Flocculation is widely used in water treatment, and creating an optimal environment for floc growth is essential to enhancing flocculation efficiency. In this paper, we developed a multi-stage flocculation reactor (MFR) with strong, moderate, and weak mixing zones. Specifically, multi-cone structures with varying diameter ratios (DR) were incorporated in the moderate zone to promote floc growth. Computational simulations revealed that an MFR with a DR of 0.5 generated a uniform and symmetric flow field, reducing zero-velocity zones and forming distinct vortices within cones. This environment facilitated gradual floc growth while minimizing breakage. When applied to treating fracturing flowback fluid, a complex and challenging wastewater, the MFR produced larger and denser flocs, with an average chord length of 180 μm and a fractal dimension of 1.7170. These flocs exhibited high viscoelasticity, with a strength factor of 68.22 and a recovery factor of 47.77, indicating superior shear resistance and recovery ability after breakage. Consequently, the MFR achieved COD and turbidity removal rates of 92.05% and 93.61%, respectively, outperforming a stirred flocculation reactor, which achieved rates of 72.29% and 83.53% for the same parameters. Additionally, the MFR demonstrated excellent pollutant removal efficiency for both mineral processing wastewater and dyeing wastewater. With gradually decreasing energy along the flow direction, the MFR provided appropriate mixing intensities for different stages of floc growth, promoting efficient formation. These findings underscore the MFR’s potential as a highly effective solution for wastewater treatment applications.
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