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Chemical Engineering Journal 362 (2019) 712–720

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Chemical Engineering Journal


journal homepage: www.elsevier.com/locate/cej

Fluid dynamics in continuous settler T


F.D.T Luna, A.G Silva, N.K. Fukumasu, O. Bazan, J.H.A. Gouveia, D. Moraes Jr., J.I. Yanagihara,

A.S. Vianna Jr.
University of the São Paulo – USP, Prof. Luciano Gualberto – Trav. 3, 380, 05508-900 São Paulo, SP, Brazil

H I GH L IG H T S G R A P H I C A L A B S T R A C T

• PIV measurement and CFD simulation


of water flow of a settler were studied.
• RANS turbulence models were tested
to predict the water flow inside the
settler.
• BSL-RSM model showed good con-
sistence with experimental data.
• Multiphase simulations with the
Eulerian-Eulerian model were per-
formed.
• Separation efficiency in the sedi-
mentation tank was investigated for
various sizes of solid particles.

A R T I C LE I N FO A B S T R A C T

Keywords: Continuous settlers are present in the treatment of effluents and domestic water. They have low operational and
Water treatment maintenance cost; however, they can reach high separation efficiency. In this work, the fluid dynamic char-
Sedimentation acteristics of the settler in bench scale, with no-concentric axial inlet in the feedwell were precisely evaluated,
Turbulence using both experimental and numeric approach. The velocity fields were experimentally obtained by PIV
Computational fluid dynamics
(Particle Image Velocimetry). Numerically, the three-dimensional flow was studied using the ANSYS CFX
Particle image velocimetry
package. For more adequate representation of velocities, the RNG κ-ε, SST κ-ω, and BSL-RSM turbulence models
were analyzed. After the validation of fluid dynamics, it was possible to perform multiphase simulations, ana-
lyzing the efficiency of solid particles removal. The Eulerian-Eulerian multiphase model was applied, along with
the particle interfacial transfer model. The profiles of axial U and radial V velocity components allowed ob-
serving that the BSL-RSM model showed consistent results when compared to the experimental data. In relation
to the separation efficiency, smaller particles (10 μm) were verified to tend to be more evenly distributed in the
settler, while larger particles are quickly deposited on the bottom. From the diameter of 100 μm, there was no
difference between the separation efficiency values obtained.

1. Introduction component (usually the liquid) is collected at the top of the equipment,
in order to achieve the phase separation [1,2].
Sedimentation is one of the processes used in the solid and liquid Settlers are equipment widely used industrially. With low operating
phase separation. It consists of a separation technique based on the and maintenance costs, high separation efficiency can be obtained.
action of gravity and the difference in density of the components: the According to Farrow et al. [1], White et al. [3], Goula et al. [4] and Al-
heavier particles deposit at the bottom of the settler tank and the lighter Sammarraee et al. [5], the sedimentation performance depends on the


Corresponding author.
E-mail addresses: flaviadaylane@usp.br (F.D.T. Luna), deovaldo@unisanta.br (D. Moraes), jiy@usp.br (J.I. Yanagihara), ardson@usp.br (A.S. Vianna).

https://doi.org/10.1016/j.cej.2019.01.088
Received 30 August 2018; Received in revised form 5 December 2018; Accepted 15 January 2019
Available online 16 January 2019
1385-8947/ © 2019 Elsevier B.V. All rights reserved.
F.D.T. Luna et al. Chemical Engineering Journal 362 (2019) 712–720

