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Anahita Raeiszadeh
Azad University of Firuzkooh, Iran
Abstract
Due to the shortage of water sources and its critical consequences, the need for water recovery is of increasing
importance.
Mineral processing plants are generally water consuming although some wastewater can be recycled. The most
common technique to recycle water is through thickening. Thickeners are built to concentrate the solids content
of the pulp and clarify the overflow water. In this paper, two approaches are employed for the design of
thickeners due to their use in the mining industry. First the Coe and Clevenger method was analysed and then
the Fitch and Talmage method was evaluated. In the conditions that settling of solids is for clarifying purposes,
counter current decantation may be used. In this paper the method of calculating the optimum thickener in type
and size regarding economic factors was evaluated and a case study of thickener design for the Mansour Abad
concentration plant is described. The thickener's area was estimated to be 4.7 m2 with depth of 1.80 0.20 m.
Introduction
Mining and industry have brought many positive achievements for mankind but they have not
prevented it from unintended negative consequences. Environmental pollution resulting from mining
and industrial activities is one of the undesired aspects and many societies are affected. One
environmental concern is tailings from flotation plants. The separation of the solid and liquid phases of
a suspension is very often a two-stage process. The first stage, known as thickening, is physicochemical
and involves the conversion of discrete, unflocculated particles of the suspension into a thickened
underflow with a clear overflow, often by the addition of a coagulant or flocculant. This step offers a
high degree of control and is efficient irrespective of the scale of the operation. This reliability is,
however, of vital importance in terms of establishing the conditions required for a similar effectiveness
of the second stage. The second stage is predominantly an physical operation, designed to reduce the
remaining water content of the thickened underflow by a suitable solid-liquid separation process,
thereby transforming it into a compact solid containing only small quantities of water.
The sedimentation concept (batch settling)
Particle size, particle density and fluid viscosity are readily recognized factors to be considered in any
sedimentation process. Less obvious are particle shape and orientation, the distortion of a deformable
particulate, the interference of one particle with another (particularly when concentrations are high), the
nearness of the wall of the container, and convection currents. These also have a significant and
varying influence on the separation process.
Materials with particle diameters of the order of a few microns settle too slowly for most practical
operations. Wherever possible, such small particles are agglomerated, or flocculated, into relatively
large clumps called 'flocs' that settle out more rapidly. Flocculation can be considered to include both
the effect of coagulation and the effect of polymer flocculation.
The settling of discrete particulate masses based initially upon modifications of Stokes' law has been
included in the research of many different solid-liquid systems. Early research work in this field
considered the settling behaviour of spherical particles for a wide range of concentrations, from dilute
to concentrated suspensions. A similar approach to that used for spheres was adopted for a study of the
sedimentation of small uniform particles by Steinour[1] and later (1950) by Hawskley[2], who both
correctly assumed that the up thrust acting on the particles is determined by the density of the
suspension rather than that of the fluid alone. For the sedimentation of uniform particles, the increased
drag is probably more attributable to a steepening of the velocity gradients than to a change in viscosity
as a result of solids concentration. In practical terms, the rate of sedimentation of a suspension of
discrete fine particles is extremely difficult to predict because of the large number of factors involved.
However, a number of empirical equations have been developed for the rate of sedimentation of
suspensions as a result of tests carried out in measuring jars or cylinders. For a given solid and liquid,
the chief factors which affect the process are the height of suspension, the diameter of the containing
vessel and its shape, and the solids concentration. Wallis [3] attempted to bring together results
obtained from a variety of conditions to categorize the behaviour of settling sediments of uniform
particles (> 100 m) sufficiently large for anomalous viscosity effects and flocculation to be regarded
as negligible.
The settling of flocculated particulate masses is a complicated process involving rearrangements in the
sediment long after the flows themselves have settled. Bottom-lying flows are compressed by the
weight of the others that settle upon them, since flows usually are bundles of particles held together by
weak forces, and which have entrapped within their structure considerable quantities of the liquid
medium. This produces sediment with varying degrees of density. A simplified history of the batch
sedimentation of a flocculated suspension is shown in Figure1. The upper section is a continuous plot
of the four zones that have been observed to develop during sedimentation and the lower sections show
the containers at various stages of settling, according to Comings et al. [4]
flows into the deposit is slowly expelled under the weight of the sediment above. This continues until
equilibrium is established between the weight of the flows and their mechanical strength.
