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© P.H. Poh
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Poh, P.H.. 2017. “Development of Design Methods for Lamella Separators”. figshare.
https://hdl.handle.net/2134/27215.
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by
April 1984
i
Ro ~ 0(1) - 0(10)
ii
ACKNOWLEDGEMENTS
...
iii
CONTENTS
(A detailed contents list is given
at the beginning of each chapt~r) Page No
Abstract ... i
Acknowledgements iii
Contents ... ,
iv
List of Tables ·.. v
List of Figures vii
CHAPTER 1: INTRODUCTION 1
CHAPTER 2: LITERATURE REVIEW 5
CHAPTER 3: EXISTING DESIGN METHODS FORLA~lELLA SEPARATORS 47
CHAPTER 4: DEVELOPMENT OF DESIGN METHODS 58
CHAPTER 5: EXPERIMENTAL PROGRAMME 93
CHAPTER 6: DISCUSSION OF RESULTS ·.. 127
CHAPTER 7: CONCLUSIONS 198
CHAPTER 8: RECOMMENDATIONS FOR FURTHER WORK 202
Appendices 204
Nome nc 1a ture 282
Bibliography ••• ... · . • 286
iv
LIST OF TABLES
v
TabLe No. Desapiption Page No.
vi
LIST OF FIGURES
vii
Figu:r'e No. Description Page No.
4.2 Batch settling behaviour in a high
aspect ratio separator 73
4.3 Typical velocity profile for the
countercurrent and cocurrent-sub-
critical modes of operation 79
4.4 Typical velocity profile for the
-- cocurrent-supercri tica 1 mode of
operation 80
4.5 Proposed design scheme for lamella
separators 92
vi i i
FiguPe No. Description Page No.
ix
FiguPe No. Description Page No.
x
Figure No. Description Page No.
xi
Figure No. Description Page No.
xii
CHAPTER 1
INTRODUCTION
1
and tend to rely heavily on empirical findings and past industrial
experience to substantiate the final design specifications. 'This
situation is often undesirable because it demands extensive pilot
plant experiments which are both time consuming and costly. The
more well tested design methods that have been reported in the
1iterature invol ve either imposing an "improvement factor" on the
Goe and GleVe~ger13 procedure for conventional thickeners,or adding
another term to the renowned Yoshi oka 68 procedure. The "improve-
ment factor" is based on the Nakamura and Kuroda 42 formula deve-
loped to predict the enhanced rate of sedimentation in an inclined
vessel. However, the proponents of these design methods concede
that their procedures are only about 50% accurate. A detailed
review of the 1iterature on the theory of incl ined sedimentati on
and the existing design methods for lamella separators is given
in Ghapte rs 2 and 3.
i i i) to estab 1is.h a useful si zing method that not only predi cts
the area requirements but also provides the conditions
under which it is applicable, and
2
iv) to develop a more comprehensive design scheme for lamella
separators, i.e. one that incorporates all the relevant
design elements and constraints, as listed below:
3
Also contained in this chapter are details of the experi-
mental facilities. i.e.
4
CHAPTER 2
LITERATURE REVIEW
Page No
2.1 THEORY 7
2.1.1 Batch inclined sedimentation models 7
2.1.2 Continuous inclined sedimentation models 18
2.1. 3 Inclined settling behaviour 'of floccula-
ted suspensions '" 22
2.1.4 Inclined settling behaviour of non-
flocculated suspension '" 24
5
Page No
2.4 ADVANTAGES AND DISADVANTAGE~ OF LAMELLA SEPARATORS 45
2.4.1 Advantages... '" 45
2.4.1.1 Low capital and operating costs 45
2.4.1.2 Higher separating efficiency 45
2.4.1.3 Convenience of construction and
installation ••• '" 45
2.4.1.4 Fewer maintenance problems 46
2.4.2 Di sadvantages 46
2.4.2.1 Short sludge detention time for
compression ••• • •• 46
2.4.2.2 Susceptibility to fouling problems 46
6
CHAPTER 2
LITERATURE REVIEW
2.1 THEORY
7
(i) Effect of angle of tilt on settling rate
t 1
>,-,,- -.-- -'--.-. -----
.'
