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SEDIMENTATION
Sedimentation is the partial separation or
concentration of suspended solid particles from a
liquid by gravity settling. This field may be divided
into the functional operations of thickening and
clarification.
Thickening
Clarification
increase the concentration of remove
a
relatively
small
suspended solids in a feed quantity of suspended particles
stream
and produce a clear effluent
Purpose designed for the heavier-duty ensure
essentially
complete
requirements imposed by a large suspended-solids removal
quantity
of
relatively
concentrated pulp
Source: Perrys Chemical Engineers Handbook, 8th Edition
As settling of solids in sedimentation is caused by the effect of gravity,
difference of density between the solids and the suspended liquid is a necessary
prerequisite. Also, it may be implied that the governing equations describing the
process will be the Stokes Law equation
=
( )
Where,
ut
terminal velocity
diameter
particle density
fluid density
and the related equations for sedimentation in the different settling regime
regions.
For the Stokes region:
Where,
x
diameter
Range of Motion
NRep
Stokes region
<2
> 500
Free Settling
any given particle is at sufficient
distance from the boundaries of the
vessel or from other particles so that its
fall is not affected by them
the relation of the diameter of particle
to the diameter of the sedimentation
vessel is over 1:200
Hindered Settling
the motion of the particle is impeded
by other particles, which will happen if
the particles are near each other even
they may not actually be colliding
the drag coefficient is greater than
that in free settling
History of Sedimentation
Year
200 B. C.
Event
Crushing and washing ores in Egypt
1556
1915
1916
1940
Figure 1. Progressive settling in a measuring cylinder: (A) clear liquid, (B) sludge
at initial concentration, (C) transition zone, (D) thick sludge at compression zone
Particles in a narrow range will settle with about the same velocity. When
this occurs, a demarcation line is observed between the supernatant clear liquid
(zone A) and the slurry (zone B) as the process continues. The velocity at which
this demarcation line descends through the column indicates the progress of the
sedimentation process. The particles near the bottom of the cylinder pile up,
forming a concentrated sludge (zone D) whose weight increases as the particles
settle from zone B. As the upper interface approaches the sludge buildup on the
bottom of the container, the slurry appears more uniform as a heavy sludge (zone
D), the settling zone B disappears, and the process from then on consists only of
the continuation of the slow compaction of the solids in zone D.
By measuring the interface height and solids concentrations in the dilute
and concentrated suspensions, a graphic representation of the sedimentation
process can be prepared as shown in Figure 1. The plot shows the difference in
interface height plotted against time, which is proportional to the rate of settling
as well as to concentration.
Operation
Thickener Types
High-Rate
Thickener
Ultrahigh-Rate
Thickener
High-Density
Thickener
Designed to produce
underflows having very high
apparent viscosity
Underflow slurries will be at a
higher concentration than for
high-rate thickeners
Clarifiers
Continuous clarifiers generally are employed with dilute suspensions, principally
industrial process streams and domestic municipal wastes, and their primary
purpose is to produce a relatively clear overflow. They are basically identical to
thickeners in design and layout except that they employ a mechanism of lighter
construction and a drive head with a lower torque capability. These differences
are permitted in clarification applications because the thickened pulp produced
is smaller in volume and appreciably lower in suspended solids concentration,
owing in part to the large percentage of relatively fine (smaller than 10 m) solids.
Clarifier Types
Rectangular
Clarifiers
Circular
Clarifiers
ClarifierThickener
Industrial
Waste
Secondary
Clarifiers
Inclined-Plate
Clarifiers
Solids
Contact
Clarifiers
Figure 4. Design curves for thickeners: (a) total flux versus concentration, and (b)
settling flux versus concentration
The
design
procedures
are
based
on
plotting
total
flux
versus
10
The Coe and Clevenger test overestimates the critical flux leading to
underdesign of thickener area, while the Talmage and Fitch procedure
underestimates it leading to overdesign. The latter procedure is less laborious
because it only requires one settling test.
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The thickener area can also be determined using a mass balance of the
whole sedimentation process. Referring to the diagram in Figure 5, let F be the
mass flow rate of solids in the feed, U the mass flow rate of solids in the underflow,
O the mass flow rate of solids in the overflow, XF the fraction of solids in the feed,
XU the fraction of solids in the underflow, 1 XF the fraction of liquid in the feed,
and 1 XU the fraction of liquid in the underflow.
The mass balances of liquid and solids in the process can be represented
by
For the limiting conditions of producing a clear overflow, the terminal settling
velocity of the particles ut should be equal to the ascending velocity of the liquid
u, so that
Substituting into the equations, transposing for A and calling it minimum area Amin:
II. Clarifiers
Clarifier performance depends on area, which is determined by the
flocculation nature of the feed suspension. When the overflow clarity is
independent of overflow rate and depends only on detention time, the required
time is determined by simple laboratory testing of residual solid concentrations in
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the supernatant versus detention time under the conditions of mild shear. This
determination is sometimes called the second-order test procedure because the
flocculation process follows a second-order reaction rate. In most cases, clarifying
performance depends on detention time and overflow rate. Tests are conducted
in a vertical tube that is as long as the expected depth of the clarifier, under the
ideal assumption that a vertical element of a suspension, which has been
clarified, maintains its shape as it moves across the tank.