characteristics of the suspended solids, geometry and dimensions of the turbulence model used. S̄Mα represents the gravitational force and M̄α is
separator tank and the flow field inside the equipment. the sum of the interfacial forces, here defined by the sum of the drag
Many papers apply CFD (Computational Fluid Dynamics) techni- force and turbulent dispersion force.
ques to model the flow within different sedimentation tanks. CFD Many authors, such as Goula et al. [5], Al-Sammarraee et al. [15],
techniques apply the theory of continuous mechanic mixtures, using Tarpagkou and Pantokratoras [16], apply the Eulerian-Lagrangian
continuity and motion equations for each constituent of the mixture, multiphase model with one-way or two-way coupling to study fluid
besides incorporating the appropriate constitutive equations. This dynamics in settlers. However, according to Clercq et al. [16] and
mathematical point of view has a huge development [6–10]. Tarpagkou and Pantokratoras [17], although the Eulerian-Lagrangian
Using CFD, Goula et al. [1] studied geometric adaptation in a settler approach provides a more detailed and realistic modeling of particle
of potable water (low concentrations of solid). The authors proposed deposition, this multiphase model should not be applied to the system
stretching the inlet piping of the suspension to facilitate the flow into which has particle volume fractions surplus of 10–12%. Therefore, as
the sedimentation region. With this modification, no recirculation there are regions in settlers that have high concentrations of the solid
zones near the heavier component outlet were observed, reducing the phase, the study of volume fraction fields using the Eulerian-Lagrangian
chance of resuspension of the particles already deposited. multiphase model is unfeasible. Therefore, as also used by Zhou et al.
Tarpagkou and Pantokratoras [11], also through CFD, observed that [18] and Panda et al. [19], we decided to study the multiphase system
the separation efficiency (rate of sediment solids on rate of solids in the using the Eulerian-Eulerian model combined with the particle model.
feeding) obtained with the use of the conventional settler was 75%,
while the one presented by an inclined parallel plate tank was 93%. 2.2. Turbulence model
Another methodology to get details about the behaviour of the fluid
inside the settler uses PIV (Particle Image Velocimetry), which can be The turbulence models of the RANS type represent a consolidated
defined as the mean displacement mapping of particle groups in a short solution to describe the turbulence within a settler tank [1,4,16,20,21].
time interval. In essence, the PIV requires seeding particles, laser light They are models that present a relatively low computational cost. They
illumination of a plane of that stream, and the particle image capture in are divided into two groups: the ones adopting the Boussinesq hy-
the plane at two moments out of phase in the order of microseconds. pothesis (two-equation models) and the ones that directly solve the
Depending on the configuration of the PIV equipment, three compo- components of the Reynolds tensor.
nents of the velocity vector can be directly obtained in the region of The RNG κ-ε is a two-equation model. It applies turbulent kinetic
interest [12]. energy (κ) and turbulent dissipation rate (ε) to calculate turbulent
Sutalo et al. [13] combined the PIV techniques with CFD simula- viscosity and turbulent tension. The model notoriously has serious re-
tions to describe the influence of the rake on the fluid behavior in the strictions when applied to flow simulations near the walls, and to
settler. In their paper, the authors presented several configurations and problems in which turbulence anisotropy has a dominant effect over the
dimensions of rakes. flow, or when the Reynolds number is low or moderate [22]. Ironically,
Alonso-Martínez et al. [14] performed PIV experiments and CFD these situations are very important to the sedimentation process.
simulations for the process of gravitational sedimentation. For the au- The SST κ-ω is a zonal model that uses the κ-ω model (based on
thors, the results of PIV experiments were useful for the reliability of turbulent kinetic energy and specific dissipation) in the viscous sub-
the numerical data, thus enabling to optimize and to investigate the layer and changes to the κ-ε in the developed zone, combining the
characteristics of the flow with low cost. qualities of each of the two models [23]. Its robust formulation near
The objective of this paper was to evaluate the solid removal effi- walls allowed its use in industrial cases; however, this model has a
ciency in a continuous settler through CFD simulations. For this, 3D higher computational processing time when compared to the previous
single phase simulations (ANSYS/CFX) are initially performed, ap- one.
plying some type RANS turbulence models. These simulations were The Reynolds stress model (RSM) computes the turbulent stresses
validated by experiments performed in a continuous settler of labora- directly by solving partial differential equations, one for each compo-
tory scale, where the velocity fields were obtained by the PIV 2D-2C nent of the Reynolds tensor. The RSM includes the anisotropic effects of
technique. Posteriorly, multiphase numerical simulations were per- turbulence, the yields of which are superior to the models based on the
formed to accurately evaluate the separation efficiency for several Boussinesq approach (previous models) when used to simulate rota-
particle sizes. tional flows and secondary currents [24]. For turbulence closing, the
BSL-RSM model uses a combined function for the dissipation equation,
2. Fundamentals (Prediction of flow fields by CFD) applying the same scope of the SST κ-ω model.