~--t:.:I_----%.t I
8
scientific explanation and interpreted this phenomenon as an
effect of Brownian movement of the lower corpuscles in the
settling column.
9
Details of the mathematical derivations are summarised as
follows. At the start of settling all particles on a surface
denoted by the line CAB (shown in Figure 2.2(a)) settle with an
initial velocity v for an elemental time dt and reach a hypo-
thetical surface DFH. Because the velocity v is assumed to
have the same,value at all points, thus AF = BH = CD. The
volume of clear liquid displaced by the particles in time dt
is therefore represented by the shaded area ABGFEC (N.B. the
volumes represented by CDE and BGH are negligibly small and
may be neglected to simplify the mathematics). In reality,
however, the particles will not take up the surface shown as
EFG because of the density and height difference between the
suspension at plane FG arid the liquid at~pciint L' Aninsta:nta.:'-
neous rearrangement will take place giving a new clear liquid-
suspension interface at plane A'B' shown in Figure 2.2(b).
Nevertheless the two volumes of clear liquid shown must be equal
and thus the area AA'BB' must equal area ABGFEC. If the initial
height of the interface AB is h and this falls to a final value
(h-dh) after the elemen~il time dt, then, by equating the two
areas a mathematical relationship will be obtained relating the
enhanced rate of sedimentation to the suspension properties and
settler dimensions, i.e.
Eqn. 2.1
10
dt 1 1
A,,....:uI.LUI.LU.J...1J..1..U.J...1J..1.I..I..LU-V-..!!---_~*_ h
(a) (b)
Eqn. 2.2
Eqn. 2.3
12
surface in the suspension. Agreement between the models and
experimental data was reported to range from good to fair.
The principal weakness of these models is that extensive
experiments are required to determine the empirical coeffi-
cients, which are complex functions of the settler dimensions
and suspension properties.
13
Clear liquid layer_----.,f::.
-.-''-i4--Susoension layer
14
on that mechanism of settling convection, a mathematical model
was subsequently developed to define the trajectories of
particles settling in very dilute suspensions. Using dimen-
sional analysis, it was shown that aside from the geometric
factors such as the shape of the settler and the angle of
inclination, the settling process is in fact governed by two
dimension1ess parameters(*): NRe , a sedimentation Reyno1ds
number and NGR , a sedimentation Grashof number. The model
predicted that NRe should be made as small as possible and NGR
as large as possible to achieve the most rapid sedimentation.
Moreover, using experimental results and numerical solutions
from their mathematical model, Hill was able to establish a
rangeofva 1; dityf6r the Nakamura"and'l<Uroda"equations :" i:e:" ,
in the dual limit that NGR~ and NRe+O. In view of the limited
range and accuracy of their numerical solutions and experimental
data, that finding was then regarded as tentative.
15
(*) Definition and physical significance of dimensionless
nuliibers
h3 g pep - p) Co
N = P (2.4)
GR \l
2
(2.5)
NOTATION
16
a sedimentation Reynolds number which is typically small; and
A, the ratio of a sedimentation Grashof number to the Reynolds
number which is typically very large. By means of an asymptotic
analysis it is reaffirmed that, as A~ and for a given settler
geometry, the enhanced rate of sedimentation can be accurately
predicted with the use of Nakamura-Kuroda equations. The model
also produced an expression for the thickness of the clear liquid
layer formed beneath the downward facing surface as well as
velocity fields in the clear liquid and suspension layers. Under
the conditions of their experiments, excellent agreement was found
with theoretical predictions.
17
of this transient behaviour the Nakamura and Kuroda equations
would overestimate the rate at which the top suspension/clear
liquid interface settled with time. However, the Nakamura and
Kuroda predictions for the owerall settling rate would still
hold under the conditions of the .model. Results of batch sedi-
.
mentation experiments were found to be in excellent agreement
with the theoretical predictions. Another outcome of their
analysis, which is perhaps more important, is that the disconti-
nuity in the clear liquid layer profile can be suppressed in
continuous settling systems but only if the feed and withdrawal
arrangements are properly designed with this aim.
