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SLS 9: Ancillary Processes

SLS 9: Ancillary Processes
     Part 1: The use and selection of flocculants
         1 GENERAL INTRODUCTION
             1.1 Scope and Contents of the Report
             1.2 Preliminary Definitions
             1.3 Consumption of Coagulants and Flocculants
         2 THE NATURE OF SOLIDS IN WATER
             2.1 Introduction
             2.2 Colloid Chemistry of Hydrophobic Colloids - The Electrical Double-Layer
             2.3 Colloid Chemistry of Hydrophilic Materials
             2.4 Potential Energy Diagrams
         3 COAGULANTS, FLOCCULANTS AND THEIR PROPERTIES
             3.1 Introduction, Classification and History
                 3.1.1 History
             3.2 Inorganic Coagulants
                 3.2.1 Lime
                 3.2.2 Ferrous Sulphate (Copperas, FeSO4.7H2O)
                 3.2.3 Introduction to the Solution Chemistry of Hydrolysable Salts
                 3.2.4 Alum (Al2(SO4)3.14H2O or Al2(SO4)3. 18H2O)
                 3.2.5 Ferric Salts (Fe2(SO4)3 .7H2O and FeCl3.6H2O)
                 3.2.6 Summary and Example
                 3.2.7 Other Coagulants
                 3.2.8 Coagulant Aids
             3.3 Pre-polymerised Inorganic Coagulants
                 3.3.1 Polyaluminium Chloride
                 3.3.2 Other Pre-polymerised coagulants.
             3.4 Natural Flocculants
                 3.4.1 Starch
                 3.4.2 Guar Gum
                 3.4.3 Sodium Carboxymethyl Cellulose (CMC)
                 3.4.4 Alginic Acids
                 3.4.5 Tannins
                 3.4.6 Isinglass, Gelatin (Gelatine) and Glue
             3.5 Synthetic Flocculants and Coagulants
                 3.5.1 Range of Synthetic Flocculants
                 3.5.2 Range of Synthetic Coagulants
                 3.5.3 Structured Cationic Flocculants
                 3.5.4 Synthesis of Polyacrylamide-Type Flocculants
                 3.5.5 Physical Forms of Synthetic Flocculants and Coagulants
                 3.5.6 Behaviour of Polyelectrolytes in Solution
             3.6 Characterisation and Analysis of Synthetic Polymers
                 3.6.1 Molecular Weight
                 3.6.2 Ionic Character
                 3.6.3 Analysis of Polyacrylamide in Solution
                 3.6.4 Determination of the Composition of Flocculants using Infra-Red Spectroscopy
         4 THE MECHANISMS OF COAGULATION
             4.1 Introduction
             4.2 Coagulation of Hydrophobic Particles
                 4.2.1 Double-Layer Compression
                 4.2.2 Adsorption Coagulation
                 4.2.3 Sweep Coagulation
             4.3 Use of Alum for Drinking Water Treatment
             4.4 Coagulation of Hydrophilic Particles
             4.5 Related Phenomena
                 4.5.1 Sensitisation
                 4.5.2 Heterocoagulation
                 4.5.3 Secondary Minimum Coagulation
         5 THE PROCESS OF FLOCCULATION AND FACTORS AFFECTING IT
             5.1 Introduction
             5.2 Flocculant Adsorption
                 5.2.1 The Silberberg Theory
             5.3 Mechanisms of Flocculation
                 5.3.1 Bridging Flocculation
                 5.3.2 Particle-Flocculant Bonding
                 5.3.3 Interactions Between Polymers and Particles Carrying the Same Charge
                 5.3.4 Interactions Between Polymers and Particles Carrying Opposite Charges
             5.4 The Effect of Flocculants on Zeta-Potential
             5.5 Smellie, La Mer and Healy's Theory of Flocculation
                 5.5.1 Validity of Smellie, La Mer and Healy's Theory
             5.6 Factors Affecting Flocculation
                 5.6.1 Flocculant Dosage
                 5.6.2 Flocculant Molecular Weight
                 5.6.3 Coagulant and Flocculant Combinations
                 5.6.4 Nature of the Substrate
                 5.6.5 Substrate Particle Size
                 5.6.6 Substrate Solids Concentration
                 5.6.7 Flocculant Ionic Charge
                 5.6.8 pH and Ionic Strength of Substrate Medium
                 5.6.9 Temperature
                 5.6.10 Polymer Addition to Substrate
                 5.6.11 Mixing and Agitation
         6 KINETICS FOR DESIGN
             6.1 Introduction
