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Minerals Engineering 62 (2014) 2530

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Minerals Engineering
journal homepage: www.elsevier.com/locate/mineng

The theoretical partition curve of the hydrocyclone


Johann Dueck a,b,, Mohamed Farghaly c, Thomas Neesse a
a
Friedrich-Alexander-Universitt, Erlangen-Nuremberg, Germany
b
L.N. Gumilyov Eurasian National University, Kazakhstan
c
Faculty of Engineering, Al-Azhar University, Qena, Egypt

a r t i c l e i n f o a b s t r a c t

Article history: In many cases, the hydrocyclone partition curve exhibits a non-monotonic course in the ne particle
Available online 26 October 2013 range. The so-called sh-hook effect indicates an increased separation of the ne fraction, which is of
practical interest and has a positive effect on solid/liquid separation. However, for classication purposes,
Keywords: the separation is less distinct. In this contribution an equation of a partition curve containing a sh-hook
Hydrocyclone
is derived considering the laws of disturbed settling in dense, polydisperse suspensions. The following
Partition curve
effects are considered: the entrainment of ne particles in the boundary layer of the coarse settling par-
Classication
Fish-hook ticles, the hindered settling due to the increased effective density and viscosity of the uid, and the coun-
Fine particle separation ter ow of the displaced uid caused by the settling particles. The calculations indicate that the sh-hook
effect is primarily caused by ne particle entrainment, which is inuenced by the feed solid content and
the feed particle size distribution. An approximated analytical solution for the partition curve is pre-
sented for aRosinRammlerSperlingBennet (RRSB)-distributed feed. Experiments using 25-mm hydro-
cyclone conrm the calculations.
2013 Elsevier Ltd. All rights reserved.

1. Introduction The phenomenon of increased ne particle removal through the


underow leads to practical consequences. For example, increasing
The fundamental scheme for the hydrocyclone is shown in the removal of ne particles is benecial for water purication by
Fig. 1a. removing mechanical impurities. However, the sh-hook effect is
The partition curve (Fig. 1b) used to characterize the separation detrimental to ne particle classication because it reduces the
efciency of the hydrocyclones involves the mass fraction T(d) for separation sharpness.
each particle size d, which is discharged in the coarse product Although the non-monotonic separation function was described
(underow). Schubert and Neesse (1980) demonstrated that the in the scientic literature (Finch (1983), many years ago, no con-
typical S-shaped partition curve derives from the superposition sensus has developed regarding the physical basis of this
of the settling ow and a turbulent diffusion ow in the rotating phenomenon.
uid. Some researchers remain skeptical (Flintoff et al. (1987), Nage-
The so-called tapping model (Neesse et al. (1991), Schubert swararao (2000)) of this effect, believing that it has no physical ba-
(2010)), which neglects the distribution of the hydrodynamic char- sis and that the experimental observations are the result of
acteristics in the processing zone of the apparatus, describes the agglomeration phenomena, measurement errors, or the variations
inuence of various factors on the separation characteristics. The in the particles size fractions relative to their shape and density.
theoretical partition curve calculated using the free settling veloc- These doubts have been analyzed and refuted by Dueck et al.
ity according to the Stokes formula, increases monotonically with d (2007).
(see the dashed curve in Fig. 1b). After analyzing the statistical properties of the measurements,
However, in many cases in the ne particle range, an increased Bourgeois and Majumder (2013) came to the same conclusion that
particle removal can be observed (see the continuous curve in the shhook effect is a real physical phenomenon.
Fig. 1b). This so-called sh-hook effect is subject of many investi- In several publications by Finch (1983), Del Villar and Finch
gations and discussions. (1992), and Kraipech et al. (2002), empirical correlations have been
developed to describe the sh-hook effect.
Schubert (2003, 2004) provided a qualitative explanation of the
Corresponding author at: Friedrich-Alexander-Universitt, Erlangen-Nurem-
berg, Germany. Tel.: +49 9131 85 23 200.
sh-hook effect using the buoyancy acting on the particles in a
E-mail address: johann.dueck@mbt.uni-erlangen.de (J. Dueck). non-uniform rotational ow. The random motion of particles of

0892-6875/$ - see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.mineng.2013.10.004
26 J. Dueck et al. / Minerals Engineering 62 (2014) 2530