18
of three viscous. stratified "fluid" layers. each of reasonably
uniform aensity moving under the action of gravity; a clarified
liquid. a feed suspension layer. and a sludge layer (see Figure
2.4). Two significant sets of results emerged from their model:
ii) that for a given settler throughput there exists two possible
operating modes (i.e. subcritical and supercritical). with
different velocity profiles. By definition. the subcritical
mode (shown in Figure 2.S(a)) is one in which the clear liquid
layer thickness is less than half the channel spacing at the
top of the· settl ing channel and decreasing gradually to a- -,.-
minimum at the base of the channel. The supercritical mode
(shown in Figure 2.S(b)). on the other hand. is one where the
clear liquid layer thickness is greater than half at the top
and increasing gradually to a maximum at the base.
19
(1) Clear liquid layer
(2) Suspension layer
(3) Sl udge 1ayer
(A) Cocurrent flow
(B) Countercurrent flow
20
Clear 1iqui d Feed
21
3
A more fundamental model by Acrivos and Herbolzheimer
suggests that the ad-hoc assumptions made by Probstein and his
co-workers. regarding the existence of thr.ee steady-state strati-
fied layers is oversimp1istic and hence only valid under certain
operating conditions. Their model showed •• for example. that in
cases where the feed is introduced into the settler along its
side. the feed and withdrawal locations must be chosen properly
to enable the formation of steady-state stratified layers.
Otherwise. transient behaviour will prevail. The subcritica1
and supercritica1 modes of operation have again been verified
theoreti ca 1ly.
22
i) Hindered settling of floes which maintain their size and
shape, and contain immobilised (intra-floc) liquid. At
this stage, only inter-floc liquid is displaced and flows
upwards between floes.
23
for practical purposes the latter case should be prevented from
occurring because of' two potential consequences. Firstly, the
overa 11 settl i ng effi ciency of the sus pens i on wi 11 drop because
of slower settling floes. Secondly, and for the same reason, the
probability of floes becoming re-entrained into the clear liquid
stream will increase dramatically.
24
the particles mechanically interact with one another, very little
further compression occurs. Any increase in concentration there-
after arises due to the sliding and tumbling of particles over
one another until they reach a stable configuration. This is in
sharp contrast with the floc compression process that would have
occurred in a,flocculated suspension under the same condition.
25
2.2 PRACTICAL DESIGN CONSIDERATIONS
Also available on the market are more complex deSigns such as the
dual flow clarification unit, as shown in Figure 2.7, where both
countercurrent flow and cocurrent flow can be achieved in the same
equipment. This is claimed by the manufacturer to have some
advantages where multiphase or heterogeneous systems are being
separated. Figure 2.8 shows a separator'unit in which clarification
and thickening may be achieved by having two packs of lamella
plates vertically above each other with the feed introduced
between them. The plate separations may be different in the two
packs and the lower pack may be vibrated, which can have beneficial
effects in the compaction of the sludge.
26
Clear liquid
Feed
Clear liquid,,·
Feed'
Sludge
Sl udge
(iii) Crosscurrent Flow
27
Clear liquid Feed
51 udqe
Clear liquid
Feed
51 udge
28
2.2.1.2 Factors influencing the choice of flow pattern
29
advocated. The separation of biological flocs in the activated
sludge waste treatment process and the separation of metal-
hydroxide on neutralisation of waste liquors from pickling plants
and the galvanic industries come under this category of applica-
tions. A summary of the above recommendations are listed in
Table 2.1.
30
made to destroy the kinetic energy of the incoming stream to the
separator. In practice this is usually achieved by fixing an
impingement plate to absorb the impetus of the feed stream
just before it enters the lamella channels.
To use the total plate area efficiency the flow into the
separator must be distributed evenly between the plates as well
as width-wise across each plate. Otherwise, a bypass situation
will develop in which some parts of the separator will become
overloaded while others underloaded. Figure 2.9 shows a typical
arrangement whereby even distribution is achieved with the
installation of a distribution plate (with identical orifices)
at the top of the separator to remove clear liquid from each of
the plate spacings.
31
Feed
..
...