             6.2 Smoluchowski - Rapid Coagulation
             6.3 Fuch - Slow Coagulation
             6.4 Effect of Particle Size Distribution
             6.5 Practical Application of Coagulation Kinetics
             6.6 Kinetics of Flocculation with Polymers.
         7 PLANT PREPARATION, ADDITION, METERING AND DOSE CONTROL OF FLOCCULANT AND COAGULANT SOLUTIONS
             7.1 Introduction
                 7.1.1 Make-Up Water Quality for Flocculants
                 7.1.2 Plant Preparation of Solid-Grade Flocculants
                 7.1.3 Eductors
                 7.1.4 Ciba Specialty Chemicals Jetwet® Disperser and FAB Units
                 7.1.5 The Wallace and Tiernan Polyprep System
             7.2 Plant Preparation of Inverse Emulsion and Liquid Dispersion Grade Flocculants
             7.3 Control Systems for Flocculant Addition
                 7.3.1 AlcotechTM TC. Automatic Flocculant Control for Thickeners
                 7.3.2 PolykonTM Process. Automatic Control of Flocculant for Chamber and Membrane Filter Presses
                 7.3.3 Control of Centifuges and Filter Belt Presses
                 7.3.4 Sludge Density Gauge
             7.4 Addition of Polymer Solutions
                 7.4.1 Pumping
                 7.4.2 Mixing Polymer into Sludges or Slurries
                 7.4.3 Computational Fluid Dynamics (CFD)
             7.5 Conclusion
         8 THE USE OF COAGULANTS AND FLOCCULANTS IN VARIOUS INDUSTRIES
             8.1 Domestic Sewage Treatment
                 8.1.1 Introduction
                 8.1.2 Sewage Treatment Process
                 8.1.3 Flocculant and Coagulant Use
                 8.1.4 State of the Art Example
             8.2 Potable Water Treatment
                 8.2.1 Introduction
                 8.2.2 Treatment Processes
                 8.2.3 Types of Raw Water and Colour Removal
                 8.2.4 The Use of Flocculants and Synthetic Coagulants in Water Treatment
                 8.2.5 Example: Sydney Water Supply
             8.3 Hydrometallalurgical Operations
                 8.3.1 Bayer Process Alumina Production
                 8.3.2 Electrolytic Zinc Production
                 8.3.3 Titanium Dioxide Production by the Sulphate Process
                 8.3.4 Other Hydrometallurgical Processes that Use Flocculants
             8.4 Heavy Metal Precipitation and Acid Mine Drainage Treatment
                 8.4.1 Example: Wheal Jane Active AMD Treatment, Cornwall, UK
             8.5 The Sugar Industry
                 8.5.1 Raw Sugar Production
                 8.5.2 The Sugar Refining Process
                 8.5.3 Regulations for Sugar Process Flocculants
             8.6 Paper Industry
                 8.6.1 Retention Aids
                 8.6.2 Dewatering
                 8.6.3 Effluent Treatment
             8.7 Mining and Mineral Processing Flocculant Applications
                 8.7.1 General Flocculation and Dewatering Characteristics of Minerals
                 8.7.2 Conventional and DeepThickening of Base Metal Tailings
                 8.7.3 Coal Washing and Reclamation (Including High Rate Thickening)
                 8.7.4 Potash Processing
                 8.7.5 Vacuum and Pressure Filtration in Mineral Processing
                 8.7.6 Ciba Specialty Chemicals RHEOMAXTM Range of Polymers and Thickening Technology
             8.8 Coagulation and Flocculation of Some Miscellaneous Substrates
                 8.8.1 COD/BOD Reduction
                 8.8.2 Oil Effluents
                 8.8.3 Bacterial Suspensions
                 8.8.4 Abattoir Effluents
                 8.8.5 Textile Effluents
                 8.8.6 Dredging Operations
             8.9 Dissolved Air Flotation (DAF)
         9 THE TESTING AND SELECTION OF FLOCCULANTS AND COAGULANTS
             9.1 Introduction
             9.2 Solid - Liquid Separation Devices and the General Limitations of Their Application
             9.3 Characteristics of Coagulation and Flocculation
             9.4 The Nature of Slurries and Sludges
                 9.4.1 Classification
                 9.4.2 Characterisation of Slurries and Sludges
                 9.4.3 Collection of Representative Samples
             9.5 Screening of Coagulants and Flocculants
                 9.5.1 Potable Water Treatment:
