Polymeric Filtration Aid - "A Decade of Lab and Plant Observations"

Presented at:
The Regional Florida
AIChE Meeting
June 5, 2004

By: Louis Irwin

ARR-MAZ Custom Chemicals
621 Snively Avenue
Winter Haven, Florida 33880
863-293-7884

Polymeric Filtration Aid A Decade of Lab and Plant Observations

Many Phosphoric Acid plants use a Polymeric Filtration Aid for increased production
and recovery. This paper presents laboratory rate data, generated over 10 years,
versus various plant conditions. Data from nineteen different plants is presented in the
following charts as a side by side comparison. Each plant was assigned a code, A
through T, so that specific information can be compared confidentially.
My first attempt of this plant comparison was an unpublished paper done for data from
1996-1997. At the request of several engineers I decided to present this data and
expand it up to a decade of data where possible.
Little did I know what I had
volunteered to do! Unfortunately of my computer data was in Qpro, in Excel, and a
lot of the plant data was not on the computer, so I had to go through a decade of data
which looks like this:

Polymeric Filter Aids work by the principle of producing larger and more
homogeneous particles or gyp crystals, allowing for faster drainage. (Think of which will
drain a cup of water faster fine sand or coarse marbles).

What this paper is:

Comparison of Lab Filtration Rate (expressed in seconds for 1000 ml Slurry per
0.1Sq/ft. filter area). Some data mathematically adjusted for 1000ml Slurry.
Comparison of various plant conditions that may effect this filter rate including:
- Slurry Gravity
- #1 Filtrate Gravity
- #1 Filtrate Volume
- Strong Wash Gravity
- Pond Wash Gravity
- Polymer Filtration Rate and its % Improvement
- Polymer Optimum PPM Dosage
Industry Averages of these plant conditions.
What this paper is NOT:
NOT-Six Sigma statistically correct, just a small piece of the Decade pie!
NOT-Always normal conditions. (Lots of data during upset conditions).
NOT- the whole picture, other factors not available for comparison that might effect
filtration rate such as Sulfate, Rock Chemistry, Reactor and Mechanical Conditions.
NOT- request to change the way you run your plant!
I will not bore you with Tables of data thats hard to read, but you my get tired of bar
charts by the time I finish! Lets roll the charts!
Many of you may have seen some of the individual plant data as shown in Chart 1A.
This is lab filtration seconds for Blanks (non-Polymer treated Slurry) for an individual
plant over one year time expressed for each filter section.
Filtration rate can vary
significantly because of various Reactor Conditions.
LAB -BLANK FILTRATION SECONDS
1000 ml Slurry, 500 ml Strong, 500 ml Pond

Chart 1A

150
140
130
120

Filtration Seconds

110
100
90
80
70
60
50
40
30
20
10
0
SAMPLE DATE
SLURRY

STRONG

POND

One Year

TOTAL

AVERAGE
SLURRY = 19.6
STRONG = 39.2
POND = 26.8
TOTAL = 85.6

Chart 1B is the average Total Filtration rate for a decade of data of individual plants
compared side by side.
CHART 1B
BLANKS

TOTAL FILTRATION RATE

per 1000ml over 0.1 sq.ft. area

TOTAL FILTRATION SECONDS

1000 ML SLURRY + 500 ML SW +500 ML PW

170
160
150
140
130
120
110
100
90
80
70
60
50
40
30
20
10
0

INDUSTRY AVERAGE = 96.8 SECONDS

PLANT CODE

Engineers can convert this lab rate to Plant Tons/Sq.Ft., which can be converted to
Plant Production Rate by the following formula:
Plant Tons/SqFt. = Leaf Rate* X Square Root of Total Drying Time/Cycle Time.
TPD = Ton/Sq.Ft. X Plant Filter Area
*Leaf Rate is a more complex formula involving various Plant Conditions and can be
used to convert Lab Leaf to Plant Leaf calculations with a scale up factor.
This Total was derived from the Slurry plus the Strong Wash and the Pond Wash
Sections combined. (Any Plant that uses a Weak Wash had this data deleted for
comparison purposes). Individually the sections look as follows:

Chart 2 shows the average Slurry Filtration Rate for each Plant.
C H AR T 2
B L AN K S

SL U R R Y S EC T IO N FILTR AT IO N R ATE
per 1000 m l over 0.1 sq .ft. area

35

1000 M L S LU R R Y

TOTAL FILTRATION SECONDS

IN D U S TR Y AV E R AG E = 19.6 S E C O N D S
30

25

20

15

10

P LAN T C O D E

Chart 3 shows the average Strong Wash Filtration Rate for each Plant.