Nomenclature

a centrifugal acceleration () n parameter of the distribution function (


entrainment constant () uin velocity of the suspension ow in the inlet (m/s)
cV total volume solid concentration () Dp inlet pressure (bar)
d particle size (lm) s internal variable of integration (lm)
dm characteristic particle size (lm) S volume split ()
Dc diameter of the cylindrical portion of the hydrocyclone T(d) partition function
(mm) Vh(d) hindered settling velocity (m/s)
Do overow diameter (mm) VS(d) settling velocity (m/s)
Din diameter of the inlet (mm) VSt,j Stokes velocity (m/s)
Dt coefcient of turbulent diffusion (m/s2) wtan maximum tangential velocity (m/s)
D(d) deceleration function for the disturbed settling () W_o suspension throughput at overow (m3/s)
E(d) acceleration function () W_u suspension throughput at underow (m3/s)
fe(d) entrainment function () qf uid density (kg/m3)
g(cV) function of solids content () qp solid density (kg/m3)
q(d) density of the particle size distribution (lm1) lf uid viscosity (kg/ms)
H depth of the sh-hook () C Gamma function ()

varying sizes in a turbulent environment was considered by Wang Therefore, this work focuses on the approximated analytical
and Yu (2010). Majumder et al. (2003, 2007) attempted to explain calculation of the separation and should be presented in a conve-
the origin of the sh-hook effect using a sudden decrease in the nient form for analytical estimations that consider the collective
settling velocity of the coarser particles due to the Reynolds effects of disturbed settling in a dense polydisperse suspension.
number restriction. Roldan-Villasana et al. (1993) introduced the
concept that a turbulent dispersion could inuence the motion of 2. Partition function
ne particles.
These concepts have not yet been applied in a systematic According to the tapping model of Schubert and Neesse (1980),
calculation to determine which parametersthe hydrocyclone, the partition function T(d) as a function of the particle size d can be
the particulate material and/or the operating conditionscontrol expressed as follows:
the characteristics of the sh-hook effect.
Kraipech et al. (2002) pointed to the mechanism of ne particle 1
Td h i: 1
entrainment by larger particles, but did not offer an appropriate Dc
1 Sexp  2D V s d
t
mathematical model. This was provided by Dueck et al. (2004),
who explained the non-monotonic separation curves through the In this equation, the volume split is represented by
W_ o _ _
entrainment of ne particles caught in the boundary layer of the SW _ u in which W o and W u are the suspensions ows of the over-
coarse, rapidly settled particles. This model is based on experi- ow and underow, respectively. The value of S can be determined
ments of Gerhart et al. (1999) and Kumar et al. (2000) and has using empirical formulas (Bradley (1965)).
already been implemented in the computations of Minkov and Furthermore, Dc is the diameter of the cylindrical portion of the
Dueck (2012). hydrocyclone, and Din is the diameter of the inlet.
By varying several parameters, the computer simulations This model assumes that the turbulent diffusion coefcient Dt of
require considerable effort. the particle is independent of its size. Thus, the shape of the

Overflow

Do
1
Inlet
Partition function
Partition function T(d), -

Din 0.75 Partition function


Vortex finder (after Stokes)
Dc
0.5

H
0.25

0
0 5 10 15 20
Du
Particle size d, m
Underflow

(a) (b)
Fig. 1. (a) Principal scheme for the hydrocyclone and (b) partition curve of the hydrocyclone.
J. Dueck et al. / Minerals Engineering 62 (2014) 2530 27