                 9.5.2 Domestic Sewage Treatment:
                 9.5.3 Organic Effluents:
                 9.5.4 Mineral Processing Slurries:
                 9.5.5 Inorganic Effluents:
                 9.5.6 Alumina, Titanium Dioxide, Sugar:
                 9.5.7 Practical Advice on Testing:
             9.6 Clarification Test Methods - Jar Test
             9.7 General Introduction to Settling Behaviour and Sedimentation Tests
             9.8 Clarifier Sizing Testwork
             9.9 Rapid Screening of Flocculants for Sedimentation Tests
                 9.9.1 Estimation of Settling Rate Required
             9.10 Thickener Sizing Testwork
                 9.10.1 Talmage and Fitch Method
                 9.10.2 Coe and Clevenger Method
                 9.10.3 Depth of Compression Zone and Deep Thickeners
             9.11 Gravity Drainage Thickening
             9.12 Vacuum Filtration
                 9.12.1 Evaluating Flocculants for Rotary Vacuum and Disc Filters
                 9.12.2 Sizing of a Disc Filter
                 9.12.3 Horizontal Belt Vacuum Filter Tests
             9.13 Pressure Filtration Testing
                 9.13.1 Evaluation of Flocculants for Pressure Filtration. using a Piston Press (Originally English China Clays Ltd, St Austell, Cornwall, now Imerys)
                 9.13.2 Belt Filter Presses
             9.14 Centrifugation
                 9.14.1 Introduction
                 9.14.2 Counter- and Co- Current Design
                 9.14.3 Evaluation of Flocculants for Centrifugation
             9.15 Capillary Suction Time (CST) Apparatus
             9.16 Miscellaneous Information on Flocculant Evaluation
                 9.16.1 Sedimentation
                 9.16.2 Filtration (Pressure)
                 9.16.3 Mixing of Flocculant with Thick Substrates
                 9.16.4 Floc and Coagula Density and Size
         10 . CONCLUDING REMARKS
         11 APPENDIX A: FLOCCULANT AND COAGULANT MANUFACTUERS AND SUPPLIERS
             11.1 SNF - Floerger
                 11.1.1 FloMin CLARIFICATION AIDS
                 11.1.2 FloMin RM RHEOLOGY MODIFIER RANGE
             11.2 Ciba Specialty Chemicals
             11.3 Degussa - Stockhausen
             11.4 Cytec Industries
             11.5 Nalco Company
             11.6 Beijing Hengju
             11.7 Kemira
             11.8 Feralco
             11.9 Goldcrest Chemicals
             11.10 Chemifloc
             11.11 Tramfloc Inc
         12 APPENDIX B: SOLID-LIQUID SEPARATION EQUIPMENT MANUFACTURERS
         13 APPENDIX C: PULP DENSITY (OR PULP SG) CONCEPTS
             13.1 Introduction
             13.2 Derivation of the Fundamental Equations
                 13.2.1 Total volume of slurry = volume of solids + volume of liquid
         14 APPENDIX D: BARNEA PLOT FOR DETERMINING COMPRESSION POINT
         15 APPENDIX E: DETERMINING THE SPECIFIC RESISTANCE OF SLURRIES TO FILTRATION
         16 APPENDIX F: GLOSSARY OF TERMS USED IN THIS REPORT
         17 REFERENCES
     Part 2: Instumentation for Slurries
     Part 3: Discharge and Handling of Cakes
         1. INTRODUCTION
             1.1 Background to Report
             1.2 Scope of Report
             1.3 Contents of Report
             1.4 How to Use the Report
                 1.4.1 Design of New Plant
                 1.4.2 Problems at an Existing Plant
                 1.4.3. Major Tables in Report
             1.5 Glossary
         2. CAKE PROPERTIES
             2.1 Scope of Chapter
             2.2 Cohesion and Adhesion
             2.3 Mechanisms of Interparticle and Particle-Surface Attraction
                 2.3.1 Molecular Forces
                 2.3.2 Mobile Liquid Binding
                 2.3.3 Immobile Liquid Bridging
                 2.3.4 Solid Bridges
                 2.3.5 Mechanical Interlocking
                 2.3.6 Effect of Porosity and Saturation on Cake Properties
             2.4 Cake Classification
                 2.4.1 Handling Properties of Rigid Cakes
                 2.4.2 Alternative Classifications of Handling Properties
                 2.4.3 Classification of Pumpable Materials
                 2.4.4 Additional Cake Classes
         3. GUIDE TO TROUBLEFREE OPERATION
             3.1 Avoidance of Problems
                 3.1.1 Use of Multipurpose Equipment
