Flocculation

Lecture No. 5
1. Purpose
Flocculation is the gentle mixing phase that follows the rapid dispersion of coagulant
by the flash mixing unit.
The purpose of flocculation is to accelerate the pace at which the particles collide,
causing the agglomeration of electrolytically destabilized particles into setteable and
filterable sizes
The aggregation of particulate matter is a 2-step process
- The coagulant is added and reduces the interparticle forces; this is coagulation.
- The particles then collide and enmesh into larger particles, floc; this is
flocculation.
2. Considerations
Raw ater !uality and Flocculation "haracteristics. Flocculation characteristics can
be e#aluated by a $ar test. Repeatability of the results must be demonstrated. F%.2.&-'.
(.')*. The residual turbidity is directly proportional to alum dosage, but not always.
+ote the effects of alum on ,aolinite, topsoil and diatomaceous earth. The initial
reaction is a decrease in turbidity, but if too much alum is added, the turbidity
increases.
Finished ater !uality -oals. .ess than ./T0.
1xample2
-i#en2 3 bentonite soil.
Find2 hat dosage of alum is effecti#e and what is the resulting turbidity.
From F%.2.&-', p.')*
3n alum dosage of 45 mg/l appears effecti#e. .esser dosage gi#e mar,edly poorer results;
increased dosages do not mar,edly effect the turbidity remo#al
The residual turbidity at an alum dosage is about 5 NTUs.
3. Type and Selection Guide
Flocculation can be pro#ided by either mechanical mixers or baffles
F%.2.&-%, p. ''' show the most common types of units. The mixing system include2
4echanical 4ixing.
- 5ertical shaft with turbine or propeller type blades
- (addle type with either horizontal or #ertical shafts
- (roprietary units such as al,ing 6eam
6affled "hannel 6asins.
- 7orizontally baffled channels
Flocculation, Page No. 2
- 5ertically baffled channels
8thers including2 Reactor "larifier (roprietary 9ystems, "ontact Flocculation and
:iffused 3ir 3gitation
9election "riteria2 9election of the flocculation process should be based on the
following criteria2
- treatment process2 con#entional, direct, softening or sludge conditioning
- raw water2 turbidity, color, T:9
- Flocculation characteristics in response to mixing characteristics. For example2 if
the floc is hard, more rigorous mixing intensity can be applied.
The order of preference is2
- #ertical shaft flocculators in properly compartmentalized, horizontal tan,s.
- paddle flocculators in properly compartmentalized, horizontal tan,s.
- baffled channel flocculation for constant flow rate plants
4. Discussion of lternati!es
4echanical 4ixing 9ystem. The mixer should ha#e the following characteristics2
- 4ust deli#ered the re;uired - #alue which may #ary by compartment.
- The shear must be low at the edge of the blades.
- .ow maintenance and operation.
Regardless of the type of flocculator, tapered mixing across the tan, is important. The
initial mixing is rigorous, but as the floc grows in size, a more gentle, less disrupti#e
regime is in order.
5ertical shaft flocculators are usually the first choice for the following reasons2
- minimal maintenance
- operational flexibility
- #ery little head loss across the tan,
- easy control of mixing intensity
6affled "hannel 9ystem. Re;uires a moderate head loss across the tan,. 9uitable for
de#eloping countries that may not be able to afford a mechanical system.
5. Desi"n Criteria#T 3.2.4$2% p.121&
The general design criteria for a basic rectangular flocculation tan, are as follows2
1nergy input2 -t<'),))) to ')),))), t </x')
&
s a#erage, -<%) s
-'
a#erage, ')-=) range
:T2 2)-%) minutes at !max.
:epth2 ')-'/>
9tages2 %-& common, 2-* range
3mong the first considerations are the selection of the mode of mixing and the
physical relationship between the flocculators and clarifiers. 9ubse;uent decisions
include2 the number of tan,s, number of mixing stages and their energy le#el and
baffling type
Flocculation, Page No. %
:esign usually based on2
- :T
- mixing energy le#el
The energy le#el is the - #alue or #elocity gradient as defined by "amp2
- < ? @
./
, units p.''=
-i#en2 (< A/)BCs, and the space influenced by the flocculator &x*x*m. The temperature is '/".