partition function is determined primarily by the settling velocity, As demonstrated by Eq. (2), the predicted sedimentation veloc-
Vs. According to Eq. (1), T(d) is a monotonous function of d if Vs(d) is ity of a particle depends not only on its size, the medium proper-
also a monotonous function of d. The Stokes formula for Vs yields ties, and the solid-phase concentration in the suspension but also
the monotonous S-shaped line of the partition function (Fig. 1b). on the particle size distribution.
The separation curve T(d) increases monotonically from T(0) < 1
at d ? 0 to T = 1 at d ? 1.
4. Approximation for the RRSB size distribution
The partition function is typically characterized using the fol-
lowing parameters:
In the present work, specic equations are derived for a typical
case when the two-parameter RRSB (RosenRammlerBennet
(a) d50 the cut size with a 50% fractional recovery in the
Sperling) function for the particle size distribution is used:
underow (Eq. (1) indicates that, for d50, V s d50
2Dt =Dc ln S).
 n1   n 
n d d
(b) T0 the value of T(0). qd exp  3
dm dm dm
(c) Tmin the minimum value of the function. When the Stokes
formula is applied to obtain Vs, T0 = Tmin. in which dm is the characteristic particle size and n characterizes the
steepness of the distribution function.
In many cases, the experimental determination of the partition For this case, the integrals in Eq. (2) can be estimated (Dueck
curve demonstrates that the curve has a minimum value for parti- et al., 2010), which leads to the following expression for the sedi-
cle sizes below 10 lm (Fig. 1b). Such separation curve behavior is mentation velocity of particles in a polydisperse suspension:
called the shhook effect. This phenomenon can result from dis- 0 11=3
turbed particle settling due to particle interactions as described by  2 2
V S d dm B 6=n 1C 6=n 1 C
several researchers (Roldan-Villasana et al. (1993), Kraipech et al. 1 gcV B C
V h d d @ 6n A
(2002), Dueck et al. (2004)). bd n
6=n 1 C 6=n 1
dm
 2   
3. Disturbed particle settling in a polydisperse suspension dm 2
 cV C 1 4
d n
Some experimental and theoretical results have been obtained Eq. (4) contains an integral representation of the gamma func-
regarding the settling of dense suspensions (Gerhart et al. (1999), R1
tion: Cz 1 0 t z ez dt. For simple engineering calculations, ra-
Gerhart (2001), Kumar et al. (2000), Dueck et al. (2004), Minkov tional functions are convenient. Taking into account that the
and Dueck (2005)). These studies focused on the settling behavior parameter n varies over a narrow range of 11.5, the following
of polydisperse suspensions. The settling of polydisperse approximation can be applied:
suspensions involves the following interparticle effects:
Cz 1 2:6  103 z6:8 :
1. Hindered settling due to an increased effective density and
viscosity of the uid. Similarly, we can write g(cV) = 0.9c0.46.
2. Counter ow of the displaced uid caused by particle settling. Thus, Eq. (4) can be presented as follows:
3. Entrainment of ne particles in the surrounding coarse settling V S d
particles. 1ED 5
V h d

If the particles size distribution is presented as a continuous in which the entrainment function E and the deceleration function
R1
function, q(d), such that 0 qsds 1, then the settling rate D are
equation of a particle can be written as follows: 0 11=3
 2
V S d
Z 1 dm @ 6:76  106 6=n 1  6=n13:6 A
2 2
1 d gcV fe bd  d cV s2 gcV fe bsqsds 2 E 0:9c0:46
V 6n
6
d
V h d 0 dbdm n
2:6  103 6=n 16=n6:8

in which, according to Dueck et al. (2004) and Minkov and Dueck  2 (  6:8 )
R1 1=3 dm 2
(2005) fe d bd s6 qsds ; gcV 94 c2=3
V exp5cV , V h V St D 3
2:6  10 cV 7
ad2j qp qf
d n
1  cV 4:5 , V St;j 18lf
, and b  15(1 + 10, 5cV).
Fig. 2 illustrates the values calculated using Eqs. (5)(7) and
The rst term on the right side of Eq. (2) corresponds to the hin-
indicates that for small particles the acceleration mechanism dom-
dered sedimentation velocity of a particle (the Stokes velocity ac-
inates, but for larger particles the deceleration effect is more
counts for the impact of solid content). The second term, the
2 important.
acceleration function E d gcV fe bd, reects the increase in
The comparison with Vh (the Stokes velocity, corrected relative
the particle velocity due to its entrainment by larger particles.
2 R1 to the solid content) demonstrates that small particles can settle at
The third term, the deceleration function D d cV 0
velocities several orders of magnitude higher than that determined
s2 gcV fe bsqsds, determines how the ow of the liquid dis-
using the Stokes law. For large particles, both functions E(d) and
placed by the settling solid phase inuences the particle settling
D(d) are negligibly small, and the actual settling velocity VS (d) is
velocity.
slightly lower than that of Stokes because the suspension has a
In Eq. (2) the following designations are used: a centrifugal
higher density and viscosity than water.
acceleration, entrainment constant, cV total solid volume con-
centration, g(cV) function of the intensity of the entrainment on
the solid concentration, fe(d) entrainment function, q(d) density 5. Experiments and calculations
of the particle size distribution, VSt(d) Stokes settling velocity,
Vh(d) hindered settling velocity, qf uid density, qp solid The experiments conducted by Gerhart (2001), taken for a com-
density, lf uid viscosity in kg/ms. parison with the calculations, are listed in Table 1.
28 J. Dueck et al. / Minerals Engineering 62 (2014) 2530

