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SLS 5: Sedimentation Processes

SLS 5: Sedimentation Processes
     Part 1 - Introduction
         1 SCOPE OF VOLUME V
         2 EQUATIONS FOR SETTLING
             2.1 Introduction
             2.2 Drag on Particles
             2.3 Terminal Settling Velocity
                 2.3.1 Limits of Stokes Law
                 2.3.2 Calculation of Terminal Velocity
                 2.3.3 Acceleration of Particles
                 2.3.4 Electrical and Magnetic Particles
             2.4 Limitations of Equations
             2.5 Settling of Fine Particles
             2.6 Presence of Walls
             2.7 Hindered Settling
             2.8 Particle Shape
                 2.8.1 Motion of Particles in the Liquid
                 2.8.2 Plotting the Data
                 2.8.3 Recommended Equations
             2.9 Non-Rigid Particles
             2.10 Effect of Motion of Liquid
             2.11 Effect of non-Newtonian Properties of Liquid
                 2.11.1 Purely Viscous Liquids without a Yield Stress
                 2.11.2 Purely Viscous Liquids with a Yield Stress
                 2.11.3 Viscoelastic Liquids
         3 ALTERNATIVE EQUATIONS
             3.1 Equations at Low Reynolds Number
             3.2 Equations for Intermediate Region
             3.3 Calculation of Terminal Velocity
             3.4 Calculation of Particle Size from Terminal Velocity
             3.5 Equations for Wall Effect
             3.6 Equations for Hindered Settling
                 3.6.1 Power Law Equations
                 3.6.2 Equations Obtained by Modifying Liquid Properties
                 3.6.3 Fluid Bed and Packed Bed Expressions
                 3.6.4 Other Equations
                 3.6.5 Hydrocyclones
                 3.6.6 Comparison of Equations
             3.7 Terminal Velocities for Irregular Particles
                 3.7.1 Motion of Particles
                 3.7.2 Equations for Specific Shapes
                 3.7.3 Equations Containing Shape Factors
             3.8 Acceleration of Particles
             3.9 Settling of Multi-Component Mixtures
                 3.9.1 Particles of Different Sizes
                 3.9.2 Particles with the Same Terminal Velocity
             3.10 Classification by Difference in Density
             3.11 Hindered Settling in non-Newtonian Liquids
             3.12 Wall Effects with non-Newtonian Liquids
         4 NOMENCLATURE
         5 REFERENCES
     Part 2 - Efficiency of Separations
         1 INTRODUCTION
             1.1 Contents of this Part
         2 MEASURES OF EFFICIENCY
             2.1 Scope of Chapter
             2.2 Total Efficiency
                 2.2.1 Reduced Total Efficiency
             2.3 Partial Efficiencies
             2.4 Grade Efficiency
                 2.4.1 Cut Size
             2.5 Reduced Grade Efficiency Curves
             2.6 Sharpness of Cut
         3 MEASUREMENT OF GRADE EFFICIENCY CURVES
             3.1 Definitions
             3.2 Grade Efficiency Testing
             3.3 Example
                 3.3.1 Cut Point
                 3.3.2 Sharpness of Cut
                 3.3.3 Total Efficiency from Grade Efficiency
                 3.3.4 Size Distributions of Products from G(d)
                 3.3.5 Reduced Grade Efficiency
             3.4 Typical Grade Efficiency Curves
                 3.4.1 Gravity Sedimentation Equipment
                 3.4.2 Hydrocyclones
                 3.4.3 Sedimenting Centrifuges
         4 GRADE EFFICIENCIES OF MULTIPLE UNITS
             4.1 Series on Overflow
             4.2 Series on Overflow with Recycle
             4.3 Series on Underflow
             4.4 Series on Underflow with Recycle
             4.5 Countercurrent Washing
             4.6 Series on Both Outlets
             4.7 Three Separators with Recycle
             4.8 Single Separator with Recycle
         5 ALTERNATIVE DEFINITIONS OF EFFICIENCY
             5.1 Efficiency of Classifiers
             5.2 Efficiency of Screens
             5.3 Efficiencies of Clarification Filters
             5.4 Efficiencies Which Include Liquid
         6 NOMENCLATURE
         7 REFERENCES
     Part 3 - Thickeners and Clarifiers
         1. INTRODUCTION
         2. THE LOGIC DIAGRAM
         3. STEPS IN THE LOGIC DIAGRAM
             3.1 Obtain Process Details and Relevant Processing Data
                 3.1.1 Type of material to be treated
                 3.1.2 Volume of pulp to be treated and range
                 3.1.3 Amount of solids present and range if any
                 3.1.4 Size distribution of solids present and range of variation
                 3.1.5 Normal temperature and range
                 3.1.6 pH and range,if any
                 3.1.7 Specific gravity of solid and liquid
             3.2 Obtain Specifications for Final Products
                 3.2.1 Overflow product
                 3.2.2 Underflow product
             3.3 Obtain Sample of Feed Slurry
                 3.3.1 Process stream actually exists
                 3.3.2 Process stream does not exist
             3.4 Obtain Sub-Samples for Testwork
                 3.4.1 Sampling from a stirred container
                 3.4.2 Sampling using two containers
                 3.4.3 W.S.L. method
                 3.4.4 Sampling from a small container
             3.5 Check Validity of Sub-Sampling
             3.6 Determine Slurry Characteristics by Preliminary Testing
             3.7 Thickening or Clarification not Possible Due to SG Considerations
             3.8 Removal of Coarse Fraction
             3.9 Decide Whether Clarification of Thickening Testing is Appropriate
             3.10 Thickening Tests
             3.11 Flocculant and Coagulant Screening Tests
                 3.11.1 Apparatus required