51 udge
32
2.2.3 Geometric parameters
2.2.3.1 Plate spacing 14 ,28
33
2.2.4 Feed entryll,l4,28,45
34
AD"''''''.' FLUM(a
1'''''''''''''''' TANK
35
Sludge concentration
Vibrated sludge
Unvibrated sludge
36
most particles have the same settling time. Circular tubes are
considered inefficient because particles entering at the top of
the tube have a greater distance to settle than those entering
at the sides. An optimum configuration is one that permits nesting
so that there is no wasted space between the channels in the sepa-
rator unit. Again, circular tubes are less efficient because of
the large amount of dead space between tubes in the array.
37
FIGURE 2.12: CHEVRON-DESIGN FOR SETTLING CHANNEL
38
interparticle contact but insufficient to shear flocs that have
.
been formed. The flocculated suspension must then flow gently
into the sedimentation tanks in a manner whereby the flocs are
not broken up.
39
2.3 INDUSTRIAL APPLICATIONS
40
The compactness of lamella separators has led to their use
in packaged skid mounted plants marketed by Anpress for the total
reclamation of water from vehicle washing process (Ward 60 ). For
this particular application, a square section tube separator is
used inclined at 3S o in a stop-start operation. Surface loadings
are reported at 0.48 m3/m2/hr based on tne effective settling area
"
available.
Van Vliet 57 describes a high lime clarification process in
which both inclined plate and tube modules are used to uprate a
conventional circular raked primary clarifier. Results show that
the efficiencies of the two modules are comparable and quite
insensitive to hydraulic loading in the range 3-12 m/hr. Because
of this the modules. are particularly useful as hydraulic uprating
agents for existing clarifiers and especially where uprating
factors of 1.5 to 2 would still ensure stable floc blanket
conditions.
It is found, from the literature, that for cocurrent flow the
required angle of inclination in water treatment is generally
300 _40 0 (from the horizontal) with a plate spacing of 35 mm.
The plates, because of their special design, are usually made
out of PVC. However, when operating countercurrently, the angle
is higher at 5S o_60 0 • This is because.the sludge layer now has
to slide against the shear force of the liquid phase.
41
2.3.2 Waste water treatment
2.3.3 ~1ining
43
2.3.4 TABLE 2.2: SURFACE LOADINGS ON TYPICAL APPLICATIONS
Surface
Type of Separator Appl i cati on LoadinQ
(m3/ m2/hr)
44
2.4 ADVANTAGES AND DISADVANTAGES OF LAMELLA SEPARATORS 28 ,56
2.4.1 Advantages
2.4.1.1 Lower capital and operating costs
45
are light weight, it is possible to install such separators on
high locations in buildings.
2.4.2 Disadvantages
2.4.2.1 Short sludge detention time for compression
46
CHAPTER 3
Page No
3.1 EMPIRICAL APPROACH ••• 48
47
CHAPTER 3
EXISTING DESIGN METHODS FOR LAMELLA SEPARATORS
48
and depending on the design, a safety factor of between 1.25 and
2 is normally added to the projected area to allow for non-ideal·
hydraulic conditions and any expected variations in the settling
properties. To complete the design, other specifications such as
the plate inclination, plate length, plate width, the feed and
withdrawal arrangements etc. are generally' specified independently
based on the experience and recommendations of the manufacturers.
49
3.2 SEMI-EMPIRICAL APPROACH
_ ~ = Fv (1 + h COSCL) Eqn.(3.l)
ut b
50
was used. The authors concede that their sizing method is only
useful in obtaining a first approximation of thickener capacity.
i.e. c p : Gc + Gp
(G) Eqn. 3.2
52
Eqn.(3.3}
= _ _...l.(.::;b/c..:C~os;::a~}-,.-;:-;:-,., Eqn.(3.4}
F v (1
+ [ 51na Cosa}
b
53
FIGURE 3.1: LIMITING TRAJECTORY FOR SETTLING PARTICLE
Q
WLn =
Fv ( 1 + L_S.:...l:.;.nrb_c:,,:o.,::.sCL::.) CO SCL Eqn.{3.5)
r
required lamella
pI ate area
sions ·and varies between 0.5 and 0.7 over a large range of concen-
54
account different vessel shapes 63 ,64 and the actual liquid flow
profile and thickness of sludge accumulated in the settl ing
channe1 40 ,59,63,64.
ii) that the thickness of the clear liquid layer beneath the
upper inclined surface and the thickness of the sludge layer
on the lower inclined surface are negligibly small.
