletage d'ArcelorMittal Canada et d'un montage de laboratoire installé à l'Université Laval. Ces équipements sont employés pour séparer les oxydes de fer de contaminants, composés majoritairement de quartz et de silicates de faible densité. / Gravimetric separation is probably the oldest process used by the mining industries for the separation of minerals. The type of gravity separator analyzed in this study is a dense bed hydraulic classifier. These devices separate minerals according to their size and density using a water stream. The main objective of the study is to develop a phenomenological model that considers the operating variables of the classifier and the physical construction of the apparatus. The model developed will be able to help operators improve existing processes by simulating different control strategies and design equipments. In addition, the algorithm can predict variables that are not measured such as the characteristics of the material inside the reactor such as local density, solids concentration, positions of the interfaces. However, the industrial reactors are complex to simulate because they operate at very turbulent flow regimes and some of the existing models cannot handle large solid variation within the reactor. The proposed models in the literature have coefficients that require parameters that need to be determined from tests conducted in the well-controlled environment of a laboratory. In order to develop the simulation algorithm, it was necessary to develop a new way of solving the mass balance and new concepts were introduced in the formulation of the model such as 1) using pulp velocity rather than the fluid velocity, 2) estimating the maximum solid concentration in the fluidized bed, 3) considering the feed characteristics, 4) estimating the turbulent diffusion as a function of the pulp velocity. The developed algorithm was tested by simulating and comparing the operation of hydraulic classifiers used at the ArcelorMittal Canada pellet plant and a laboratory set-up at Laval University. This equipment is used to separate iron oxides from contaminants composed mainly of silicon dioxides.

La nouvelle loi canadienne sur l’amiante chrysotile décrétée par le gouvernement fédéral devrait entrer en vigueur au courant de l’année 2019 et les nouvelles normes environnementales qui en découleront nous forcent déjà à trouver des solutions pour réduire de façon significative l’impact environnemental et de revaloriser des résidus d’exploitation du chrysotile. Une des façons de réduire cet impact environnemental et revaloriser ce résidu consiste à concentrer la lizardite et l’antigorite comme matériaux générateurs de magnésium (Mg) et éliminer le chrysotile (cancérigène). Ces minéraux sont abondants dans les résidus miniers d’exploitation du chrysotile de l’ancienne mine Carey Canadian à East-Broughton dans le sud du Québec. La présente étude propose donc une revue des procédés de séparation physique des phases minérales serpentiniques et une étude détaillée sur la séparation gravimétrique par voie humide (hydrocyclonage/décantation) pour différentes classes granulométriques et une étape finale de séparation magnétique à sec pour l’extraction des minéraux magnétiques (magnétite) dans le concentré de la décantation. Les propriétés physiques, chimiques et minéralogiques du résidu initial ont été obtenues par tamisage grossier, par analyse de densité et surface spécifique, par fluorescence aux rayons X, par spectroscopie RAMAN, par MEB-EDS et par DRX. Les résultats les plus importants de cette étude sont qu’il est possible d’éliminer le chrysotile, sous forme de surverse, par hydrocyclonage en régime dilué (30% solides dans la pulpe) tout en concentrant la lizardite et l’antigorite (sousverse) avec des récupérations en Mg de l’ordre de 70 à 80 % en poids de Mg en sousverse. La séparation liquide-solide a été effectuée à 5 % de solides dans la pulpe et a permis d’augmenter la pureté du concentré d’hydrocyclonage (sousverse) avec des récupérations en Mg dans la sousverse variant entre 36 et 70 % partant des fines particules vers les grossières. La séparation magnétique a permis d’augmenter la pureté du concentré de décantation (sousverse) par l’extraction du fer. Ce qui a conduit à des récupérations croissantes en fer de 30 à 60 % à partir de particules grossières vers les fines. Les rapports Si/Mg et Fe/Si en fonction de la taille des particules pour les fractions non-magnétiques (concentrés) ont également été examinés dans une tentative d’estimation du fer résiduel présent par substitution intra-réseau Fe-Mg et Fe-Si dans les concentrés non-magnétiques. Mots clés: Hydrocyclone, Décantation, Séparation magnétique, Chrysotile, Lizardite, Antigorite. / Canada's new law on chrysotile asbestos is expected to come into force in 2019 by the federal government, and the resulting new environmental standards are already forcing us to find solutions to significantly reduce the environmental impact and revalorize chrysotile mining residues. One of the ways to reduce this environmental impact and enhance this residue is to concentrate lizardite and antigorite as magnesium (Mg) generating materials and eliminate chrysotile (carcinogenic). These minerals are abundant in the chrysotile mining tailings of the former Carey Canadian mine in East-Broughton in southern Quebec. The present study therefore proposes a review of the physical separation processes of serpentine mineral phases and a detailed study on wet gravimetric separation (hydrocycloning / decantation) for different granulometric classes and a final dry magnetic separation step for the extraction of minerals magnetic minerals (magnetite) in the concentrate of the decantation. The physical, chemical and mineralogical properties of the initial residue were obtained by coarse sieving, density and surface area analysis, X-ray fluorescence, RAMAN spectroscopy, SEM-EDS and XRD spectroscopy. The most important results of this study are that it is possible to eliminate chrysotile, in the form of overflow product, by dilute hydrocycloning (30% solids in the pulp) while concentrating lizardite and antigorite (underflow) with recoveries in Mg of the order of 70 to 80% by weight of Mg underflow. The liquid-solid separation was carried out at 5% solids in the pulp and made it possible to increase the purity of the hydrocyclone concentrate (underflow) with Mg recoveries in the underflow varying between 36 and 70% starting from the fine particles to the coarse ones. Magnetic separation made it possible to increase the purity of the settling concentrate (underflow) by extracting iron. This led to increasing recoveries of iron from 30 to 60% from coarse particles to fine ones. Si / Mg and Fe / Si ratios as a function of particle size for non-magnetic fractions (concentrates) were also examined in an attempt to estimate the residual iron present by intra-network substitution Fe-Mg and Fe- Si in non-magnetic concentrates. Keywords: Hydrocyclone, Decantation, Magnetic separation, Chrysotile, Lizardite, Antigorite.