                 3.1.2 Matching Equipment for Sequential Operations
                 3.1.3 Plant Layout for Avoiding or Minimising Handling
                 3.1.4 Selection of Equipment to Minimise Problems
             3.2 General Solutions to Specific Problems
                 3.2.1 Solutions to Problems Caused by Cake Adhesion
                 3.2.2 Solutions to Problems Caused by Cohesion
                 3.2.3 Solutions to Problems Caused by Separation of Solid and Liquid
                 3.2.4 Solutions to Problems with Pumpable Cakes
                 3.2.5 Solutions to Problems with Abrasive Materials
                 3.2.6 Solutions to Problems with Corrosive Materials
                 3.2.7 Solutions to Problems with Friable Particles
                 3.2.8 Solutions to Problems with Other Degradable Materials
                 3.2.9 Solutions to Problems with Hazardous Materials
         4. DISCHARGE FROM FILTERS AND CENTRIFUGES
             4.1 Discharge Requirements
                 4.1.1 Selection of Suitable Discharge Method
             4.2 Selection of Cloths
             4.3 Discharge from the Separating Surface
                 4.3.1 Gravity
                 4.3.2 Centrifugal Discharge
                 4.3.3 Cloth Movement
                 4.3.4 Gas Blowback
                 4.3.5 Wet Discharge
                 4.3.6 Vibration
                 4.3.7 Mechanical Discharge Devices
                 4.3.8 Transfer Rollers
                 4.3.9 Manual Discharge
             4.4 Removal of Cake from Separator
                 4.4.1 Deflector Plates
                 4.4.2 Removal of Pumpable Pastes from Separators
                 4.4.3 Removal of Cake from Pressure Filters
         5. STORAGE
             5.1 Requirements of a Storage System
             5.2 Stockpiles
             5.3 Bulk Containers
             5.4 Tanks
             5.5 Bins
                 5.5.1 Definitions
                 5.5.2 Problems Associated with Bins
                 5.5.3 Flow Patterns in Bins
                 5.5.4 Gravity Discharge
                 5.5.5 Discharge Aids
                 5.5.6 Structural Design of Bins
                 5.5.7 Level Measurement
         6. CONVEYORS
             6.1 Requirements of a Conveyor
             6.2 Portable Storage
             6.3 Gravity Transfer
                 6.3.1 Vertical Chutes (Pipes)
                 6.3.2 Inclined Chutes
             6.4 Belt Conveyors
             6.5 Apron Conveyors
             6.6 En Masse Conveyors
             6.7 Screw Conveyors
             6.8 Vibratory Conveyors
             6.9 Bucket Elevators
             6.10 Pneumatic Conveyors
                 6.10.1 Dilute Phase Pneumatic Conveyors
                 6.10.2 Fluidised Bed Pneumatic Conveyors
                 6.10.3 Dense Phase Pneumatic Conveyors
             6.11 Pumps
                 6.11.1 Choice of a Pump
                 6.11.2 Feeding Pumps
                 6.11.3 Progressing Cavity Pump
                 6.11.4 Screw Pump
                 6.11.5 Plunger Pump
                 6.11.6 Piston Pump
                 6.11.7 Diaphragm Pump
                 6.11.8 Peristaltic Pump
                 6.11.9 Rotary Ram Pump
                 6.11.10 Lobe Pump
                 6.11.11 Pressurised Vessels
                 6.11.12 Centrifugal Pumps
         7. FEEDING AND METERING
             7.1 Requirements of a Feeder
                 7.1.1 Definitions
                 7.1.2 Specification
                 7.1.3 Causes of Error
             7.2 Selection of Feeder Type
             7.3 Volumetric Feeders for Rigid Cakes
                 7.3.1 Screw Feeders
                 7.3.2 Volumetric Belt Feeders
                 7.3.3 Vibratory Feeders
                 7.3.4 Rotary Table Feeder
                 7.3.5 Rotary Plough Feeders
                 7.3.6 Rotary Star Feeder
             7.4 Gravimetric Feeders
                 7.4.1 Batch Scales
                 7.4.2 Loss in Weight
                 7.4.3 Weigh Belts
                 7.4.4 Nuclear Belt Weighing
                 7.4.5 Gravimetric Vibrating Feeders
             7.5 Feeding Pumpable Pastes
                 7.5.1 Metering Pumps
                 7.5.2 Loss in Weight
                 7.5.3 Flowmeters
         8. PREPARATION FOR DOWNSTREAM EQUIPMENT