I) where the interface between the clear liquid and the suspen-
sion is at the level of the feed inlet, as shown in Figure
3.2(a). The bulk suspension is assumed to be homogeneous
and at high concentration.
Il) where the interface between the clear liquid and the suspension
is again at the level of the feed inlet. However, a discontinuity
between low and high concentration regimes exists in the bulk
suspension (see Figure 3.2(b», and
55
(al
Clear liquid
(b)
Clear liquid
Feed
Low cone.
Sludqe
( c)
l:lear liquid
Feed
56
Ill) where the interface between the clear liquid and the sus- .
pension is above the feed inlet. As shown in Figure 3.2(c),
the location of discontinuity between the low and high
concentration regimes is at the level of the feed inlet.
.
pension properties, expressions were obtained to describe the
concentration distribution and solids fluxes along the entire
length of the lamella thickener. These expressions were then
used to calculate the maximum thickener capacity. It was found,
from plots of solids flux versus concentration curves, that
lamella thickening, under the conditions of the analysis, is
in fact a special case of vertical thickening. This design
method suffers the drawback that it may only have limited,'
industrial applications because of the ad-hoc assumptions made
regarding the settling behaviour and steady-state conditions
that may exist in a lamella thickener.
57
CHAPTER 4
Page No
4.1 INTRODUCTION 59
58
CHAPTER 4
DEVELDPMENT OF DESIGN METHODS
4.1 INTRODUCTION
59
selves have inherent weaknesses because of too many ad-hoc assump-
tions. For instance, the authors simply assume the existence of
steady-state stratified layers in the settl ing channel s, whi ch
Acrivos and Herbolzheimer have since shown do not exist in all
cases. In practice the shortcomings of the existing design methods
have also given rise to two common but serious problems: the
excessive contamination of the supernatantwith re-entrained parti-
cles from the suspension layer and the frequent inability to achieve
the designed level of sludge thickening.
60
iii) Flow stability constraint) to minimise the re-entrainment of
) particles from the suspension layer
) into the clear liquid layer, and
iv) Sludge flow constraint ) to ensure a continual removal and
) rapid removal of sludge formed on
) the lower inclined surfaces.
61
4.2 DESIGN CONSTRAINTS
62
Acrivos and Herbolzheimer to establish the necessary conditions
for the formation of a steady state clear liquid/suspension inter-
face in both the low and high aspect ratio vessels will be dis-
cussed below.
For the purpose of clarity, the steps in which the flow models
are developed (i.e. based on the principles of continuum mechanics 53 ,54)
are summarised as follows:
63
based on the following assumptions:
Eqn. 4.1
fi4
'Jp = 'Jp
~~----Interface
X=O
., ..
,
Eqn. 4.2
2
R {ilU + U ilU + V ilU} = _ ~Px + ACose + {a u+ il2U} Eqn. 4.3
TI ax av a aX2 ay2
and
R {ilV + U ilV + V av} = Eqn. 4.4
TI all aY"
67
Step 2: Determination of stretched variables
i . e.
aU + aV - 0 Eqn. 4.5
3)(* aY"-
68
Eqn. 4.6
a(A l/3U) = _ ap
....
.:
a(A -1/3V') ax + ACose
2'"
!J!. + Cose
aY'2
Eqn. 4.7
and
'" + ~'" =
au 0 Eqn. 4.8
ax ay
69
a2~ + Cose =0 Eqn. 4.9
'"
ay2
at ~ =0 Eqn. 4.10
(i.e. zero liquid velocity at the walls)
O
r
70
Since A is asymptotically large the equation above can be simplified
to
'" = Y Cose ax
au'"
ax '"
a<5·
and hence,
The solution for the clear liquid layer thickness '"<5 is obtained
via the following kinematic condition at the clear liquid/suspension
interface i.e.
"V "". .
71
The above equation is essentially a mass balance describing the
.rate of growth of the clear liquid layer as a function of the
influx of liquid through the interface and the net flow rate of
liquid along the clear liquid layer itself. Substituting ~ and ~
into Equation 4.14 the latter becomes:
72
4.2.1.13 Development of flow fields in a high aspect ratio
separator (i.e. h/b = O(A 1 / 3 ))
The flow fields developed for both the batch and continuous
settling systems will be dealt with in turn.