Find2
'.D-
2.Dhat size motor is A/)BCs, assume e<=)E
'.D -
From 3pp.*, p.*%2 F'/", <'.'=x')
-%
+.sCm
2
, +<+ewton < ,g.mCs
2
, the units of are ,gCm.s
5 < &x*x*m
5 < '&&m
%
- < ?@
./
< ?@
./
G = 7s
!
2.D7ow many hp is A/)BCs
',<')))BCs
A/)BCs x G', C ')))BCsD < .A/,w
'hp < .=&*,w
.A/,w x G'hpC.=&*,D < '.'&hp
4otor size < '.'&Ce < '.'&C.=
"otor si#e = .$%&'
The #elocity gradient indicates the contacts that are being made. The gradients are
produced by hydraulic or mechanical mixing.
The number of particle contacts is2
+ < n'n2G-C*DGd' H d2D
%
units p.''=
+ is the number of contacts between n'and n2 particles. Therefore, the rate of flocculation
increases with the number and size of the particles and with the power input but decreases
with the #iscosity of the fluid.
The mean #elocity gradient for baffled systems is2
- < GD
./
< GD
./
, units p.''=
in which is the specific weight, *2.&lbCft
%
and
<absolute #iscosity, 2.=%x')
-/
lb.sCft
2
F/)F
The gradient increases with the head loss across the tan, and decrease when the #iscosity
and time increase. In plane 1nglish, the more turns and cur#es the more the mixing; the
thic,er the li;uid and the longer it ta,es, the less the mixing.
1xample2
-i#en2 Rectangular basin, .<<&>, :<&./>, !<A.=4-:, ater F/)F, <absolute
#iscosity, 2.=%x')
-/
lb.sCft
2
Flocculation, Page No. &
Loss ' .5(
2
)2" #typical&
Find2 -
t<5C!<&> x &> x &./> C A.=4-:x'./&=cfsC4-: < =2C'%.&*
t< /.%/s
h total < no of baffles x loss per baffle
#<!C3 < '%.&*CG&x'D +ote the entire distance is &>, but there are & compartments, therefore each
compartment is &C&<'>wide.
#<%.%=fps
h < head loss per baffle, see graphic <./#
2
C2g < ./G%.%=D
2
CG2x%2.2D
h < head loss per baffle < .)AA2ft
head total < % baffles x .)AA2ft
head total < .2*&ft
- < GD
./
<

GD
./

G = %%$.% f's/ft
For mechanical systems with paddles2
- < G":3#
%
C25D
./
units p.''=
": is a shape factor, use '.A Gp.''=D. 3 is the cross sectional area of the paddles. - is
increases as the area of the paddle increases, the #elocity of the paddle increase and -
decreases and the fluid gets thic,er or the #olume of the tan, increases. 3 #ery important
consideration is that #, the relati#e #elocity of the paddle with respect to the fluid is from .
/-.=/ of the peripheral #elocity of the paddle.
-i#en2 If - < G":3#
%
C25D
./
and - < ?@
./
Find2 3 power e;uation
G":3#
%
C25D
./
< ?@
./
s;uare both sides
( < 5 x ":3#
%
C25, <
P = ()*+
%
/,
-i#en2 The outside blade of a paddle wheel is rotating at &rpm. The distance from the center of
the shaft to the outside of the paddle element Ga piece of wood, perhaps a *Jx')>D is =>.
Find2
'.D hat is the peripheral speed of the outside blade
2.D 1stimate the blade #elocity relati#e to the water.
'.D hat is the peripheral speed of the outside blade
# < rps x :Cre#olution < &re#Cmin x 'minC*)s x G=ftx2D, => is a radius
# < 2.K%fps
2.D 1stimate the blade #elocity relati#e to the water.
#, the relati#e #elocity of the paddle with respect to the fluid is from ./-.=/ of the peripheral
#elocity of the paddle.
