Modelling the impact of two different flocculants on the performance of a thickener feedwell

Abstract

The performance of a thickener feedwell depends not only on its ability to generate large-sized aggregates from feed particles but also on aggregate density. The performance of the flocculant BASF Rheomax® DR 1050 has been previously compared to a conventional anionic flocculant in turbulent pipe flocculation of mineral suspension, suggesting that the flocculant can generate denser aggregates (i.e. larger effective fractal dimension). Such aggregates are generally stronger and reduce the need for solids dilution, with both factors favouring faster settling velocity at the feedwell exit. To investigate the impact of the internal aggregate structure on the flocculation performance of a feedwell, Computational Fluid Dynamics (CFD) simulations of a basic open feedwell with shelf design were carried out for both flocculants. A calcite with a fine particle size (Omyacarb 5) was modelled to emphasise the impact of the flocculation process on flow fields at the feedwell exit. Simulations were conducted using CFX-4.4 two-phase flow formulation incorporating equations for a population balance model of the flocculation process. The impact of the fractal dimension on the effectiveness of the aggregation process is presented for low and high solids concentrations. Comparison of the performance of the flocculants is presented in terms of both predicted mean aggregate size and settling flux.