Discontinuit
Xc
X=O .
73 /
The relevant equations that have been derived to predict the
steady-state section of the clear liquid layer and the critical
position of discontinuity are given below:
=~ ~ (3 X tane)1/3)
~
B=A 1 /3B
Position of discontinuity,
Eqn. 4.18
74
I) Cocurrent flow
Overall Consideration
75
system because that is the condition under which all the flow
models have been developed. However, it is believed that even
at higher concentrations the important predictions regarding the
qualitative behaviour will remain unchanged. In particular, the
existence of discontinuity in a batch settling system and the
corresponding need for steady state constraints in a continuous
system.
76
channel given by the equation below,
For the purpose of this research which is concerned with the use of
a parallel plate lamella separator of channel width, W, and channel
spacing, b, the hydraulic diameter is given by (W 2Wb
+ b) •
2pWbv
(w+bh < 500 Eqn. 4.21
Q
If v is represented in terms of the actual flow rate as WD' then, by
77
substitution into Equation (4.21) gives
2pQ
(w +b) \l < 500
78
It has been shown by Probstein and his co-workers that
currently operated lamella separators, i.e. those operating in
the countercurrent and cocurrent-subcritical modes are inherently
susceptible to particle re-entrainment because of the existence of
a part of the suspension layer which is relatively unstable and
moving upward at high velocity with the clear liquid stream -
an illustration of this effect is given in Figure (4.3) •
.
'
Cl
79
has a more favourable velocity field. As shown in Figure (4.4).
part of the clear liquid layer just adjacent to the suspension/
clear liquid interface is actually dragged downward in the direc-
tion of the settling suspension thereby helping to stabilise the
interface and also the particles around that region •
...,...,;~---Suspension layer
Clear liquid
layer -------:-r-
Interface
80
Based on current knowledge there is no reliable design method
available which can be used to suppress the effect of flow insta-
bility, though in the literature some initial work has been under-
taken by Leung 34 • Working with the supercritical mode of operation,
the author attempted to characterise the unstable nature of the
interface between the clear liquid layer and the suspension layer
as a function of settler angle and feed rate. It is shown that at
low settler angles (i.e. a < 100 from the horizontal) the destabili- .-
sing mechanism is associated with an inflectional point in the flow
due to shear; and at high angles (i.e. 100 < a < 60 0), with a
gravity destabilising mechanism. The former, however, is not rele-
vant to most industrial applications because the range of angles
covered is far below that needed to satisfy the sludge flow con-
straint. Of relevance is the high angle case, where theory and
experiments have been used to define the dependence of the critical
flow rate for the onset of turbulence at the interface (i.e. Qturb)
on the settler angle, the channel spacing and the density difference
between the clear liquid layer and the feed suspension layer.
A number of significant findings have been made which should serve
as a useful basis for the design of a stably operating system:
81
while the transverse component ~
p
sinn is stabilising. It
therefore suggests that the critical flow rate for the onset
of turbulence, Qturb' is proportional to Cotn.
A?
it follows that excessively long and narrow channels will be
susceptible to flow instabilities because any wave disturbance
that is generated along the length of the interface will have a
chance to propagate and amplify to breaking point, whence particles
get ejected into the clear liquid stream. It is believed that, for
a given channel spacing and angle of inclination, there exists a
corresponding optimum channel length beyond which negligibly small
improvement 'to the settler efficiency can be .expected. It is
planned to verify experimentally the existence of such an optimum
channel length and to recommend its use as an upper limit for the
purposes of design.
83
The normal practice of overproviding the angle. of inclination
is undesirable because of the competing interest to obtain the
greatest projected area for sedimentation. The underprovision of
a, on the other hand, is even more undesirable because it will
result in poor sludge flow leading to a build-up along the entire
length of the lamella plates. In extreme cases the sludge layer
may grow eventually to fill the entire channel, thereby rendering
the separator inoperable.
84
4.3 SIZING METHOD
85
verflow: Q
o
eed Qf' Co
/,f :
(cocurrent)
",
'Middle-feeding
· .