#>< 2.K%fps x ./
+- = .47f's
Flocculation, Page No. /
#>< 2.K%fps x .=/
+- = ,.,.f's, use .75 unless ot&er/ise stated
The number of stages used in design is determined by2
- Type of subse;uent treatment unit.
- Raw water.
- 9hort circuiting and types of baffles
- .ocal conditions
5ertical 9haft Flocculators. :CTL%/, where : is the diameter of the blade and T is the
tan, diameter. The maximum flow induced by the mixing blade should be less than
Afps in the first stage and less than 2fps in the last stage. hen properly produced, the
floc should ha#e the characteristics and appearance of snow fla,es.
7orizontal 9haft Flocculators. The ad#antage of the horizontal shaft is that one shaft
can operate a number of agitators and thereby reduce the number of dri#e units but if a
dri#e fails, more agitators will be put out of business. 6asic design criteria include2
- The total paddle area should be ')-2/E of the tan, cross-sectional area. If the
paddles are too big, they will rotate the water causing a reduction in eddies and
turbulence.
- 1ach arm should ha#e a minimum of % paddles, so that dead space especially near
the shaft will be eliminated.
- The peripheral speed of the paddles should be between ./ and %.%fps.
- The - #alue should be /)s
-'
and then be reduced to ') or /s
-'
in the last stage
6affled alls. 1ach baffle should ha#e orifices that &-* inches in diameter uniformly
distributed across the #ertical surface and a #elocity of '.2-'.A fps should be produced
in each hole at maximum flow. The baffle is placed perpendicular to the flow. The top
of the baffle is slightly submerged, 'C2 inch, to allow scum to flow o#er the top. The
orifice formula is !<"3G2ghD
./
, "<.A, see p.''A.
-i#en2 The total orifice area a#ailable is 2)ft
2
. !</)4-:
Find2
'.D total number of orifices
2.D orifice #elocity
%.D headloss through the orifice
'.D total number of orifices
&-*J in diameter, use /J
3 < :
2
< .=A/ x G/C'2D
2
3 < .'%*ft
2
number or orifices < total areaCorifice area < 2)ft
2
C .'%*ft
2
Corifice
number or orifices < '&= orifices
2.D orifice #elocity
#<!C3 < /)4-: x './&=cfsC4-: C 2)ft
2

#<%.A= fps, +ote2 this is too high, should be from '.2-'.Afps
%.D headloss through the orifice
!<"3G2ghD
./
/)4-: x './&=cfsC4-: < .A x .'%*ft
2
G2 x %2.2 x hD
./
&.A& < G*&.&hD
./
2%.%K < *&.&h
& = .%$ft
Flocculation, Page No. *
*. +peration and ,aintenance
Three basic operational procedures2
- chec, the size of the floc
- remo#al of the scum from the water surface
- algae control
-. ./a0ple
-i#en2 3 flocculation basin. !<'24-:, horizontal shaft, paddle wheel. The mean -<2/s
-'
F
/)F. t<&/min. The -t must be between /),)))-')),))). 0se % stages of e;ual depth in which
the ->s decrease2 &/,2),'). .<./, .<%7. The paddles are to be made of redwood, ')>x*J. The
outside blade is to be './> from the floor of the tan, as well as from the top of the water surface.
0se * bladesCwheel and maintain a clear spacing of '2J between blades. 3d$acent wheels are to
maintain a clear spacing of 2&-%*J between blades. The wall clearance is to be between '2-'AJ.
":<'./) for the paddles. 0se the power e;uations (<.K=":3#
%
and (<5-
2
.
Profile
24$3*1 typ
Flo2 in and out of
t3e paper% * 4lades
1.55
1.55
121 typ
*1 typ
165 typ
Section
Plan
Find2
'.D 6asin dimensions
2.D :esign the paddle wheel
%.D "alculate the ( for each compartment and the rotational speed of the paddles, pro#ide for a
'2& turndown.