2.1. Equations 3. Material and methods

The mathematical representation of the flow within the settler is 3.1. Experimental apparatus
based on the following considerations: (a) Incompressible fluid with
constant physicochemical properties; (b) Isothermal, stationary and The settler developed for this study, as shown in Fig. 1, is a cy-
turbulent flow; (c) Smooth and static wall. lindrical recipient of transparent acrylic crystal, measuring 0.2 m and
With these weights, the Reynolds-averaged Navier-Stokes (RANS) 0.17 m in diameter and height, respectively. The tank has one inlet at
equations are: the top of the equipment and two outlets: one at the top (Overflow —
Clarified outlet) and the other at the center of the equipment base
∇ ·(f α ρα Ūα) = 0 (1) (Sludge outlet). Inside the settler, there is a feedwell, which is a cy-
lindrical body, also of transparent acrylic crystal, measuring 0.08 m in
∇ . [fα (ρα Ūα ⊗ Ūα)] = −fα ∇pα + ∇ . {fα μα [∇Ūα + (∇Ūα )T − ρui′¯u′ j]} diameter and 0.150 m in height. The fluid enters the feedwell through
an axial tubing, non-concentric to the central axis, with length equal to
+ S̄Mα + M̄α (2)
0.075 m. The ratios between the studied dimensions are based on real
in which fα and ρα represent the volumetric fraction and the specific sedimentation tanks.
mass of the α phase, and Ūα indicates the velocity of the α phase. μα The experimental unit contains a storage tank (Tank III) for the
denotes the dynamic viscosity and − ρui′¯u′j is the Reynolds tensor, flows of the settler two outlets, as depicted in Fig. 1. The stored sus-
which can be related to (μt) turbulent viscosity, depending on the pension is used to feedback the settler tank. To ensure a uniform feed,

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Fig. 1. Experimental apparatus; (I) feedwell; (II) sedimentation tank; (III) storage tank; (IV) pump; (V) control panel; (VI) area of interest (in the laser sheet section)
and 2D coordinate system; (VII) CCD camera and (VIII) YAG: laser.

the storage tank contains an axial mixer moved by a variable rotation 3.3.2. Multiphase flow
motor. The suspension circulates through this system using a cen- Water and calcium carbonate flows were analyzed. The Eulerian-
trifugal pump with a 22-mm diameter rotor. Eulerian multiphase model was applied, along with the particle inter-
The design of the used prototype followed the geometry of the in- face transfer model. The drag force was calculated by the Gidaspow
dustrial circular clarifiers that can serve as thickeners [25]. The di- model, and turbulence by the BSL-RSM model. The cases studied were
mensions of the circular prototype were defined from the high-rate monodisperse with different diameter sizes of the solid phase.
settlers, which have not presented long diameter-depth ratios [26]. To quantify the equipment separation efficiency, the Eq. (3) is used,
Besides that, two design elements were improved. The extensive length a relation also used by [5]:
of the feedwell was designed in order to prevent that short circuits in
C
the feeding with high turbidity would interfere on the clarified over- E(\%) = 100. ⎛1 - L ⎞
⎜ ⎟