CO""",;;~---- --
Underf10w: Qu' cu
Eqn. 4.23
bvoW hS'
b1ne)
h
were Q0 = Cose (1 + Eqn. 4.24(b)
RI'>
Since, in most industrial applications, the ratio of the vertical
height of the separator to the channel spacing (h/b) is much
greater than 1, Equation (4.24) may be simplified to:
bvoW ( h S·ln9)
Q = -"-Co,,-,s;..,;s'----,.,;.... ..;,.b_
f (1 _Co)
C
u
h v Wtans
i.e. Q = _-=.0--r:--
f (1 _ CO)
C
u
x vo WSins
Eqn. 4.25
(1 _ CO)
cLi
• laminar flow
• small particle Reynolds number, and
• large. A
87
4.4 PROPOSED DESIGN SCHEME
88
TABLE 4.1: SUM~'ARY OF DESIGN VARIABLES AND CONSTRAINTS
89
be sufficiently steep to satisfy the first constraint of the proposed
design scheme, i.e. the sludge flow constraint. The latter is a
safeguard for achieving a continual and rapid removal of sludge
collected on the lower inclined surfaces.
90
minimise the re-entrainment of particles into the clear liquid
stream. In the final analysis it is proposed that the designed
channel length be based on the more limiting of the two constraints.
91
FIGURE 4.5: PROPOSED DESIGN SCHEME FOR LAMELLA SEPARATORS
Design Specifications
( ..
ANGLE, OF INCLINATION
~
Physical constraint
(i.e. potential clogging)
- -- -----
CHANNEL SPACING
( CHANNEL LENGTH )
( CHANNEL WIDTH )
Number of settling
channels required
92
CHAPTER 5
EXPERIMENTAL'PROGRAMME
Page No
5.1 INTRODUCTION 94
93
CHAPTER 5
EXPERIMENTAL PROGRAMME
5.1 INTRODUCTION
94
aspect ratio of vessel (i.e. h/b) = 0(1) - 0(100)
concentration of solids in suspension = 0-30 volume %
angle of inclination = 0_90 0 .
Cocurrent and countercurrent flows were tested and the former included
both the subcritical and supercritical modes of operation. The exis-
tence of two optimum operating conditions were also verified experi-
mentally: i.e. the optimum aspect ratio and the optimum angle of
inclination. In practice, the former would impose an upper limit
on the length of the separator to ensure minimal re-entrainment of
particles into the supernatant. On the other hand, the optimum
angle of inclination would give a continual and rapid removal of
sludge along the lower inclined surface of the lamella separator.
95
A specially constructed batch rig was used for this purpose.
Results from this series of experiments will be used to devise a·
design strategy for achieving maximum separator throughput with
high sludge concentration in the underflow.
..
. ,
test materials used in the experiments and their selection
criteria;
details of the experimental rigs;
details of the experimental techniques and operating proce-
dures.
96
5.2 EXPERIMENTAL VERIFICATION OF INCLINED SEDIMENTATION BEHAVIOUR
5.2.1 Test Materials
5.2.1.1. Criteria for choice of materials
97
TABLE 5.1 : CLOSELY MATCHED REFRACTIVE INDEX SYSTErl
Particles
98
Non-spherical glass beads were removed from the bulk sample
with the use of a vibrating inclined surface (i.e. inclined at
approximately 10 degrees from the horizontal). The spherical
glass beads, by virtue of their higher freedom of rotation, rolled
rapidly to the bottom of the inclined surface where they were collec-
ted. However, the non-spherical ones remained along the inclined
surface and were subsequently removed.
, ..
A common specific gravity for the remaining glass beads was
obtained by removing the imperfect ones, i.e. those with voids in
them. This was easily achieved by floating the imperfect beads in
a mixture of Carbon Tetrachloride and di-iodomethane having the same
specific gravity (i.e. 2.46) as the perfect glass beads. The compo-
sition of that liquid mixture is given below:
99
The rheological properties of this plasticisers mixture were
obtained with the use of a Weissenberg R18 Rheogoniometer. The
mixture was confirmed to be Ne\~tonian in nature and having a
viscosity of 22.2528centipoises at 25 0 C - the temperature at
which all the experiments were conducted.
100
For photographic reasons the vessels were constructed entirely out
of transparent clear perspex.