The subject of this PhD thesis is the development of an efficient system that can simultaneously pump and separate a gas-liquid mixture, in particular an oil-air mixture. Two-phase flows are encountered in many applications (petroleum extraction, flow in nuclear power plant pumps, pulp and paper processing, etc.) but this study is mainly focused on lubrication systems of aircraft gas turbine engines.<p><p>The pump and separator system (PASS) for two-phase flows developed in this PhD thesis aims to perform three functions simultaneously:<p>• Send back the oil to the tank (oil pumping)<p>• Separate the air from the oil (de-aeration)<p>• Separate the oil from the air (de-oiling) and release the sealing air into the atmosphere (venting). <p>Particular care is given to the liquid flow rate lost at the gas outlet of the system.<p>Consequently, it could replace the scavenge pumps and oil-air separators existing in present lubrication systems. This modification provides several advantages: simplification of the lubrication circuit, reduction of oil consumption and of the size of the lubrication system.<p><p>This research is divided into three axes: the theoretical study of the important physical mechanisms taking place inside the two-phase flow pump and separator system, the experimental development, tests and optimization of different PASS prototypes, and also the numerical simulations of the two-phase flow inside these prototypes. Although the experiments were the central pillar of this research, the three axes were closely imbricated.<p><p>The PASS design includes three main components:<p>• An inlet chamber with one or several tangential inlets giving a natural centrifugation to the flow,<p>• An impeller (forced centrifugation) with an axial and a radial part followed by a volute chamber,<p>• A metallic foam that lets pass micron and sub-micron droplets and which is followed by an axial vent port.<p><p>The centrifugation causes the liquid (oil) to move radially outwards in an annular body (a liquid ring) generating pressure. The thickness of this liquid ring inside the impeller is mainly determined by the pressure coefficient (related to the back-pressure and the rotational speed). When the back-pressure increases, the thickness of the liquid ring increases too. An advantage of the PASS is that it does not impose any relation between the liquid head and the liquid flow rate, contrary to common centrifugal pump. It self-regulates the radial position of the gas-liquid interface to sustain the operating conditions.<p><p>The de-aeration efficiency mainly depends on the pressure coefficient (for a constant liquid viscosity or temperature) or on the thickness of the liquid ring. The pressure gradient which appears in the liquid rotating in an annular body acts like a dam for the gas phase. Indeed, the gas movement is mainly determined by the pressure field (buoyancy) while the liquid distribution is dominated by centrifugal and Coriolis forces. Buoyancy tends to accumulate the gas phase near low pressure areas (PASS hub, suction side of the blades, clearances between closed impeller and casing).<p><p>The first oil-air PASS prototype produces high viscous losses due to the high peripheral velocity and liquid viscosity. Therefore, the pumping efficiency is poor compared to common impeller pumps. However, the pumping is not the key function of the PASS and a power consumption below 5 kW is acceptable for the application considered in this work. For applications that require lower power consumptions, a reduction of the rotational speed must be considered.<p><p>Thus, the rotational speed and the impeller diameter are two major constraints for the PASS design which determine the de-aeration and pumping efficiencies. The impeller diameter also influences the size of passage sections for the air flow. The air velocity must be kept as low as possible because the entrainment of droplets increases when the air velocity rises (drag forces on droplets). Indeed, this large influence of the air flow rate on the oil consumption (de-oiling efficiency) was demonstrated by a theoretical analysis, the experiments and the CFD simulations. The production of droplets in the inlet pipes when the two-phase flow is annular is a key phenomenon regarding the oil consumption.<p><p>In addition to the air flow rate, other variables also influence the oil consumption:<p>• Air-oil temperature: when the temperature rises, the oil consumption increases because the surface tension and the oil density are reduced. Moreover, as the air density also decreases, the air velocity rises.<p>• Oil flow rate: the oil consumption rises more or less linearly with the oil flow rate. However, the influence of the oil flow rate on the inlet droplet size is uncertain.<p>• Rotational speed: the rotational speed has obviously a strong impact on the oil consumption without metallic foam. However, experiments showed that the metallic foam efficiency is almost independent on the rotational speed. Therefore, the oil consumption with the Retimet foam does not depend on the PASS rotational speed.<p>• Altitude or air density: the oil consumption decreases when the air density is reduced because the drag forces on droplets also decrease.<p>The gas density (altitude) is also supposed to influence the de-aeration efficiency but this could not be tested or simulated in this work (the de-aeration efficiency gets probably better when decreasing the gas density because the buoyancy forces increase).<p><p>Theory, experiments and numerical simulations also allowed the prediction of performance of the first oil-air prototype for real in-flight operating conditions. Two problems have been identified: the de-aeration efficiency at MTO and cruise ratings and the oil leak throughout the vent in cold start and windmilling. To solve them, some modifications of the lubrication system have been suggested. With these modifications, the oil-air PASS should become very efficient and attractive for engine manufacturers. / Doctorat en Sciences de l'ingénieur / info:eu-repo/semantics/nonPublished