flowing performance; and the non concentric feedwell inlet improved ⎝ Co ⎠ (3)
the recirculations within this feedwell, which maximized the mixture in
in which E represents the liquid/solid separation efficiency; CL and Co
this region.
represent the mass fraction of solid particles in the clarified outlet and
the mass fraction of solid in the settler feeding, respectively.
3.2. PIV measurements
3.3.3. Geometry and mesh
As shown in Fig. 1, the experimental flow field was measured by The geometry was developed for the sedimentation tank using the
PIV, acquired by DANTEC Dynamics based on a Nd: YAG pulsed laser ICEM CFD, version 16.0. The dimensions are equal to the settler used in
emitter (532 nm, 1200 mJ, 7 Hz, Litron Lasers Ltd., Rugby, UK), CCD the experimental step, except for two adaptations: (a) it was necessary
camera (FlowSense 4M MK II, 2048 × 2048 pixels, focal length of to delimitate the clarified outlet region for the numeric study, placing a
500 Mm), narrow optical filter of 532 nm and computer with a digital top wall of the sedimentation tank and considering a 1.856. 10−3 m2
data acquisition system. The fluid in the settler was followed by hollow area representing the outlet and, (b) in the feedwell outlet, the arches in
glass microspheres coated with silver of diameter equal to 10 μm. the experimental unit were not taken into account. For the simulations,
a continuum lateral area representing the outlet was considered; how-
ever, the outlet area size was the same as that of the experimental unit
3.3. CFD simulations (10−3 m2).
The mesh was developed from a blocking strategy, using the ICEM
For the present work, two situations were adopted, applying the CFD, version 16.0. The blocking used was the result of several strategies
CFX code, version 16.0: tested in this study and comprised 156 blocks. A mesh dependency
study was performed to determine the best relation among precision,
stability, and computational cost. Some meshes (0.4; 1.0; 1.4; 2.5 and
3.3.1. Single phase flow 3.5 million of cells) were considered and, obviously, the results are
Only the water flow was studied to verify the mathematical model slightly different. The mesh used is composed of 2.5 million hexahedral
comparing it with the results obtained experimentally (PIV analysis). In volumes presented in Fig. 2.
this case, the volumetric fraction (fα) is equal to 1, and the interfacial The final mesh showed good quality, since met the orthogonal
forces (M̄α ) are equal to zero (Eqs. (1) and (2)). Three turbulence quality and skewness criteria. Indeed, a large number of elements,
models were evaluated: RNG κ-ε, SST κ-ω and BSL RSM models (models around 94.8% for orthogonal quality and 96.5% for skewness, showed
that presented more adequate results in a previous analysis, among κ-ε, quality values over 0.80, since the value 1 corresponds to the ideal
RNG κ-ε, κ-ω SST κ-ω, SSG-RSM and BSL RSM models). value for both criteria studied.

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Fig. 2. Geometry and hexahedral mesh used in the numerical study.

3.4. Boundary conditions resuspension problems.

The operational conditions used in the PIV analysis consist in con- 4.2. Validation of the velocity profiles
trolling the feeding flow (water and solid particles) equal to
43.5 ml.s−1. In the sludge outflow, two situations were studied: Fig. 4 displays the indications of the experimental velocity vector
15.5 ml.s−1 and 3.5 ml.s−1. In the clarified outlet, the ambient pressure diagrams, using sludge outflow equal to 15 ml.s−1, and the numerical
(1 atm) was established. velocity diagrams (for the RNG, SST and BSL-RSM turbulence model).
Aiming to obtain the efficiency data of the experimental multiphase Under the same operation conditions, a similar flow pattern is observed
flow for each diameter studied, the flow rates (water and calcium with the presence of a recirculation zone. The vortices were also ver-
carbonate with equal diameter size) of the inlet and sludge outlet were ified by Joodi and Hameed [27], analyzing the water flow in horizontal
simultaneously controlled by valves and maintained equal to sedimentation tanks; by Goula et al. [15], when they investigated the
43.5 ml.s−1 and 15.5 ml.s−1, respectively; the solid volumetric fraction influence of temperature on the flow lines inside a circular settler, and
in the inlet was kept equal to 20%. Sludge and clarified outlet flow rates by Tarpagkou and Pantokratoras [11], studying the sedimentation be-
were collected for a certain period of time and, posteriorly, the obtained havior in lamellar tanks using the κ-ε, SST κ-ω and RNG κ-ε turbulence
mass was placed in the oven in order to obtain the value of solid flow models, respectively.
present in each outlet. In relation to the fluid jet that leaves the feedwell, there is a dif-
For validating the mathematical model (single phase flow) through ference between the experimental and numerical results: in the ex-
CFD simulations, the same conditions were applied to the inlet and to perimental result, the outflow jet is smaller, with a slope slightly up,
the clarified outlet. In the sludge outlet, a flow equal to 15.5 ml.s−1 was while those obtained numerically present greater range of velocity, and
used. are directed to the settler base.
In relation to the multiphase study, the volume fraction of the Figs. 6 and 7 respectively show the profiles of U velocity component
feeding was equal to 20% of the solid phase; the carbonate diameter (velocity in the direction x – Fig. 5) and V velocity component (velocity
varied from 10 μm to 250 μm and the other contour conditions were in the direction y – Fig. 5), obtained using the RNG κ-ε, SST κ-ω and
kept constant, equal to those for the single phase flow study. BSL-RSM turbulence models, and comparing them to the values from
the PIV analysis, shown with their standard deviation (represented by
4. Results and discussions bars). Velocity components data were collected in the axial positions
distant from the base (0.070 m, 0.080 m, 0.090 m and 0.100 m), as
4.1. Experimental results presented in Fig. 5.
Fig. 6 shows that the RNG κ-ε model properly presents the velocity
The water flow lines on the xy plane, obtained in both cases ex- profile trend, but the values are overestimated, which was equally ob-
perimentally studied, are shown in Fig. 3. A fluid recirculation zone is served by Al-Sammarraee et al. [5], when they studied turbulence in
observed at the top and at the bottom of the jet that leaves the feedwell. rectangular settlers, using the standard κ-ε model. Values obtained
These vortices position and intensity changes with the variations in the using SST κ-ω turbulence model cannot properly describe the flow (a
flow rate in the sludge outlet. velocity central peak is not numerically observed).
According to Shahrokhi et al. [2], the existence of these recircula- For the present study, the model that best represents the U velocity
tion zones has adverse effects, which are mainly decreasing the tank component is that which directly calculates Reynolds tensors (BSL
effective area of separation and inducing high turbulence intensity. This RSM), except in the 0.100 m position (Fig. 6(a)). White et al. [4] also
can not only reduce the possibility of the particle deposit, but also cause observed the efficiency of the RSM model to describe turbulence in

