Introduction to flocculation

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1 Introduction to flocculation With upgrading we understand, the further processing of the final products from the enrichment stages in a process. This is valid both concerning the valuable minerals (the concentrate) and the waste minerals (the tailings). In the first case upgrading means improving the product value by bringing the concentrate to transportability or into a completely dry form. Processing can also go further to calcining and sintering. On the tailing side upgrading means that waste material (wash water, process effluents etc.) is properly taken care of in order to protect the environment, to recover process water and to turn certain portions into valueables. Upgrading by methods Sedimentation Mechanical Dewatering Clarification/Thickening Gravity (Conventional) Low Pressure Clarification/Thickening Medium Pressure (Compact) High Pressure Thermal drying Thermal processing Direct Calcining Indirect Sintering (pelletizing) Upgrading by operation costs Upgrading has its price, increasing with the energy input for removal of the process water (or process liquid). The rules are simple! 1. Can we do the job with sedimentation only? If not - how far can we reach by sedimentation thereby saving money in the following dewatering stage? 2. How far can we reach with mechanical dewatering? Can we save a thermal stage by increasing the dewatering pressure? 3. If the particles are coarse, can gravity dewatering do the job? The cost is close to the same as for sedimentation. 4. If thermal dewatering is needed, can energy be saved in drying by improved mechanical dewatering? Sedimentation Sedimentation is a continuous solid-liquid separation process with settling of solids by gravity. Clarification is the process for removal of solids from a dilute solid/liquid suspension. Thickening is the process for concentrating particles in a supension by gravity compression Flocculation All sedimentation technologies are related to particle size. One way of improving the settling speed generally is therefore to increase the size of the particles. Fine particles can be connected together by coagulation or flocculation. The settling rate of the combined particles will be higher than that of each individual particle. Coagulation: Surface charges are neutralized by addition of chemicals of opposite charge. Ex: Fe+++ (iron sulphate) Al+++ (aluminium sulphate) Ca++ (lime) A coagulated aggregate will reform after breaking (e.g. pumping). The curves above must always be considered when we are selecting equipment for an upgrading circuit for concentrate drying or disposal of a washing effluent. Flocculation: Polymeres with molecule chains which physically link the particles together (mechanical bridging). A flocculated aggregate will not reform after breaking. 1

2 Flocculation System A handling system is needed for flocculant utilisation. This comprises provision to mix, store and dilute the polymer. The dilute polymer is then mixed with the feed slurry and allowed to condition (or age) before a sedimentation or dewatering process. Flocculation - addition and mixing time Conventional Clarifier Clarification is achieved when the liquid upstream velocity VL is lower than the sedimentation velocity of the solids VS 2

3 Conventional Clarifier sizing Clarifier diameter is selected to give a suitable upstream velocity (m/h). This is also expressed as Surface Load, meaning the volume of slurry m 3 /h fed per m 2 of clarifier surface. Typical surface areas are given below. Example: A wash water (100 m 3 /h) coming from a sand operation needs to be clarified. Surface load is 0.5 m 3 /h/m 2. Select clarifier diameter. Required area is: 100/0.5 = 200 m 2 = required diameter = 15.9 = 200 where d is Select a 16 m clarification tank! Note! When thickening is also a critical part of the sedimentation process, the tank diameter has to be cross-checked with the diameter for thickener duty, see next page. Conventional Thickener Continuous thickening to give the required solids concentration in the underflow depends on balancing the volumetric solids flow rate at a critical concentration with the diameter of the thickener. 3

4 Conventional Thickeners Sizing Thickener selection is based upon the unit area, defined as m2 of thickener area required per tph of solids. Typical figures for unit area are given below. Clarification/ thickening cross checking (metric) Clarification and thickening are process definitions. The equipment can be applied to both duties. If this is the case we have to select the tank area for each duty and select the largest of the two. Example: Cu concentrate (k80= 80 μm), 10 t/h or 18m³/h Surface load (with flocculation) = 1.5 m/h Unit area = 2 m²/(t/h) Clarification area = 18/ 1.5 = 12 m² Thickening area = 10x2 = 20 m² Select a Clarifier / Thickener of 20m², diameter 5 m. 4