'.D 6asin dimensions
Flocculation, Page No. =
5 < !t < '24-: x &/ minutes x './&=cfsC4-: x *)sCminute
5 < /),'22.Aft
%
.<./, .<%7, <2.<*7
5 < .7 < %7 x *7 x 7
5 < 'A7
%
'A7
%
< /),'22.Aft
%
7 < '&.)=> use '&>-%J
< *7 < *G'&.)=D
< A&.&> use A/>-)J
. < %7 < %G'&>-%JD
. < &2>-KJ
new 5 < .7 < G'&.2/DGA/.)DG&2.=/D
0 = 5,71..2 ft
%
3 = 4-!%4
5 = 15-!.4
6 = 4,-!24
2.D(addle wheel
"alculate the numbers of indi#idual ')> wheels across the A/> width.
9ince the blades are ')>x*J, the width is ')>. The width of the tan, is A/>, A/C')A wheels, but
there are clearances in#ol#ed, so try = wheels.
.et the clear space between the wheels be s, sC2 at the walls, therefore, let s<clearance.
=s H =G')D < A/
s < 2.'&> which is between 2&-%*J, so = wheels is 8M.
"hec, maximum blade area;
4ax blade area < 2)E x cross-sectional area < .2)7 < .2)GA/DG'&.2/D
4ax blade area < 2&2.2/ft
2
"alculate actual blade area
Try * blades per wheel, gi#en but typical.
3 < wheelsCtan, width x bladesCwheel x blade area
3 < = wheels x * bladesCwheel x G*JC'2 x ')>D
* = ,.ft
,
7 "a8 blade area = ,4,.,5ft
,
9:
1.55
1.55
121 typ
*1 typ
165 typ
Consider t3e
s3aft 25 in
dia0eter
Startin" fro0 s3aft at t3e center and 2or7in" do2n
15#s3aft& 8 15#clearance& 8*)12 )2#1)24oard& ' 2.255
2.255 8 *)12 )2#1)2 4oard& 8 15 #clearance& 8*)12 )2 '3.-55
3.-5 8*)12 )2#1)2 4oard& 8 15 #clearance& 8*)12 )2 '5.255
5.255
3.-55
2.255
9'14.255
1.:-55left o!er
; 1%55% +<
Flocculation, Page No. A
%.D (, power
t < 5C! < /',=A).Kft
%
C'2x')
*
gpd x x '&&) minutesCday
t = 4$.41 minutes
-t < 2/s
-'
x &*.&A minutes x *)sCminute
Gt = $2,7,. bet/een 5.,...!..,... 9:
#elocity of the water,# < =/E of the maximum peripheral #elocity
The distance tra#eled is : or 2r per re#olution, re#Cs x :Cre# < :Csec
# < .=/ x 2r x RGre#olutions per secondD
#'Gfirst compartmentD < .=/ x 2G/.2/>D x R
#'Gfirst compartmentD < 2&.=&R
#2Gsecond compartmentD < .=/ x 2G%.=/D x R
#2Gsecond compartmentD < '=.*=R
#%Gthird compartmentD < .=/ x 2G2.2/>D x R
#%Gthird compartmentD < ').*)R
(<.K=":3#
%
<.K=":3'#'
%
H.K=":32#2
%
H .K=":3%#%
%
< .K=":3G#'
%
H #2
%
H #%
%
D, 3'<32<3%
( < .K=G'./)DG./>x')>board dim.DG2 boards,'up,'downD?2&.=&
%
H'=.*=
%
H').*'
%
@R
%
(<%'=,K=*R
%
first compartment
(<5-
2
< < 2.=%x')
-/
lb.sCft
2
x /',=A).K ft
%
C%G% compartmentsDx &/
2
(<K/).= ft.lbCs x 'hpC//)ft.lbCs
P'=.7%&'
K/).= ft.lbCs C =wheels < %'=,K=*R
%
; = ..75 r's
R(4GmaxD < .)=/ rps x *)sCmin
;P"<ma8= = 4.5.r'm
R(4Gmin F '2& turndownD < &./)rpmC&
;P"<min > ?4 turndo/n= = .%r'm
(eripheral speed of outside blade
# < circumference x R(4
#' Gactual # as opposed to =/ED < R x 2r
#' < .)=/ x 2G/.2/D
+ = ,.47f's
second compartment
(<5-
2
< < 2.=%x')
-/
lb.sCft
2
x /',=A).K ft
%
C%G% compartmentsDx 2)
2
(<'A=.A ft.lbCs x 'hpC//)ft.lbCs