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Fig. 3. Streamlines of the water in a diametral plane of the settler for the sludge outlet flows equal to: (a) 3.5 ml.s−1 and (b) 15.5 ml.s−1.

Fig. 4. Vector maps for each case under study; (a) Experimental (PIV); (b) RNG κ-ε turbulence model; (c) SST turbulence model and (d) BSL-RSM turbulence model.

settler tanks, comparing numerical velocity profiles to experimental smaller than the ones from PIV, mostly in the positions closer to the
values obtained by the LDV technique. bottom (Fig. 7(c) and (d)).
The V velocity component (Fig. 7) allows observing that the RNG κ-ε The BSL RSM model enables to correctly verify the velocity profile
model cannot rightly predict the velocity profile. Despite being widely near the wall, even though the results still present velocity values below
used, this model is not adequate to flows with low Reynolds number the empirical data. However, if the standard deviation is taken into
[28]. For the settler under study, we have low Reynolds number values: account, the numerical values obtained using this model are in ac-
in the sedimentation region (experimentally studied), the value of the cordance with the experimental results.
higher dimensionless number is around 2.104. In general, among the turbulence models studied, the BSL RSM
The SST model correctly represents the velocity variation near the model is verified to better represent the profiles of the two velocity
wall, as expected, since its advantage is the accurate prediction of the components studied. This can be justified by its being a model that does
boundary layer flow [23]. The results, however, show velocity values not use the Boussinesq hypothesis in its formulation.

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two mixture zones are verified, one located on the feedwell bottom,
anticlockwise, and the other located at the top of the feedwell. Ac-
cording to Zhou et al. [18], for flocculation, a stage that normally
happens inside the feedwell, a mixture maximum is convenient to op-
timize the process.
Near the clarified outlet (settler top), the presence of vortices is
verified. According to Shahrokhi et al. [2], this may be an advantage for
the sedimentation process by allowing the particles that were being
dragged to return to the separation process, consequently increasing the
particle resistance time inside the equipment.
Fig. 9 shows the planes of solid volume fraction on a xy plane, going
through the central axis (z = 0), for three studied diameters: 10 μm,
50 μm and 250 μm. As expected, it is difficult for the smaller particles to
settle (small-size particles are imprisoned in the fluid recirculations)
and, therefore, as can be seen on Fig. 9 (a), the plane of concentration
Fig. 5. Position of studied lines. presents an almost homogeneous behavior along most of its extension.
The solid volume fraction is 20% (value established at the entrance),
also observed by Al-Sammarraee et al. [5], studying the sedimentation
4.3. Multiphase simulation: particle sedimentation efficiency
of particles with 20 μm diameter in rectangular tanks.
With diameters equal to 50 μm and 250 μm (Fig. 9(b) and (c)), a
Fig. 8 shows the streamlines for the water continuous phase on a xy
higher solid concentration is observed at the bottom of the settler. The
plane going through the settler central axis (z = 0), obtained from the
diameter increase causes an extension of the clarified liquid region,
multiphase study with diameter of solid phase equal to 25 μm. Re-
which leads to the conclusion that larger particles (Fig. 9(c)) are not
circulation areas are observed on the plane shown. Inside the feedwell,