             8.1 Reducing the Moisture Content of the Cake
                 8.1.1 Predrying
                 8.1.2 Product Recycle
             8.2 Making Pastes more Fluid
                 8.2.1 Reducing Solids Concentration
                 8.2.2 Mechanical Working
                 8.2.3 Use of Additives
             8.3 Reducing the Size of the Cake Lumps
             8.4 Increasing the Size of the Feed
             8.5 Altering the Shape of the Cake
                 8.5.1 Preforming
             8.6 Other Pretreatment Processes
             8.7 Other Downstream Operations
                 8.7.1 Cake is Final Product
                 8.7.2 Further Processing
                 8.7.3 Milling
                 8.7.4 Disposal
         9. CHARACTERISATION OF CAKES
             9.1 Levels of Measurement
             9.2 Reasons for Characterising Cakes
             9.3 Basic Particle and Cake Properties
                 9.3.1 Particle Size
                 9.3.2 Porosity
                 9.3.3 Saturation
                 9.3.4 Permeability
             9.4 Empirical Tests
                 9.4.1 Empirical Tests for Discharge from Filters
                 9.4.2 Tests for Friability
                 9.4.3 Tests for Abrasiveness
             9.5 Powder Strength Testers
                 9.5.1 Shear Tests
                 9.5.2 Measurement of Single Parameters
                 9.5.3 Adhesion
                 9.5.4 Angles of Repose
                 9.5.5 Atterberg Limits
             9.6 Pumpable Cakes
         10. REFERENCES

Volume SLS IX : Part 1 Flocculation and coagulation

The report provides a comprehensive review of both coagulants and flocculants. The basic physical chemistry of colloids is explained. Mechanisms of hydrophilic and hydrophobic coagulation and factors affecting flocculation are described. The practical applications of kinetic theories to design are given. Chemical additives used for particle aggregation are classified in terms of their properties. Measurement of characteristics such as molecular weight, ionic content, polymer configuration, chain length and adsorption are described. A list of commercially available flocculants is also given. The section on plant design describes techniques for the handling, storage and dissolution of flocculants as well as the metering, mixing and addition of the solution to the slurry. Problems of handling thickened sludges and the effects of flocculants on the environment are described. Laboratory tests to screen flocculants for sedimentation and filtering applications are described and examples given of the use of flocculants in different industries. Novel processes such as selective flocculation, floccular flotation and pelleting flocculation are also described.


Volume SLS IX : Part 2 Instrumentation for solid-liquid separation
Volume SLS IX : Part 3 Discharge and handling of cakes

Part 3 provides practical guidance for discharge of cakes from the separating surface in filters and centrifuges; for the discharge of cakes from vessels (eg from the filter and from storage vessels); for the conveying of cakes between equipment; for the feeding of cakes at constant rate; and for pretreatment of cakes before dryers. Typical problems are listed and it is shown that many of these arise because binding forces are high. These forces (eg capillary suction, solid bridging) cause particles to bind to each other (cohesion) or to surfaces (adhesion). Methods of measuring cohesion and adhesion are described but because it is often not possible to utilise such measurements, the report adopts a more empirical approach.

This empirical approach classifies cakes by their physical properties (eg sticky, brittle, matted cakes) which can be done by visual examination. The cake classifications are defined in terms of the binding forces and by the state of the cake (eg desaturated, compressed). Ways of overcoming problems (eg adhesion to surfaces, lumps too large) are described and related to the different classes of cake. The solutions described include; layout of equipment to avoid storage or handling; modification of cake properties; modification of surfaces; and correct choice of equipment. The various types of storage, conveyor and feeder are described and the applications given.