                 3.11.2 Reagents required
                 3.11.3 Preparation and strength of solutions
                 3.11.4 Testwork
             3.12 Flocculant and Coagulant Optimisation
                 3.12.1 Apparatus required
                 3.12.2 Testwork
                 3.12.3 Calculations
             3.13 Collect Data on Floc Shear Sensitivity
             3.14 Thickener Sizing Tests
                 3.14.1 Modified Talmage and Fitch method
                 3.14.2 Apparatus required
                 3.14.3 Testwork
                 3.14.4 Identifying the compression point
                 3.14.5 Alternative plotting methods
                 3.14.6 The Oltmann construction
                 3.14.7 The Coe and Clevenger method
                 3.14.8 Wilhelm and Naide method
             3.15 Ultimate Pulp Density Tests
                 3.15.1 Stirred test
                 3.15.2 Unstirred test
             3.16 Collect Data on Sludge Properties
                 3.16.1 Torque loading for thickeners
                 3.16.2 Handling the thickened slurry
             3.17 Consider Control Possibilities
             3.18 Comparison with Product Specifications
             3.19 Estimate Thickener Dimensions
             3.20 Other Design Considerations
             3.21 Economic Evaluation
             3.22 Clarification Testing
             3.23 Preliminary Tests to Select Reagents and Quantity
             3.24 If No Reagents are to be Added
             3.25 The Long Tube Test
                 3.25.1 Apparatus required
                 3.25.2 Testwork
                 3.25.3 Calculation
                 3.25.4 Shortened long tube procedure
                 3.25.5 Calculations
             3.26 The Short Tube Test
                 3.26.1 Apparatus required
                 3.26.2 Testwork
                 3.26.3 Calculation
             3.27 Detention Time Test
                 3.27.1 Apparatus required
                 3.27.2 Testwork
             3.28 Bulk Settling Test
                 3.28.1 Apparatus required
                 3.28.2 Testwork
                 3.28.3 Calculation of data from detention time and bulk settling tests
             3.29 Collect Data on Sludge Properties
             3.30 Comparison with Product Specifications
             3.31 Products Inadequate
             3.32 Products Adequate
             3.33 Estimate Clarifier Dimensions
             3.34 Other Design Considerations
             3.35 Economic Evaluation
             3.36 Compare Final Data and Select Most Suitable Design
         4. PREDICTION AND REALITY IN THICKENER DESIGN
             4.1 Comparison of Different Laboratory Methods
             4.2 Comparison of Laboratory and Pilot Scale Data
             4.3 Comparison Between Laboratory and Full Scale Data
             4.4 Conclusions
         5. TOPICS REQUIRING FURTHER ATTENTION
             5.1 Floc Strength and Shear
             5.2 Properties of Thickened Pulps
             5.3 Scale-up
             5.4 Centrifugal Testing
         6. NOMENCLATURE
         7. GLOSSARY OF TERMS USED IN THIS REPORT
         8 REFERENCES
         9 APPENDIX 1 NEW THEORIES, THICKENER DESIGNS AND SCALE-UP TECHNIQUES
         10 APPENDIX 2 TABLE OF USEFUL EQUIVALENTS
     Part 4 - Classifiers
         1. INTRODUCTION
             1.1 Scope of the report
         2. THE FEED PULP
             2.1 The properties of the feed pulp
                 2.1.1 The nature of the particles
                 2.1.2 Liquid properties
                 2.1.3 Interactions between liquid and solid
                 2.1.4 Concentration of suspended solids
                 2.1.5 Selection of a thickening device
         3. METHODS AVAILABLE
             3.1 Methods based on sedimentation under gravity
                 3.1.1 Principles of sedimentation
                 3.1.2 Batch sedimentation techniques
                 3.1.3 Continuous sedimentation techniques
             3.2 Methods based on centrifugal forces
                 3.2.1 Principles of sedimentation under centrifugal forces
                 3.2.2 Batch type machines
                 3.2.3 Continuous type machines
                 3.2.4 Cyclones
             3.3 Methods based on filtration
                 3.3.1 Shriver continuous thickener
                 3.3.2 Peterson Roto-Disc clarifier
                 3.3.3 The Schenk centrifugal concentrator
                 3.3.4 The Dyno filter/thickener
                 3.3.5 The Genter thickener
                 3.3.6 The Oliver-Borden thickener
                 3.3.7 The Sweetland filter thickener
                 3.3.8 The Hardinge super thickener
             3.4 Miscellaneous methods
                 3.4.1 Fast sand filters
                 3.4.2 Shell pelletising separator
                 3.4.3 Flotation
         4. CONCLUSIONS
         5. RECOMMENDATIONS
         6 REFERENCES
     Part 5 - Hydrocyclones
         1 INTRODUCTION
         2 THEORIES AND MODELS
             2.1 Introduction
             2.2 Flow Patterns
                 2.2.1 Main flow pattern
                 2.2.2 Central air core
                 2.2.3 Underflow discharge
                 2.2.4 Short-circuit flow
                 2.2.5 Experimental observations
             2.3 Liquid Velocities
                 2.3.1 Tangential velocities
                 2.3.2 Axial (vertical) velocities
                 2.3.3 Radial velocities
             2.4 Particle Trajectories in the Flow
                 2.4.1 Entry into jet
                 2.4.2 Axial and tangential movement
             2.5 Models
                 2.5.1 The equilibrium orbit theory
                 2.5.2 Residence time theory
                 2.5.3 Turbulent two-phase flow theory
                 2.5.4 Crowding theory
                 2.5.5 Regression models