Fig. 6. Component of the U velocity as a function of the radial position for distances (a) 0.100 m from the bottom; (b) 0.090 m from the bottom; (c) 0.080 m from the
bottom and (d) 0.070 m from the bottom.

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Fig. 7. Component of the V velocity as a function of the radial position for distances (a) 0.100 m from the bottom; (b) 0.090 m from the bottom; (c) 0.080 m from the
bottom and (d) 0.070 m from the bottom.

250 μm). The V velocity is observed to show higher values (in module)
within the feedwell, around 0.45 m.s−1 for the three cases studied.
However, in the feedwell external area, the higher discrepancy is ver-
ified to be obtained for the 250 μm diameter case (Fig. 10(c)), which
presents negative velocity values, meaning the particles sedimentation.
For the smaller diameters, geometric adaptations are verifiably neces-
sary, especially in regions of fluid recirculation, to enhance these par-
ticles settling. The process was also performed by Goula et al. [1], Al-
Sammarraee and Chan [19], Shahrokhi et al. [20], Lane et al. [29] and
Panda et al. [30].
The separation efficiency was calculated using Eq. (3) for the cases
studied. Fig. 11 shows these efficiency values as a function of the solid
phase diameter, obtained both numerically and experimentally. It is
possible to observe that both values are in accordance. As expected,
sedimentation efficiency rises as the particles size increases, because
Fig. 8. Continuous phase streamlines using the Eulerian-Eulerian multiphase the larger particles quickly settle due to their heavier masses and higher
model. inertia in relation to turbulence [5]. For both methodologies, a con-
siderable difference in the efficiency value obtained is no longer ob-
dragged by the liquid (as observed in Fig. 10(c), the V velocity com- served from diameter 100 μm.
ponent exhibits negative values, which means the particles are settling).
Fig. 10 shows the V velocity component behavior in the dispersed
phase (calcium carbonate) on a xy plane going through the central axis 5. Conclusions
of a settler for the three diameter sizes studied (10 μm, 50 μm and
PIV 2D measurements were performed in an acrylic settler on pilot

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Fig. 9. Volume fraction of the solid on a xy plane for cases of solid phase diameters equal to: (a) 10 μm; (b) 50 μm and (c) 250 μm.

Fig. 10. Component of the V velocity of the dispersed phase for cases of diameters equal to: (a) 10 μm; (b) 50 μm and (c) 250 μm.

observed. The slugde flow rate variation was observed to influence the
positioning and size of the vortices within the settler.
Initially, in the numerical study, models for the single phase system
(water) were tested and verified by qualitative and quantitative com-
parisons with the experimental results, noticing that the velocity fields
calculated using the turbulence model BSL-RSM were in accordance
with the measured experimental results. However, the velocity results
obtained from RNG κ-ε and SST κ-ω models failed to correctly represent
the fluid behavior in the settler.
With the consistency between computational and experimental re-
sults, it was possible to use the numerical data to obtain details of the
flow characteristics in the settler. The numerical analysis of the fluid
dynamics behavior of the suspension (water/calcium carbonate) within
the equipment could be verified by streamlines, volume fractions and V
velocity component.
Numerical results of the water/solid separation efficiency using the
settler presented values within the range of 3–70%, with calcium car-
bonate diameter variation in the interval from 10 μm to 250 μm. This
showed that, to improve the sedimentation of small particles, it will be
necessary to make geometric adaptations to the sedimentation tank
under study.

Acknowledgement
Fig. 11. Separation efficiency as a function of the solid phase diameter.
The authors acknowledge Brazilian National Research Council
(CNPq) for the financial support, Brazil.
scale and a 3D numeric model was used to simulate the hydrodynamics
within the equipment. The tank flow was studied under the code ANSYS
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