How flocculant selection can influence

solids dilution requirements in

thickener feedwells
M Tanguay1, P Fawell1, A Grabsch1 and S Adkins2
1

 Flocculated aggregates are

usually fragile.
Need to achieve the right
balance of applied shear,
reaction time, dosage and
solids concentration.
Optimising these variables
in a thickener feedwell can
be quite difficult.

Settling rate

Flocculation is a sensitive process

Solids concentration

Where do we come in?

AMIRA P266 has applied
computational fluid
dynamics (CFD) to full-scale
feedwell optimisation.
Adding a flocculation model
(PB-CFD) allows prediction
of aggregate size.
Can readily capture solids
concentration effects on
flocculation performance.

How to deal with high solids feeds?

Some feedwells can provide a degree of natural
dilution prior to flocculation, but difficult to control.
Direct feed dilution elevates settling rate requirements.
External solids dilution devices (E-duc, Turbo-dil) utilise
clarification zone liquor.
Flocculant choice can reduce the need for dilution:
Limited examples of this having a large influence.
Never previously studied by CFD.
Focused on one product (Rheomax DR 1050 from BASF).

Flocculation kinetics in pipe flow

Magnafloc 336

Rheomax DR 1050

Profiles obtained for both flocculants across a range of dosages, solids

concentrations and flow rates, then a population balance (PB) applied.

Modelling outcomes
Magnafloc 336

Rheomax DR 1050

d agg
eff s
dp

3 D f

Fractal dimension (Df)

2.40 with Magnafloc 336

2.55 with Rheomax DR 1050

Fractal aggregate structures

Fractal dimension 2.05

Fractal dimension 2.40

Fractal dimension 2.51

Computational domain

Inlet flow rate

1000 m3 h-1

Inlet velocity

1.5 m s-1

Feed solid concentration

5,10,15,20% w/w

Flocculant dosage

20 g t-1

Flocculant concentration

0.01%

Overflow rate

150 m3 h-1

Deliberately set low to keep the bed low

and reduce its impact on feedwell flows

PB-CFD predicted aggregate sizes

Example PB-CFD output

A snapshot in time for
just one condition.
Shows that there is a
wide variety of particle/
aggregate paths.
50000 paths considered
for each case.

Predicted settling velocities

vs. time in thickener
30

Magnafloc Rheomax
336
DR 1050

Settling velocity (m h-1)

25

5% w/w

20

10% w/w
15

15% w/w
20% w/w

10

Shelf height
5
0

Feedwell exit
0

50

100

Time (s)

150

200

Predicted solids throughput

Maximum throughput of solids (t h-1)

Injected slurry
concentration

Rheomax DR 1050

Magnafloc 336

5% w/w

168

141

10% w/w

323

182

15% w/w

359

157

20% w/w

348

159

First time PB-CFD has been used to predict throughput.

First demonstration of the potential impact of
flocculant selection.

Mean path analysis

Particle paths processed with a 1D flocculation model
taking conditions (flocculant concentration, solid
fraction, shear rate, etc.) from the CFD solution.
Aiming to depict process from the point of view of a
finite set of particle flowing in the thickener.
Two approaches attempted:
to average the processed output of each particle path.
to process the average of all particle paths.

Averaging performed on 500 particle paths.

1D flocculation model vs. full PB-CFD

1D flocculation model vs. full CFD

Processing individual particle paths and averaging results is okay.

Processing the averaged particle paths is not okay.

But what does it mean?

Variability in particle paths may play a significant role
in the overall output of the thickener.
Full scale thickener cannot be treated as a reactor
producing a homogeneous output:
Our CFD modellers get to keep their jobs.
Still may be scope to refine/speed-up the analysis.

PB-CFD does show that achieving a denser aggregate

from feedwell flocculation should produce a higher
flux under the right conditions.

But what does it mean in practice?

Just because you can get a higher flux, doesnt mean
you will, or even need to.
Flocculant selection may have reduced impacts:
When rise velocity of the thickener is low.
When applied dosages are low or solids dilution is high.

In particular, benefits from higher aggregate density

may not be realised in sub-optimal feedwells:
Shear is too high, leading to excessive breakage.
Shear is too low, leading to poor mixing/short-circuiting.

Acknowledgements
This work has been part of ongoing collaboration
between CSIRO and BASF.
It also builds upon techniques developed within the
AMIRA P266 Improving Thickener Technology series of
projects (see www.p266project.com), of which BASF has
been a long-term sponsor.