1.0E+05
Entrainment function E(d)

Counter Current function D(d)


1.0E+03

Sedimentation functions,-
Total effect 1+E(d)+D(d)

1.0E+01

1.0E-01

1.0E-03

1.0E-05
0.01 0.1 1 10
Relative particle size, (d/dm)

Fig. 2. Disturbed settling functions (Eqs. (5)(7)) dening the interaction of particles during settling in an RRSB-distributed suspension, depending on the relative particle size
(data used for calculation: n = 1.2, dm = 6 lm, cv = 0.04).

The particle size distribution for the dispersed materials used in 6. Comparison of the calculated and measured partition curves
the experiments can be approximated using Eq. (3) with the
parameters dm = 6 lm and n = 1.23 provided in Table 1. Using the values of S, Dc, Vs and Dt, the partition function in Eq.
In Eq. (1), the volume split value (S) is derived from the exper- (1) can be determined. Fig. 3 presents the calculation of the settling
imental results with a value of S = 7.5. velocities and the partition curves for two different conditions:
The centrifugal acceleration (a) was determined using the for- rst, for the settling according to Stokes, and second, considering
mulas of Schubert et al. (1990) and Heiskanen (1993) as follows: the disturbed settling in dense suspensions.
The settling velocity as a function of particle size is a non-
a w2tan =Dc 8 monotonous function. As previously mentioned, the shape of the
partition curve under given operational conditions depends only
in which the maximum tangential velocity is on the settling velocity. Therefore, the partition curve may have a
shape similar to that of the settling velocity curve versus the par-
Din
wtan 3:7 uin 9 ticle size. Non-monotonous course of the sedimentation velocity
Dc could be the reason for the so-called sh-hook effect, which, in
practice, often manifests itself as the measured curve. This result
and the velocity of the suspension ow in the inlet is
is in agreement with the investigations of Gerhart (2001) and Due-
!0:5 ck et al. (2007).
Dof Dp A comparison between the calculated values and the experi-
uin 0:52 : 10
Din qf mental results under the conditions listed in Table 1 is presented
in Fig. 4.
For the diffusion coefcient Dt the following equation can be
The separation model indicates that there is sufcient con-
used (Schubert et al. (1990)):
dence in the explanation of the sh-hook effect. No further accor-
dance can be expected for the deviation between the experimental
Dt 16  104 wtan Dc : 11
and calculated values given the extensive simplications in the
Applying these formulas to the parameters listed in Table 1, the ow model.
following values can be obtained: Experimental partition functions demonstrate the sh-hook ef-
fect, which can be characterized by the depth H (the difference be-
uin 5:33 m=s; wtan 7:9 m=s; a 2490 m=s2 ; tween the value of partition function at d = 0 and the minimum
Dt 3:2  104 m2 =s: value of the separation curve) as indicated in Fig. 1b. The calculated
and measured values of H, depending on the solid content (cv) for
Using these values, Eqs. (5)(7) can be applied to calculate the the materials provided in Table 1, are plotted in Fig. 5.
settling velocities of particles of varying sizes. The sh-hook depth (H) presents a non-monotonic curve versus
the solid content cv as predicted by the disturbed settling. Fig. 5
also indicates that the values of T(0) vary with cV in a manner sim-
Table 1
ilar to that of H.
Parameters of hydrocyclone experiments. Using this fact, the dependence of T0 on the suspension param-
eters can be analyzed as follows:
Hydrocyclone diameter Dc = 25  103 m
Inlet diameter Din = 10.5  103 m
In Eq. (5), D can completely neglected relatively to E if d tends
Overow diameter Dof = 1  102 m toward zero as demonstrated in Fig. 2. Considering the denomina-
Feed pressure Dp = 105 Pa tor of Eq. (6), in the function E, the term containing d can be
Particle density qp = 2.6 g/cm3 neglected.
Particle size distribution of ne material (Mf) dm = 6 lm, n = 1.2
After the transformations, the settling velocity of the smallest
Particle size distribution of coarse material (Mc) dm = 11 lm, n = 1.3
particles, Vs(0) (d tends toward zero), can be obtained:
J. Dueck et al. / Minerals Engineering 62 (2014) 2530 29