If the suspension is nonflocculant, or if flocculation takes place prior to
settling, the overflow clarity is independent of detention time and depends only
on the overflow rate Q according to the relation:
where ut is the maximum particle settling velocity that yields a satisfactory clarity
in a simple laboratory sedimentation test, H is the height of the laboratory
container, and t is the time in which the supernatant liquid becomes clear.
For nonflocculant suspensions, gravity clarifiers are sometimes used as for
solids classification. The theoretical grade efficiency curve G(x) of the clarifier can
be predicted, assuming laminar flow and no end effects, by
where ut is a function of particle size and can be found if Stokes law applies.
13
=
=
= 0.001365 /
18
18 (0.001)
Verifying the applicability of the chosen sedimentation region, by calculating the
particle Reynolds number:
=
=
= 0.06825
(0.001)
The approximation was correct and the settling time is valid. Finally, due to the
high concentration of solids, correction due to this factor is in order. Transposing
for the corrected settling velocity and substituting values, the real settling velocity
is
= (1 )4.65 = (0.001365)(1 0.25)4.65 = . /
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LIQUID-SOLID SEGREGATION
Gravity Settlers
Type 1. Sedimentation
The settling of dilute slurries where there is little particle-to-particle
interaction is commonly referred to as Type I settling. All particles settle
independently; consequently, if a particle size distribution is known and the
settling rate of individual particles is known, then a settler can be designed.
If the terminal velocity (Ut) of the smallest particle to be separated is known or can
be calculated, then the overflow area (A1) can be calculated from the equation
15
16
TYPE II SEDIMENTATION
Slurries exhibiting Type II behavior are sufficiently thick and flocculent that
the solids tend to settle as a mass, giving a rather sharp line of demarcation
between the clear liquid overflow and the settling solids. For such systems, the
design is normally controlled by the thickening capability of the basin, although
the basin design must be adequate to provide sufficient overflow area to clarify
the liquid overflow.
A settler for Type II slurries is normally referred to as a thickener. They are
sometimes constructed as a rectangular basin; however, most often they are of
circular cross-section. In the rectangular basin, solids are normally removed by a
traveling syphon that moves longitudinally back and forth along the basin. In the
circular design, a raking mechanism is used to convey the settled solids slowly to
the center of the basin where, as with the rectangular basin, a syphon is used for
their removal.
The design methods most commonly used for Type II settlers and thickeners
rely on the taking of experimental data and on empirical analysis of the data to
obtain a design.
Problem on Design (Handbook of Separation Process Technology, 1987)
The settling data for a water-cement slurry, presented by Cremer and Davies
(1957), will be used.
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Clark et al. (1971) present the method for determining the surface area large
enough to prevent the rate of liquid rise from exceeding the velocity of
subsidence of the sludge interface:
=
The subsidence velocity (Vs) for cement slurry Vs = 0.66 ft/h. Then
=
2363 3 /
=
= 3580 2
0.66 /
Next, the area required for thickening in the bottom of the basin is determined by
the method explained by Fitch (1971), where H0 is the initial height of the slurry in
the graduated test cylinder:
=
0 0
=
=
= 13.1 / 2
(3.2 )
=
100000 /
=
= 7625 2
13.1 / 2
18
=
=
= 113
= 0.3935 0.4
=
=
10000 2
As Fitch (1971) indicates, the accepted procedure is to use a minimum depth of
3 ft for the sludge layer. This then makes the method conservative because more
compression will be realized in a 3 ft layer than in a 0.4 ft layer.
The total depth is not well defined; however, in this case a total depth of 6-9 ft
would be adequate.
Gravity settlers can be reduced significantly in volume by using multiple parallel
plates spaced about 1 in. apart. The plates are inclined to the vertical so that the
solids will slide off the plates. The minimum area requirement can be computed
for the parallel plate designs by the previously described calculation procedure
for a gravity settling basin. The actual vertical distance is calculated from the
geometry and the residence time is calculated from the flow rate and volume of
the plate stack.
19
References:
Geankoplis, C. (2003). Principles of Transport Processes and Separation
Processes. Fourth Edition. New Jersey: Prentice Hall.
Green D. and Perry R. (2008). Perrys Chemical Engineers Handbook. Eighth
Edition. New York: McGraw-Hill Companies, Inc.
Rhodes, M. (2008). Introduction to Particle Technology. Second Edition.
England: John Wiley & Sons Ltd.
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