MAGNAFLOC® 155 is a high–molecular-weight anionic polyacrylamide flocculant widely used for solid–liquid separation in heavy industrial processes. It is designed to efficiently flocculate fine suspended solids, particularly inorganic mineral particles, clays, metal hydroxides, and oxide slurries, under neutral to alkaline operating conditions. Due to its balanced anionic charge density and strong polymer-bridging capability, MAGNAFLOC® 155 has become a proven solution in mining, coal preparation, alumina refining, and industrial wastewater treatment.

1. Flocculation Mechanism and Functional Properties

MAGNAFLOC® 155 functions primarily through a polymer bridging mechanism. Its long polymer chains adsorb onto multiple particles simultaneously, forming large, dense flocs that settle rapidly under gravity. The anionic functional groups enhance interaction with positively charged or partially neutralized mineral surfaces, promoting fast aggregation and stable floc formation.

Key functional properties of MAGNAFLOC® 155 include:

• Rapid settling and clarification

• Strong, shear-resistant flocs

• High overflow clarity

• Compatibility with inorganic coagulants

• Stable performance across a wide pH range

These characteristics make MAGNAFLOC® 155 suitable for high-rate and high-solids thickening systems.

2. Application in Mining and Mineral Processing

2.1 Tailings Thickening and Water Recovery

One of the main applications of MAGNAFLOC® 155 is in tailings thickening in mining operations such as:

• Copper and base-metal mines

• Gold and precious-metal processing

• Iron ore beneficiation

• Phosphate and industrial mineral processing

In tailings circuits, fine particles generated during grinding and flotation remain suspended and must be efficiently separated before discharge or storage. MAGNAFLOC® 155 enhances sedimentation in:

• Conventional thickeners

• High-rate thickeners

• High-density and paste thickeners

The use of MAGNAFLOC® 155 results in higher underflow solids concentration, improved water recovery, reduced tailings volume, and lower operating costs in tailings management systems.

2.2 Process Water Clarification

MAGNAFLOC® 155 is also applied for clarifying recycled process water. By removing fine suspended solids, it reduces turbidity and prevents scaling, abrasion, and fouling of downstream equipment. Improved water quality enhances grinding efficiency, flotation selectivity, and leaching performance, contributing to stable plant operation.

3. Application in Coal Preparation and Washing

In coal washing plants, MAGNAFLOC® 155 is commonly used in black-water clarification systems. It effectively flocculates fine coal particles and associated clays in:

• Coal tailings thickeners

• Clarifiers and settlers

• Water recovery circuits

The polymer improves settling rates and overflow clarity, allowing efficient reuse of process water. This not only reduces freshwater consumption but also supports compliance with environmental discharge regulations.

4. Application in Alumina Refining (Bayer Process)

MAGNAFLOC® 155 is suitable for use in alumina refineries, particularly in red mud settling and washing circuits within the Bayer process. After bauxite digestion, large volumes of highly alkaline slurry containing fine red mud solids must be separated from pregnant liquor.

When applied in:

• Primary settlers

• Mud washers

• Counter-current decantation (CCD) circuits

MAGNAFLOC® 155 provides:

• Faster red mud settling

• Improved clarity of sodium aluminate liquor

• Enhanced recovery of caustic soda

• Reduced solids carryover

Its chemical stability under high pH and elevated temperatures ensures reliable performance in continuous alumina production environments.

5. Application in Industrial Water and Wastewater Treatment

5.1 Primary and Secondary Clarification

MAGNAFLOC® 155 is widely used in industrial wastewater treatment plants treating:

• Mineral processing effluents

• Metallurgical wastewater

• Chemical plant discharge

• Power plant ash and cooling water blowdown

Used alone or as a co-flocculant with inorganic coagulants such as ferric chloride or alum, MAGNAFLOC® 155 enhances floc size and settling velocity, leading to improved removal of suspended solids and reduced sludge volume.

5.2 Sludge Thickening and Dewatering

MAGNAFLOC® 155 is effective for sludge conditioning prior to mechanical dewatering. It improves performance in:

• Gravity sludge thickeners

• Belt filter presses

• Vacuum filters

• Centrifuges

The polymer forms strong, well-structured flocs that release water easily, resulting in higher cake solids and lower sludge handling and disposal costs.

6. Preparation, Dosage, and Handling

MAGNAFLOC® 155 is supplied as a dry, free-flowing granular powder. Proper solution preparation is critical for optimal performance:

• Typical make-down concentration: 0.1–0.3%

• Hydration time: 45–60 minutes

• Gentle agitation to prevent polymer chain degradation

Dosage requirements depend on solids concentration and slurry characteristics, typically ranging from 5 to 80 g per tonne of dry solids.

7. Key Benefits and Conclusion

In conclusion, MAGNAFLOC® 155 offers:

• Efficient solid–liquid separation

• Rapid settling and high overflow clarity

• Dense underflow and improved water recovery

• Reliable performance in neutral to alkaline systems

• Reduced operating and environmental management costs

Because of its versatility and consistent performance, MAGNAFLOC® 155 is a trusted flocculant in mining, coal preparation, alumina refining, and industrial water treatment applications.