STRONG WASH SECTION FILTRATION RATE

per 1000 ml over 0.1 sq.ft. area

80

INDUSTRY AVERAGE = 45.7 SECONDS

75

CHART 3
BLANKS

500 ML STRONG WASH

TOTAL FILTRATION SECONDS

70
65
60
55
50
45
40
35
30
25
20
15
10
5
0

G H

J K L M N
PLANT CODE

Q R

Chart 4A shows the average Pond Wash Filtration Rate for each Plant.
CHART 4A
BLANKS

POND WASH SECTION FILTRATION RATE

per 1000 ml over 0.1 sq.ft. area
65

INDUSTRY AVERAGE = 31.5 SECONDS

500 ML POND WASH

TOTAL FILTRATION SECONDS

60
55
50
45
40
35
30
25
20
15
10
5
0

B C D

G H

L M N O P Q R

PLANT CODE

Chart 4B shows all three-section rates for each Plant.

VARIOUS SECTION FILTRATION RATE

per 1000 ml over 0.1 sq.ft. area

80

SLURRY

75

STRONG WASH

CHART 4B
BLANKS
POND WASH

TOTAL FILTRATION SECONDS

70
65
60
55
50
45
40
35
30
25
20
15
10
5
0

8 9 10 11 12 13 14 15 16 17 18 19
PLANT CODE

Chart 4C shows the percent of Total Rate for all three sections on an Industry Average.
How does your plant filter profile compare?
VARIOUS SECTION % of FILTRATION RATE

CHART 4C
BLANKS

Slurry
20.2%
Pond
32.5%

Strong
47.2%

INDUSTRY AVERAGE

Lets look at some of the Plant factors that effect filtration rate:
Chart 5 shows the Filter Slurry Specific Gravity.

Slurry Specific Gravity

(x1000)

1625

INDUSTRY AVERAGE = 1.551 SG

CHART 5

Slurry SG

SPECIFIC GRAVITY (X1000)

1600

1575

1550

1525

1500

1475

1450

B C D

E F

G H

I J K L M N O P Q R S
7
PLANT CODE

Chart 6 shows the Slurry Filtration Rate versus Slurry Specific Gravity.

SLURRY SG X1000

1625

35

1600

30

1575

25

1550

20

1525

15

1500

10

1475

1450

FILTRATION SECONDS

CHART 6

SLURRY SG versus SLURRY Filtration Seconds

0
B

PLANT CODE
Slurry SG

Slurry Filtration Sec

Chart 7 shows the Total Filtration Rate versus Slurry Specific Gravity.
CHART 7

SLURRY SG versus TOTAL Filtration Seconds

180

1625

160

1600

SLURRY SG X1000

120
1550

100

1525

80
60

1500
40
1475

20

1450

0
B

PLANT CODE
Slurry SG

TOTAL Filtration Sec

FILTRATION SECONDS

140
1575

Chart 6 & 7 would indicate that higher Slurry Gravity helps filtration rate. This is thought
to be a wrong conclusion from various Plant data, as when comparing individual plant
conditions, most plants show a linear regression of increased filtration rate for increased
Slurry Gravity.
Chart 8 individual Plant response to Slurry Specific Gravity.
LAB -BLANK FILTRATION
Slurry SG versus Total Filtration Seconds

Chart 8

150
140

Filtration Seconds

130
120
110
100
90
80
70

y = 0.6761x - 884.98
R2 = 0.1142

60
50
1425

1450

1475
1500
Slurry SG (x1000)

1525

1550

Chart 9: #1 Filtrate Specific Gravity versus Filtration Rate.

CHART 9

#1 FILTRATE Specific Gravity

1380
INDUSTRY AVERAGE = 1.314 SG

#1 FILTRATE SG

#1 FILTRATE GRAVITY (X1000)

1360

1340

1320

1300

1280

1260

1240

B C

G H

M N

PLANT CODE
9

O P

Q R

The #1 Filtrate Gravity should have an effect on Slurry and Total Filtration Rate.
Chart 10: #1 Filtrate Specific Gravity versus Slurry Filtration Rate.

#1 FILTRATE SG X1000

1380

35

1360

30

1340

25

1320

20

1300

15

1280

10

1260

1240

FILTRATION SECONDS

CHART 10

#1 FILTRATE versus SLURRY Filtration Seconds

0
B

PLANT CODE
SLURRY SG

SLURRY Filtration Sec

Chart 11: #1 Filtrate Specific Gravity versus Total Filtration Rate.

CHART 11

#1 FILTRATE versus TOTAL Filtration Seconds

180

1380

160

1360

120
1320

100

1300

80
60

1280
40
1260

20

1240

0
B

PLANT CODE
Slurry SG

TOTAL SECONDS

10

FILTRATION SECONDS

#1 FILTRATE SG X1000

140
1340

On a Plant comparison, there is no clear conclusion on effect of #1Filtrate Gravity

versus Filter Rate. However on an individual basis most plants show a linear regression
for increased filtration rate with higher #! Filtrate Specific Gravity
Chart 12: #1 Filtrate Specific Gravity versus Total Filtration Rate.
CHART 12

LAB BLANK FILTRATION

#1 Filtrate SG versus Total Filtration Seconds
100

FILTRATION SECONDS

90
80
70
60
50
40
30
20
y = 0.8416x - 1043.9
R2 = 0.1461

10
0
1300

1310

1320

1330

1340

1350

#1FILTRATE SG (x1000)

The individual plants have ranged from 0 to 14 seconds increase in filtration rate per 10
units (0.010) of #1 Filtrate Specific Gravity. Industry average is 5.7 seconds, which I
believe is low due to other factors effecting rate data over a large time period.

