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Some trains operating with greater stability than others not known why at
the outset of the study
Preconceptions/assumptions
Underflow yield stress directly related to flocculation (type,
dose, conditions), causing raking and pumping problems
So
Assumption that suboptimal flocculation was causing operational issues
Therefore
Investigation of sediment rheology flocculated under various conditions will
determine optimum flocculation conditions and address operational issues
Testwork
Shear yield stress was primary measurement in all instances
Torsion
Head
Trialled 10, 20, 30 and 50gpt of each flocculant type (1, 2 and 3)
The best performing flocculants and doses also had most favourable PSDs
(more coarse) in terms of achieving a lower yield stress for a given solids
concentration.
Flocculant Type
500
Day 3 LWF 50gpt Floc 1
450
Day 8 LWF 50gpt Floc 2
400 Day 10 LWF 50gpt Floc 3 Mean: 34mm
350 d50: 8mm
d90: 92mm
Yield Stress (Pa)
300
250
Mean: 41mm
200
d50: 8mm
150 d90: 130mm Mean: 50mm
100
d50: 10mm
50 d90: 161mm
0
0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65
Solids Mass Fraction (x)
200
Particle Size (um)
150 d50
d80
d90
100
50
0
0 2 4 6 8 10 12
Day
Mean: 45mm
d50: 9mm
d90: 138mm
Mean: 46mm
d50: 8mm
d90: 147mm
Mean: 63mm
d50: 16mm
d90: 198mm
Preliminary finding
Therefore
Optimising flocculant type or dose will have little effect without prior
consideration of process variability and control
Operator Inputs
Decrease Floc Dosage
Bed Height
Downstream Controls
Decrease UF Pump Speed
Overflow turbidity
Low Reading Increase Floc Dosage
Bed Height response to underflow pump
IN PRACTICE
Bed height responds rapidly to changes in UF pump speed
Makes UF pump speed good control variable for this strategy
Bed Height response to floc dose
IN PRACTICE
Bed height responds relatively quickly to changes in floc dosage
Minimises fluctuations in floc dosage rate to mostly well within 50% of set points
Bed Height Control effect on rake pressure
IN PRACTICE
Provides relative operational stability for long periods of time
Bed height and rake pressure stay mostly within 25% of set points
Control Strategy B:
Rake Pressure Control
Control Parameter Control Responses Other Influences
Downstream Controls
High Reading Increase UF Pump Speed
Operator Inputs
Decrease Floc Dosage
Rake Pressure
Downstream Controls
Decrease UF Pump Speed
Overflow turbidity
Low Reading Increase Floc Dosage
Rake pressure response to underflow pump
IN PRACTICE
As rake pressure increases, UF pump cannot operate efficiently
Rake pressure and UF pump are out of sync and do not stabilise
Rake pressure response to floc dose
IN PRACTICE
Floc dose is out of sync with rake pressure due to temporal differences
Floc dose also used to control overflow clarity and is unreliable as control parameter
Rake Pressure Control effect on bed height
IN PRACTICE
Significant amounts of fluctuation in both rake pressure and bed height
Bed height and rake pressure fluctuate to in excess of 50% of set points
Control Philosophy Comparisons
Washer Control Strategy A
Parameter Maximum Deviation (%) Average Deviation (%)
Bed Height 23.46 5.75
Rake Pressure 31.96 11.59
Optimising flocculant type or dose will have little effect without prior
consideration of feed variability and process control