Published Article

Integrated Ion-Selective Water Regeneration and Conveyor-Based Sludge Management for Zero Liquid Discharge and Dust

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Abstract

The growth of mineral extraction and processing is accompanied by increased industrial
wastewater generation and dust particle emissions, representing one of the most pressing
environmental challenges facing the modern mining industry. Mining and metallurgy
enterprises use water at virtually every stage of the technological process, including
hydraulic transport, mineral processing, dust suppression, equipment cooling, and water
recycling. This results in the generation of significant volumes of wastewater containing
suspended solids, dissolved salts, heavy metal compounds, and other pollutants, which
negatively impact aquatic ecosystems and environmental quality.
At the same time, the intensive use of quarry trucks, trains, and handling facilities
generates large quantities of mineral dust. Particles of the PM₁₀ and PM₂₅ fractions
pose a heightened environmental hazard due to their ability to remain suspended for
extended periods, spread over significant distances, and adversely affect the health of
workers and residents in adjacent areas. Due to increasingly stringent environmental
requirements, technologies that simultaneously reduce water consumption, minimize waste
generation, and reduce dust levels at production sites are becoming increasingly important.
Globally, reagent precipitation, coagulation and flocculation, membrane technologies,
reverse osmosis, electrocoagulation, ion exchange processes, and various sorption methods
are used to treat industrial wastewater. Despite the high efficiency of some technologies,
most are characterized by significant operating costs, high energy consumption, the
formation of secondary liquid concentrates, or the need for complex regeneration of filter
media. These drawbacks are particularly acute when treating large volumes of mine and
process water at mining facilities.

One of the most promising areas for the development of modern water treatment systems is
the implementation of the Zero Liquid Discharge (ZLD) concept, which envisions
maximum reuse of treated water and the virtual elimination of liquid waste discharge into
the environment. However, the implementation of ZLD technologies at large mining
facilities is complicated by the need to treat tens of thousands of cubic meters of water per
day while maintaining high cost efficiency and operational reliability.
An additional challenge remains the management of sludge generated during wastewater
treatment. In many cases, transporting and storing sludge requires significant operating
costs, and the high moisture content of the sludge complicates its further processing or safe
disposal. For this reason, a promising approach is integrating water treatment processes
with mechanized dewatering systems and continuous conveyor-based solids removal,
ensuring the stable operation of treatment facilities and reducing the environmental impact
on the facility.
This study proposes an integrated process flow diagram combining a water treatment
system (WTS), based on the selective extraction of pollutants from wastewater, with a
mechanical dewatering system and continuous conveyor sludge removal. This approach
allows water treatment and waste management processes to be considered as a single
engineering system focused on the reuse of treated water for the plant's process needs,
including dust suppression systems, recycled water supply, and auxiliary production
processes.
The research's scientific novelty lies in the development of a comprehensive technological
solution that integrates selective water treatment, mechanized removal of dewatered
sludge, and reuse of purified water into a single, closed-loop production cycle. Unlike
traditional approaches, the proposed system considers wastewater treatment and solid
waste management as interrelated processes, thereby improving the environmental
efficiency and sustainability of mining operations.
The aim of the study is to develop and scientifically substantiate an integrated technology
for the treatment of mine and industrial wastewater using a water treatment complex
(WTC) and a conveyor system for the removal of dewatered sludge, ensuring the reuse of
purified water, reducing dust formation and implementing the principles of Zero Liquid
Discharge (ZLD) technology in the mining industry.

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How to cite this article

Keywords

mining; wastewater treatment; ion-selective sorption; water treatment complex; conveyor sludge removal; water reuse; Zero Liquid Discharge (ZLD); dust suppression; sustainable development.

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