Continuous flocculation

Figure 8 A comparison of the effects of mixing time on batch and continuous flocculation of kaolin at 3% solids by weight by 4mgL of a non-ionic polymer (after Suharyonofl ...

Continuous flocculation in stirred tanks shows similar trends with regard to agitation/mixing conditions as for batch systems. The overall performance of continuous flocculation processes tends to be inferior to that which can be obtained in batch systems. This is attributed to a closer approach to equilibrium in the continuous case. In-line flocculation, by injection of polymer into turbulent flow in a pipe, is widely practised in industry and offers certain advantages. Multiple addition at several points along the length of a pipe is preferred to single-point addition. 

Meanwhile, polymer molecular mass (M) decreases and duration of the process (t) as well (Figure 1). We continued flocculant synthesis until the volume of reaction solution stopped decreasing. The further prolongation of synthesis results in gradual increase of that volume due to hydrolysis of amide groups and formation of acrylic acid elements in the polymer. Sulphuric acid concentration also affects solubility and flocculating properties of the product. 

Therefore, the segregated rubber phase, plus the coating layer, now—above critical volume concentration—building elongated and continuous flocculates or tubular and necked network structures within the separated layers, also are forming a continuous phase, so we are dealing with a bi-continuous structure, one... 

Fig. la Optical arrangement to observe continuously flocculation and defloccu-... 

In a 500 ml. wide-mouthed reagent bottle place a cold solution of 25 g. of sodium hydroxide in 250 ml. of water and 200 ml. of alcohol (1) equip the bottle with a mechanical stirrer and surround it with a bath of water. Maintain the temperature of the solution at 20-25°, stir vigorously and add one-half of a previously prepared mixture of 26-5 g. (25 -5 ml.) of purebenzaldehyde (Section IV,115) and 7 -3 g. (9-3 ml.) of A.R. acetone. A flocculent precipitate forms in 2-3 minutes. After 15 minutes add the remainder of the benzaldehyde - acetone mixture. Continue the stirring for a further 30 minutes. Filter at the pump and wash with cold water to eliminate the alkali as completely as possible. Dry the solid at room temperature upon filter paper to constant weight 27 g. of crude dibenzalacetone, m.p. 105-107°, are obtained. Recrystallise from hot ethyl acetate (2-5 ml. per gram) or from hot rectified spirit. The recovery of pure dibenzalacetone, m.p. 112°, is about 80 per cent. 

The trend in the use of deep bed filters in water treatment is to eliminate conventional flocculators and sedimentation tanks, and to employ the filter as a flocculation reactor for direct filtration of low turbidity waters. The constraints of batch operation can be removed by using one of the available continuous filters which provide continuous backwashing of a portion of the medium. Such systems include moving bed filters, radial flow filters, or traveling backwash filters. Further development of continuous deep bed filters is likely. Besides clarification of Hquids, which is the most frequent use, deep bed filters can also be used to concentrate soflds into a much smaller volume of backwash, or even to wash the soflds by using a different Hquid for the backwash. Deep bed filtration has a much more limited use in the chemical industry than cake filtration (see Water, Industrial water treatment Water, Municipal WATERTREATiffiNT Water Water, pollution and Water, reuse). 

Originally designed for the continuous filtration of conditioned sewage sludges, as were most of the filter belt presses available, the Manor Tower press is increa singly used for the treatment of paper mill sludge, coal, or flocculated clay slurries. 

Eor evaluation of flocculants for pressure belt filters, both laboratory-scale filters and filter simulators are available (52,53) in many cases from the manufacturers of the full-scale equipment. The former can be mn either batchwise or continuously the simulators require less substrate and are mn batchwise. The observed parameters include cake moisture, free drainage, release of the cake from the filter cloth, filter blinding, and retention of the flocculated material during appHcation of pressure. 

Addition Point. The flocculant addition point in a continuous system can also have a significant effect on flocculant performance. The turbulence as the flocculant is mixed in and the floes travel toward the point where they enter the thickener or filter causes both the formation and breakup of floes. Usually there is an optimal addition point or points which have to be determined empirically. In cases where the same polymer is being added at two or more points, the relative amounts added at each point may also affect performance. Thus providing multiple addition points in the design of new installations is recommended (56). 

Design and operation of recirculation systems can be compHcated. Problems are avoided by using a sludge-blanket clarifier, in which feed enters below a blanket of accumulated and flocculated soflds which become fluidized in the zone-settling regime by the upflowing feed. Feed soflds are trapped in the blanket. The soflds content of the blanket continuously increases and part must be bled off in order to maintain the mass balance. 

If there is particle—particle interaction, as is the case for flocculated systems, the viscosity is higher than in the absence of flocculation. Furthermore, a flocculated dispersion is shear thinning and possibly thixotropic because the floccules break down to the individual particles when shear stress is appHed. Considered in terms of the Mooney equation, at low shear rates in a flocculated system some continuous phase is trapped between the particles in the floccules. This effectively increases the internal phase volume and hence the viscosity of the system. Under sufficiently high stress, the floccules break up, reducing the effective internal phase volume and the viscosity. If, as is commonly the case, the extent of floccule separation increases with shearing time, the system is thixotropic as well as shear thinning. 

The sequence, flocculation — coalescence — separation, is compHcated by the fact that creaming or sedimentation occurs and that this process is determined by the droplet size. The sedimentation velocity is monitored by the oppositely directed forces which form the buoyancy and the viscous drag of the continuous phase on the droplet ... 

Viscosity Increase. The flocculation rate of an emulsion is iaversely proportional to the viscosity of the continuous phase and an iacrease of the viscosity from 1 mPa-s (=cP) (water at room temperature) to a value of 10 Pa-s (100 P) (waxy Hquid) reduces the flocculation rate by a factor of 10,000. Such a change would give a half-life of an unprotected emulsion of a few hours, which is of Httle practical use. 

The method is apphcable for unflocculated pulps or those in which the ionic characteristics of the solution produce a flocculent structure. If polymeric flocculants are used, the floccule size will be highly dependent on the feed concentration, and an approach based on the Kynch theoiy is preferred. In this method, the test is carried out at the expec ted feed solids concentration and is continued until underflow concentration is achieved in the cyhnder. To determine the unit area, Talmage and Fitch (op. cit.) proposed an equation derived from a relationship equivalent to that shown in Eq. (18-45) ... 

Operating Costs Power cost for a continuous thickener is an almost insignificant item. For example, a unit thickener 60 m (200 ft) in diameter with a torque rating of 1.0 MN-m (8.8 Mlbf in) will normally require 12 kW (16 hp). The low power consumption is due to the very slow rotative speeds. Normally, a mechanism vi l be designed for a peripheral speed of about 9 m/min (0.5 ft/s), which corresponds to only 3 r/h for a 60-m (200-ft) unit. This low speed also means veiy low maintenance costs. Operating labor is low because little attention is normally required after initial operation has balanced the feed and underflow. If chemicals are required for flocculation, the chemical cost frequently dwarfs all other operating costs. 

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