P,=.%4&'
'A=.A ft.lbCs C =wheels < %'=,K=*R
%
R < .)&& rps
R(4GmaxD < .)&& rps x *)sCmin
;P"<ma8= = ,.$4r'm
R(4Gmin F '2& turndownD < 2.*&rpmC&
;P"<min > ?4 turndo/n= = .$$r'm
third compartment
(<5-
2
< < 2.=%x')
-/
lb.sCft
2
x /',=A).K ft
%
C%G% compartmentsDx ')
2
(<&*.K/ ft.lbCs x 'hpC//)ft.lbCs
P%=..15 &'
&*.K/ ft.lbCs C =wheels < %'=,K=*R
%
R < .)2=* rps
R(4GmaxD < .)2=* rps x *)sCmin
;P"<ma8= = .$$ r'm
Flocculation, Page No. K
R(4Gmin F '2& turndownD < '.** rpmC&
;P"<min > ?4 turndo/n= = .4, r'm
Go o+er e8am'le 'roblems in boo@, '.,%
39"A59;: No. 5, Flocculation
Read "hapter % pp. ')&-'%K
(roblems2
5*. -i#en2 :iatomaceous earth
Find2 hat dosage of alum is effecti#e and what is the resulting turbidity.
5B. -i#en2 The power deli#ered by a tan, is './hp, -<%/s
-'
, T<%)".
Find2 hat are the re;uired tan, dimensions if .< and the depth <'/>, 'hp<//)ft.lbCs
5(. -i#en2 9ee F.%.2.&-'). The boards are *Jx')>s except the diagonals which are
''>long and the #ertical members which are => long. The channel x-section is ''> wide by
'2> deep.
Find2 The total paddle area should be ')-2/E of the tan, cross-sectional area.
7as the criterion been metN
5). -i#en2 3 baffled tan,. -<*)s
-'
, the ,inematic #iscosity,, is .AKAx')
-*
m
2
Cs, 2/". and
!<%m
%
Cs. There are %) turns. The head loss at the turn is h<M#
2
C2g, where M<'./, p.'2/.
t<')min
Find2
'.D total head loss
2.D The #elocity at each turn, slit.
5A. -i#en2 3 cross-flow, horizontal shaft, paddle-wheel flocculation basis is to be designed
for a flow of 2/,))) m
%
Cday with a mean - of %)s
-'
F ')"G<'.%)= centipoise,
'centipoise<')
-%
+-s
2
C,g-mD and a t</) minutes. 3ssume .<% and <:. The -t should
be between /),)))-')),)). Tapered flocculation is to be pro#ided and three compartments
of e;ual depth in series are to be used. The - #alues determined from laboratory tests are2
-'</)s
-'
, -2<2/s
-'
and -%<'/s
-'
. These gi#e an a#erage of %)s
-'
. The compartments are to
be separated by slotted, redwood baffle fences and the floor of the basin is le#el. The basin
should be '/m in width to ad$oin the settling basin. The speed of the blades relati#e to the
water is %C& of the peripheral blade speed. 3ssume * pieces of wood per paddle, % up, %
down2 :'<'.=)m, :2<2.*)m, :%<%./)m, four assemblies Ggroups of * pieced of woodD per
shaft. 1ach piece of wood is '/cm wide and %m long.
0se the power e;uations2 (<":3#
%
C2 and (<5-
2
, in which ":<'./), <KKK.=,gCm
%
.
Find2
'.D -t and 5
2.D 6asin dimensions
%.D :esign the paddle wheels
&.D ( in each compartment
/.D Rotational speed of each horizontal shaft in rpm
*.D The peripheral speed of the outside paddle blades in mCs
Flocculation, Page No. ')
5F. -i#en2 :esign the flocculators for your pro$ect.