11

According to lab data, the biggest factor in Total Filtration Rate is the Strong Wash
Section, as this can be over 50% of the Filtration Rate.
Chart 13 shows the Plant Strong Wash Specific Gravity. Industry average is 1.084 SG.
CHART 13

STRONG WASH Specific Gravity

1150

STRONG SG

STRONG WASH SPECIFIC GRAVITY (X1000)

INDUSTRY AVERAGE = 1.084 SG

1125

1100

1075

1050

1025

1000

B C

G H

J K L M N
PLANT CODE

O P

Q R

Chart 14 shows the Plant Pond Wash Specific Gravity. Industry average is 1.017 SG.
CHART 14

POND WASH Specific Gravity

1050

POND SG

POND WASH SPECIFIC GRAVITY (X1000

INDUSTRY AVERAGE = 1.017 SG

1040

1030

1020

1010

1000

C D

G H

J K L M N
PLANT CODE

12

Q R

Another factor is vacuum and its correlating filter speed or flooding. Dry sections allow
a loss of vacuum that if allowed to become to low can be very detrimental as shown in
Chart 15.
Chart 15: Vacuum versus Lab Filtration Rate.
1000 ML S LURRY

VACUUM STUDY-FILTRATION SECONDS

500 ML S TRONG
500 ML P OND

CHART 15

120
T OT AL

110

FILTRATION SECONDS

100
90
80
70
60
50
40
30
20

18

16
14
VACUUM - IN

12

10

Slurry Solids is another factor in Filtration Rate. I dont have actual % Solids data, but I
do have #1 Filtrate Volume. This is an indirect correlation to solids, but gyp moisture
retention of the Slurry also effects this volume.
Chart 16: #1 Filtrate Volume: Industry average = 35.1% of Filter Slurry.
CHART 16

#1 FILTRATE VOLUME
(from 1000 ml Slurry)
550

INDUSTRY AVERAGE = 35.1%

525

#1 FILTRATE VOLUME

500

#1 FILTRATE VOLUME

475
450
425
400
375
350
325
300
275
250

G H

M N O

PLANT CODE
13

Q R

It is difficult to control all these variables for best filtration all the time. Polymeric
additives have helped to smooth the ride and in some Plants Polymeric additives are a
necessity for good Filtration Rates.
Chart 17: Various Plant Filtration Rate with Polymer.
CHART 17

Polymer -TOTAL FILTRATION RATE

per 1000ml over 0.1 sq.ft. area

130

1000 ML SLURRY + 500 ML SW +500 ML PW

TOTAL FILTRATION SECONDS

120
INDUSTRY AVERAGE = 80.0 SECONDS

110
100
90
80
70
60
50
40
30
20
10
0

B C D

G H

J K L M N O
PLANT CODE

P Q R

Chart 18: Various Plant Polymer % IMROVEMENT over Blanks.

Polymer & % IMPROVEMENT FILTRATION RATE

CHART 18

per 1000ml over 0.1 sq.ft. area

50

1000 ML SLURRY + 500 ML SW +500 ML PW

45

INDUSTRY AVERAGE = 17.7%

% IMPROVEMENT

40
35
30
25
20
15
10
5
0

C D

G H

J K L M N
PLANT
CODE
14

Q R

Polymeric Additives vary in molecular weight and ionic charge. ARR-MAZ Custom
Chemicals has determined, using lab filtration tests for the past 14 years, the proper
Polymer, optimum Dosage, and expected performance improvement in filtration rate.

Optimum PPM Dosage

Chart 19: Polymer Optimum Dosage (PPM).

Powder Polymer Optimum Dosage

for Maximum Filtration Performance

120
115
110
105
100
95
90
85
80
75
70
65
60
55
50
45
40
35
30
25
20
15
10
5
0

CHART 19

1000 ML SLURRY + 500 ML SW +500 ML PW

INDUSTRY AVERAGE = 20.0 PPM

B C

G H

J K L M N
PLANT CODE

O P

Q R

CONCLUSION:
Many factors effect filtration, and it is important to note that a Plant evaluation of the
performance of a Polymeric Filtration Aid can be distorted by the variations in these
factors (ie, background noise). Lab filter tests can help monitor some of these factors
and determine if a Polymeric Filtration Aid might be applicable for your current plant
conditions. Its also important to note that changes in your plant conditions may dictate
changes in your application of Filtration Aid. (ie: on/off, type, dosage, etc.)
A decade of data suggests that if you dont already use a Filtration Aid, you should
consider testing one to see if it can smooth out the many filtration variables in your plant
and allow for extra production and recovery.
On the Horizon:
9 As mining moves Southward, new process and filtration challenges will arise.
9 Polymeric Filter Aides / crystal modifiers can play a role in future operations.
9 Polymer technology continues to evolve with advances in products and application
equipment.
15