                 2.5.6 Dimensionless group model
                 2.5.7 Analytical flow models
                 2.5.8 Numerical simulations of the flow
         3 TYPES OF HYDROCYCLONES
             3.1 Introduction
             3.2 Cylindro-conical Hydrocyclones with Opposing Flow of Products
                 3.2.1 Narrow cone angle designs
                 3.2.2 Wide angle designs
                 3.2.3 Water only cyclones
                 3.2.4 Spiral and curved cone designs
                 3.2.5 Magnetic hydrocyclones
             3.3 Cylindro-conical Hydrocyclones with Co-current Flow of Products
             3.4 Cylindrical Cyclones
                 3.4.1 Cylindrical cyclones with tangential feed
             3.5 Dense Media Cyclones
                 3.5.1 Dynawhirlpool separator
                 3.5.2 Tri-flo separator
                 3.5.3 Larcodems separator
             3.6 Turbo-cyclones
             3.7 Liquid-liquid Separation
             3.8 Liquid-gas Separation
         4 APPLICATIONS
             4.1 Clarification
                 4.1.1 Single pass operation
                 4.1.2 Series on overflow and multiple pass systems
                 4.1.3 Examples of clarification
             4.2 Thickening
                 4.2.1 Single pass operation
                 4.2.2 Two or three stage operation
                 4.2.3 Examples of thickening duties
             4.3 Classification of Solids by Size
                 4.3.1 Single pass operation
                 4.3.2 Multipass operation
                 4.3.3 Examples of classification duties
             4.4 Washing of Solids
                 4.4.1 Co-current washing
                 4.4.2 Counter-current washing
                 4.4.3 Examples of washing
             4.5 Sorting by Solids Density
                 4.5.1 Separation of coal from waste
                 4.5.2 Other mineral separations
             4.6 Liquid-liquid Separation
             4.7 Liquid-gas Separation
         5 DESIGN
             5.1 General Approach
             5.2 Feed Data Collection
             5.3 Decide on Operation
             5.4 Estimation of Design Parameters
                 5.4.1 Clarification
                 5.4.2 Solids recovery
                 5.4.3 Classification
             5.5 Decision on Design Method
             5.6 Design from Manufacturer's Information
                 5.6.1 Design from charts
                 5.6.2 Design from grade efficiency curves
                 5.6.3 Design of Krebs cyclones from manufacturer's information
             5.7 Dimensionless Group Method
                 5.7.1 Design at low feed concentrations
                 5.7.2 Design at high feed concentrations
             5.8 Design using Empirical Equations
             5.9 Design from Testwork and Scale-down
                 5.9.1 Scale-down
                 5.9.2 Test rigs
             5.10 Optimisation
             5.11 Recycle and Series Arrangements
                 5.11.1 Grade efficiency of recycle and series arrangements
                 5.11.2 Selection of a recycle or series arrangement
                 5.11.3 Design of recycle or series arrangements
         6 OPERATION
             6.1 Installation of Cyclones
                 6.1.1 Unpacking and assembly
                 6.1.2 Orientation
             6.2 Feed Preparation and Supply
                 6.2.1 Removal of coarse particles from the feed
                 6.2.2 Feed supply
                 6.2.3 Feed connection
             6.3 Monitoring of Underflow
             6.4 Overflow Arrangements
             6.5 Dense Medium Circuits
             6.6 Environmental Factors and Safety
             6.7 Maintenance
                 6.7.1 Inspection and replacement
                 6.7.2 Prediction of wear rate
             6.8 Hydrocyclones in Series
                 6.8.1 Series arrangements without intermediate pumps
                 6.8.2 Counter-current washing
             6.9 Hydrocyclones in Parallel
                 6.9.1 Linear arrangement of vertical cyclones
                 6.9.2 Linear arrangement of horizontal cyclones
                 6.9.3 Circular arrangement of vertical cyclones
                 6.9.4 Circular arrangement of horizontal cyclones
             6.10 Control
                 6.10.1 Clarification
                 6.10.2 Solids recovery
                 6.10.3 Classification
             6.11 Monitoring
                 6.11.1 Pressure drop
                 6.11.2 Flowrates
                 6.11.3 Solids concentration
                 6.11.4 Particle size distribution
                 6.11.5 Temperature
             6.12 Problems and Solutions
         7 NOMENCLATURE
         8 REFERENCES
         9 APPENDIX A : List of companies manufacturing or marketing hydrocyclones
     Part 6 - Reslurry Washing
         1. INTRODUCTION
             1.1 NOMENCLATURE
             1.2 OBJECTIVES
         2. GENERAL SOLUTIONS
             2.1 UNDERFLOW CONCENTRATIONS KNOWN
             2.2 OVERFLOW:UNDERFLOW RATIOS KNOWN
         3. SOLUTIONS FOR SPECIAL CASES
             3.1 CASE IN WHICH OVERFLOW:UNDERFLOW RATIO IS CONSTANT
                 3.1.1 Analytical Solutions
                 3.1.2 Trends in Solute Flows
                 3.1.3 Trends in Liquid Flows
                 3.1.4 Trends in Solute Concentrations
                 3.1.5 Graphical Solutions
             3.2 CASES IN WHICH ALL SEPARATORS EXCEPT FIRST ARE IDENTICAL
             3.3 CASE WHEN THE FEED CONTAINS NO LIQUID
         4. INEFFICIENT MIXING
             4.1 CASES WHEN MIXING IS INEFFICIENT
             4.2 CALCULATIONS USING A MIXING EFFICIENCY
             4.3 CALCULATIONS BASED ON BYPASS OF UNDERFLOW
         5. BATCH OPERATIONS
         6. NOMENCLATURE
         7. LEACHING REFERENCES
     Terms and Conditions