1.0E+08 1
Stokes velocity

Settling velocity, m/s

Partition function, -
1.0E+06 0.75
Settling velocity

1.0E+04 0.5
Partition function
(Stokes velocity)
1.0E+02 0.25
Partition function
(disturbed settling)
1.0E+00 0
0.1 1 10 100
Relative particle size d/dm, -

Fig. 3. Calculated partition curves and settling velocities for a 25-mm hydrocyclone using a ne particle suspension and solid content cV = 0.04. The parameters are listed in
Table 1.

1 1
Mf (calc) Mc (calc)
Mf (exp) Mc (exp)
0.8

Partition function, -
0.8 dm=6 m
Partition function, -

0.6 dm=7 m
0.6
dm=8 m
0.4
0.4
dm=9 m
0.2
0.2 T(d) after
Stokes
0
0 0.1 1 10 100
0.1 1 10 100 Relative particle size, m
Relative particle size, m
Fig. 6. Partition curves for different dm values at n = 0.23 (all other parameters are
provided in Table 1).
Fig. 4. Calculated and measured partition functions for a 25-mm Hydrocyclone
using a solid content cV = 0.04, a ne particle suspension Mf and a coarse particle
suspension Mc (parameter are listed in Table 1). The maximum value of VS(0) in Fig. 5 occurs at the concentra-
tion cV = 0.09, which is higher than the experimental value of
approximately 0.04.
0.8 0.6 In addition, VS(0) explicitly depends on the parameters dm and n
2
from the size distribution in Eq. (12): V S 0 / dm and VS(0) / n2.26.
Mc (exp) Given VS(0), T0 can be easily estimated based on Eq. (1).
0.6 The calculated and experimental curves of H are qualitatively
Fish-Hook depth H,-

Mc (calc) 0.4 similar, but quantitative differences can arise for various rea-
sonsthe simplications included in Eq. (5), for example. Speci-
T(0), -

Mf (exp)
0.4
cally, these variations may be caused by the difference between
the inlet solid concentration used for the calculations and the ac-
Mf (calc)
tual cV values inside the hydrocyclone.
0.2
T(0) for Mc The physically reasonable model appears to adequately de-
0.2
scribe some of the effects observed in the experiments. A paramet-
T(0) for Mf ric study using the particle size distribution Eq. (3) was performed
to clarify the effect of the constants in the equation on the value of
0 0 the sh-hook.
0 0.1 0.2 0.3 0.4 In Fig. 6, each curve is drawn by changing one variable only (dm)
with all other parameters held constant. The increase in dm causes
Solid volume concentration cV,-
a marked increase in T0 and smooth increases in the Tmin values,
Fig. 5. Comparison of calculated and measured sh-hook depths as a function of leading to an increased depth of the sh-hook effect (H), which
the solid concentration. can be interpreted as follows: the coarser the particles, the greater
the chance for small particles to enter the boundary layer of a large
particle and be captured by it.
4:5 2:26
V S 0 7:07V St dm c0:46
V 1  cV n 12 This phenomenon is conrmed by the experiments of Gerhart
(2001) in which small and coarse materials were mixed in various
in which VSt(dm) is the Stokes sedimentation velocity for a particle proportions. In these experiments, the value of H increased steadily
of size dm. with the proportion of the coarse material.
30 J. Dueck et al. / Minerals Engineering 62 (2014) 2530

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Partition function, -

experimental investigation of disturbed settling in a polydisperse suspension.


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0.6 Proc. of ICMF-2004. Fifth Int. Conf. on Multiphase Flow, 30 May4 June 2004,
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