Overall process time often depends very much on the type of settling aid used. Coagulants such as lime
may give process times of several hours whereas acrylic-based polymer flocculants can achieve process
times of a fraction of this. Process requirements and cost are therefore very important considerations in
the selection of a settling aid between these two extremes.
Spherical and quite compact flows can often be achieved by using combinations of electrolytes and
polyelectrolyte's and mixing in a specialised fashion (Hamza [8]). Such flows are not only denser and
faster settling, but also entrain less of the suspending liquid and hence produce a more distinct
separation.
Qf
QC
Qu Cu
) Qu (1
Cu
C
QC
(1 u )
Cu
s
C
1
1
) = QC (
)
Cu
C Cu
where Q0/A represents the superficial velocity of the liquid being displaced by settling solids, C and
are the concentration and density of pulp respectively and lower indexes u, s and f represent underflow,
solid and feed ; if the thickener is to discharge a clear overflow this must not exceed the settling rate of
solids at concentration C. Thus, by substituting the velocity by U, the equation becomes
A=
Qf C f 1
1
( )
U
C Cu
Application of the Coe and Clevenger method can often lead to values of thickener area which are
inadequate, as described by Scott [10], Yoshioka et al.[8], Talmage and Fitch [9], and others. The main
source of error suggested for this tendency to underestimate is the behaviour of the suspensions in
batch tests, which often leads to overestimation of thickener fluxes. Such behaviour may occur as a
result of channelling or short circuiting of fluid through the higher concentrations and may possibly be
partly attributable to segregation of the particulate during compression in the case of flocculated
suspensions. If the cylinder diameter used is small, wall effects may cause irregularities in settling
behaviour. The Coe-Clevenger relationship may still be valid in compression but no adequate
theoretical model has been developed which relates interface subsidence rates in batch tests to settling
rates in continuous operation.
In a batch test, settling commences with a uniform initial concentration of solids as shown in Figure 2.
The concentration in zone 3 must range between the original concentration in zone 2 and that of the
final condition in zone 4. If the solids handling capacity per unit area (SHC) is lowest at some
intermediate concentration a zone of such concentration must start to build up since the rate at which
solids enter this zone will be less than the rate at which they will leave. The mathematician Kynch [6]
showed how to determine the concentrations and fluxes in these zones by constructions on the
transition section of a single batch settling curve. Talmage and Fitch [9] used Kynch's approach to
determine the critical zone, or limiting flux, for a continuous thickener directly from a Kynch-type
construction.
The total mass of solids in the batch test is C0h0a. When any capacity-limiting concentration layer
reaches the interface, all solids in the column must have passed through it since it was propagated up
from the base of the column.
C j at j (U j + w j ) = C o ho a
If hj, is the height of the interface at time tj, and since it has been shown by Kynch that the upward
velocity of any specific layer is constant,
wj =
hj
tj
C j at j (U j +
hj
tj
) = C o ho a
C o ho
h j + U jt j
hj hj
tj o
This simplifies to
hi=hj+tjuj
Combining equations:
C j h j = C o ho
This means that hi is the height of uniform slurry of concentration Cj which contains the same amount
of solids as the initial slurry.
The settling velocity as a function of concentration may be developed from a single settling test by use
of the above relationship. Using arbitrarily chosen values of concentration, Cp the corresponding value
of hi can be calculated. Uj can then be determined as the slope of the line drawn through the point hi
and the tangent to the settling curve and a complete set of data showing Uj as a function of Cj can
therefore be developed from one settling test. These data can be represented graphically as shown in
Figure 4
required for a series of concentrations using the data showing U as the function of concentration (c),
developed previously, and substituting in the Coe-Clevenger formula results in:
1
1
A C j Cu
UA =
Qf Cf
u
Whichever concentration layer gives the largest unit area is then used as a design basis. With Figure 3a,
a simple geometrical construction may be used to obtain these areas directly.