 

Volume SLS V : Part 1 Introduction

Volume V covers thickeners and clarifiers, classifiers and hydrocyclones. This part summarises the content of the volume and explains how the volume is laid out and how to use it to best effect. It also summarises equations for particle settling velocities under different conditions.


Volume SLS V : Part 2 Efficiency of Separations

This part covers the fundamental relations for classification of particles and grade efficiency curves.


Volume SLS V : Part 3 Thickeners and clarifiers

The report gives a logic diagram showing the method to be adopted for carrying out laboratory tests for determining the size and other design features of a clarifier or thickener. Worked examples are given where appropriate. The initial stages are to define the requirements, obtain representative samples and to decide whether a clarifier or thickener is required. Selection and optimisation of flocculants is dealt with. For thickener design, alternative methods of identifying the compression point are compared. In addition to allowing determination of the size of thickener required and the ultimate pulp density, the report also provides data on torque loading, control and handling of the thickened slurry. For clarifier design both long tube and short tube tests are described. Economic evaluations are given and there is a comparison between laboratory-scale predictions and full-scale performance.


Volume SLS V : Part 4 Classifiers

At present information on classifiers may be found in SL V Part 1.


Volume SLS V : Part 5 Hydrocyclones

This part starts with a section on the theory. The types available are described and applications given. There is then a design procedure based on a logic diagram. The procedure allows systems of multiple cyclones to be specified. Worked examples are given. There is a section on installation, operation and control of hydrocyclones which includes environmental factors and safety. A list of manufacturers is given. A BROWSE version is available with live equations.


Volume SLS V : Part 6 Reslurry washing

This part gives ways of calculating the performance of a series of separators in which countercurrent washing is achieved by reslurrying the thickened slurry after each stage. Both batch and continuous operations are considered.