5 Conventional Clarifier/Thickener Design Bridge type For smaller thickeners, up to m diameter, the rakes and drive mechanism are supported on a bridge superstructure, which straddles the tank as shown. Centre Pier type For tanks over m diameter a bridge structure will be imractical. The mechanism and rakes are therefore supported from a centre pier and the bridge is only used for access and to support feed pipe and launder. Design options Up to 20 m elevated tank with underflow at ground level. Above 20 m tank at ground level with underflow in a tunnel. 5

6 Conventional Clarifier/Thickener Drive system Drive mechanism For bridge and centre pier mounting. Options with and without automatic rake lifting system. Automatic torque monitoring. Slewing ring bearing to accommodate out of balance loads on rakes. Worm and wheel and multistage epicyclic gearbox drive. Conventional clarifier/thickener control Torque is electronically detected and monitored. Increased torque is a sign that the solids loading in the thickener may be building up. This could indicate a process problem (change in feed, blocked underflow etc.). In all these cases rakes and drive have to be protected. Conventional clarifier/thickener drives torque definitions 10 year Torque The torque loading at which the drive head will have a calculated wear life of 10 years (also called equivalent torque). Cut Out Torque Nominal 3000 hours wear life. App. 3 x 10 year torque. If the monitoring system detects a torque above this level the drive head will stop and a alarm will be raised in order to protect the rakes. Peak Torque Practical maximum torque. App. 2 x cut out torque. 6

7 Conventional Clarifier/Thickener Drive Sizing Duty classification Typical duties 1. Water treatment, river or lake water clarification, metallic hydroxides, brine clarification. 2. Magnesium hydroxide, lime softening, brine softening. 3. Copper tails, iron tails, coal refuse tails, coal, zinc or lead concentrates, clay, titanium oxide and phosphate tails. 4. Uranium counter-current decantation (CCD), molybdenum sulphide. 5. Iron oxide concentrates, magnetite, iron pellet feed, ilmenite. Examine solids loading or specifications to determine whether duty is thickening or clarification. Proceed to relevant section to select drive head. Drive head torque rating BN and CN = drives without lifting BL and CL = drives with lifting 7

8 Clarifier drive selection Clarifiers, operate with a low solids loading and drives are selected according to formula below Tc = KxD 2 Tc = Process Cut Off torque (Nm) K = Clarifier duty factor (see below) D = Clarifier Diameter (m) Duty factor: Select a drive head from the Drive Head Torque values above, so that the specified cut out torque is greater then calculated Tc. Example: Select a bridge mounted drive head for a 35 m diameter clarifier (no lift required). Application: lime sludge clarifying. K factor = 210 giving a Tc = 210 x 35² = Nm. Select a drive head type BN 24, cut out torque Nm. Example: Select a pier mounted drive head with a lift suitable for a 50 m diameter thickener handling an underflow of 130 tph of solids. Te = 256x50x 130 = Nm. Select CL 28 drive head with a 10 year torque of Nm. Thickener drive selection Here we are calculating with Process Equivalent Torque (or 10 year torque), according to formula: Te = 256 x D x M Te D M = Process Equivalent Torque = Thickener diameter (m) = Solids in underflow (tph), see duty above Select a drive head from the Drive Head Torque values above, so that the 10 year torque is greater than Te calculated above. 8

9 Conventional Clarifier/Thickener Areas Conventional Clarifier/Thickener Tank Depth Use minimum depth if feed volume flow rate is less than 1.2 m3/m2,h. Conventional Clarifier/ Thickener Tank Bottom Slope For small thickeners no slope restrictions (up to 45 O ). For larger diameter thickeners (>dia 45 m) a two-slope tank is recommended for height saving reasons. Inner 1/3 (9 O ) out 2/3 (5 O ) Slope for 1/3 of dia 165 mm/m (9 degrees) Slope for 2/3 dia (outer) 80 mm/m (5 degrees) 9

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