In Kynch's equation: C o ho = C j h j = C u hu
Where Cu is the desired underflow concentration and hu is the corresponding height:
hj
h j hu
h
1
1
1
1
=
= u
=
C j C o ho C u C o ho
C j Cu
C u ho
and
hu hi
1
C o ho
hu hi
1
=
If Uj is represented by slope hj at Q: u j =
ti
C
j
u
So that: UA =
hu hi
tu
tu
C o ho
tu
C o ho
If hc is the required depth of the compression zone for a flat-bottomed tank the depth will become:
hc =
Vc
A
hc =
4Vc
d 2
Which can also be modified to consider the conical section of the thickener. The total depth of a
thickener is usually estimated by allowing for clarification and settling zones as well and these usually
lie in the cylindrical section. Between 1m and 1.5m are usually allowed for each to provide for size
capacity when this technique is applied.
0.48
FD Fc n
Cv =
R 1
So Cs T
R n +1 1
0.054(F D )I
15.80 I MS FD Fc
n
V
R (n + 1)
=
( R n +1 1) 2
S o C s T (R 1)
0.48
Which:
CF: constant costs ($/year); CT : total costs($/Y); D :solving ratio;
F :solving ratio in inlet; R :solving ratio over to underflow; FC :constant cost ratio;
I :dissolved solid ratio (TPD); IMS :marshal & swift index; n :number of thickeners;
SO :Feed (TPD); T :number of working days; F :correction factor of currency;
V :sedimentation velocity (m/hr): ; pulp Density.
UA = 0.0694
tu
C o ho
Which:
4 0.0197 240
D=
4 0.01 240
D=
0.5
= 2 .4 m ( 4 .7 m 2 )
0.5
= 1 .7 m ( 2 .4 m 2 )
hc =
( s 1)t r
s A( p 1)
Where:
( 2.3 1) 2.3
= 0.319m(TPH ) 1
2.3(1.2 1) 4.7
The feed rate is 2.75 TPH and therefore the required depth is estimated to be 0.8 m. Considering 12 m
height for retaining clarified water, total depth will be 1.82 metre.
36
34
32
30
height from cylinder base (cm)
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
0
10
12
14
16
18
20
22
24
26
Figure 5 Sedimentation chart of Pb & Zn waste with adding 10 gr/ton A100 Floc
38
36
34
32
30
28
26
24
22
20
18
16
14
12
10
8
6
4
2
0
0
10
12
14
16
18
20
22
24
Figure 6 Sedimentation chart of Pb & Zn waste with adding 15 gr/ton A100 Floc
Economic results
After construction of the thickener in accordance with the work described above, water consumption
was reduced from 400 m3 per day to 100 m3 per day thus decreasing water provisioning costs. This
work has also improved environmental aspects of the facility.
Acknowledgements
The authors express appreciation to Firuzkooh University, the Young Iranian Scientist Club (bpj) and
Mansour Abad mineral processing plant for their kind assistance.
References
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of high nitrate and carbonaceous wastewater', Environmental Progress; New York; Apr 2008
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28 Apr. 2008
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uniform size angular particles'. Ind. Eng Chem., 36,618-624, 804-847 (1944)
[4] Hawskley, P.G.W. 'The effect of Concentration on the settling of suspensions and flow through porous
media'. Inst. Phys. Symp. 1950. p. 114(1950)
[5] Wallis, G.B., 'A Simplified one-dimensional two - Component vertical flow', Inst. Chem. Eng. Symp. on
Interaction between Fluids and Particles, 19,9-16(1962)
[6] Comings, E.W., Pruiss, C.E.and De Bord, C., 'Continuous settling and thickening', Ind. Eng Chem., 46,
1164-1172 (1954)
[7] Coe, H.S. and Clevenger, G. H., 'Methods for determining the capacities of slime thickening tanks'. Trans.
AIME, 55, 356,384(1916)
[8] Anderson, A.A. and Sparkman, J.E., 'Review of sedimentation theory', Chem. Eng., 75-80(1959)
[9] Gaudin, A.M. and Fuersienau, M.C., 'Experimental and mathematical model of thickening', Trans. Soc. Min.
Eng., 223, 122-129 (1962)
[10] Hamza, HA., 'Least cost flocculation of clay minerals by polyelectrolyte', Trans. IMM, Sect. C, 87, C212
(1978)
[11] Fitch, E.B., 'Current theory and thickener design', Ind. Eng. Chem., 58, 18 (1966)
[12] Kynch, G.J.,Trans. Faraday Soc, 48, 166 (1952)
[13] Zoma, A., ' Calculation optimum number of stages in continuous countercurrent decantation (CCD),
Minerals and metallurgical processing, pp 118-120 (2010)