101
15 mW He-Cd laser Concave Convex Cyl indri ca 1 Inclined
lens lens lens
[""
~
o
N
103
which was used to magnify the initial laser beam. Moreover, to
improve the sharpness and intensity of the slit a convex lens was
used to concentrate the magnified laser beam (from the concave
lens) onto the cylindrical lens. The He-Cd laser tube and the
set of lenses were all secured to an optical bench and the latter
was bolted to a stand, which allowed the whole laser unit to be
moved vertically along its main rod. In this way the entire length
of the settling vessel could be illuminated for filming purposes.
A series
,
of experiments was conducted to verify the predicted
velocity fields in the clear liquid layer that was formed during
batch inclined sedimentation in low aspect ratio vessels. The
liquid velocity measurements were made using a Malvern Laser Doppler
Anemometer. The principle of the measurement technique was to detect
the Doppler shift in two convergent laser beams caused by microscopic
dust particles suspended naturally in the liquid stream. The Doppler
shift was then analysed in a signal processor to produce an average
time for the dust particles to pass from one fringe to the next of
the interference pattern set up by two intersecting laser beams
(see Figure 5.2). Since the distance between fringes was known,
the liquid velocity was easily ~alculated.
104
two beams of equal intensity which were then combined to produce a
fringe system at the cross-over point. With the use of a drive
unit on the phase modulator the fringes were caused to move
linearly in space either in the same direction as the flow, or
against the flow. The result being to decrease or increase the
Doppler shift detected by the signal processor so that the direc-
tion of flow could be ascertained.
Si gna 1 1fVV\1
Processor Oscill os cope
Display
Photomultiplier
Detection System
105
FIGURE S.3(a): SIGNAL PROCESSOR OF LASER ANEMOMETER
106
A photomultiplier was positioned in front of the cross-over point
to detect the Doppler shift frequencies, which were in the form
of photon signals. Analog pulses of these photon signals were
counted and then stored in digital form in a Malvern K7023 digital
correlator. Output from the signal processor was obtained either
in graphical form on an oscilloscope, or in numerical form on a
computer printout. A photographic view of the experimental arrange-
ment is shown in Figures 5.3(a) and 5.3(b).
Experimental procedure
107
0D ~ clear liquid layer thickness
u ~ longitudinal velocity component
.:
Suspensi on 1ayer
108
Operation of the digital counter gave a trace on the oscilloscope
screen of the type shown in Figure 5.4, from which the values of
91' g2 and g3 were obtained.
G2
:
1--
.. ......
.. : '.
.. ·.·· ..
'
.. . ..
.. .. .. ...
. . .
··· .... ..
.
r g2
1
g3
g,
109
u ={(samp1e time per c } Eqn.5.1
where Cl = angle between the fringes and the direction of the longi-
tudinal velocity component.
(In our experiments this angle was set equal to the angle of incli-
nation of the vessel, measured from the horizontal).
A
S = di \lR
Eqn.5.2
i ---1
--::::~~=---_ _-"lT
----.J~
110
In addition, the turbulence intensity, n, at the position of measure-
ment was estimated using the equation below:
where:
III
5.2.2.4 Agitator
Base: ----{
plate
Equally spaced holes
The size of the base plate is made just slightly smaller than the
internal dimensions of the batch vessel to promote effective dis-
persion of particles in the suspension.
11?
Agitation of the suspension was provided by a cyclic up and
down movement of the perforated plate along the length of the
inclined vessel. For consistency, the number of cyclic movements
of the agitator was fixed at 20 in every test. Preliminary tests
showed that any residual disturbance in the suspension that was
induced by the agitator was small and rapidly dissipated, i.e. less
than 5 seconds after the cessation of agitation. Thus it would
have a negligible effect on the actual behaviour of the settling
suspension. The rapid dissipation was brought about by the viscous
suspension liquid which provided a strong damping effect.
When using the agitator care was taken to prevent the introduc-
tion ·of air bubbles into the suspension. During the cyc1.ic movement
of the agitator its perforated plate was always kept within the
bulk suspension so that it could not generate air bubbles through
surface breakages at the liquid/air interface. The introduction of
air bubbles into the suspension was prevented because of the follo-
wing potential problems:
113
motion on the Vanguard would be very difficult, if not,
impossible.
114
No. of rectangular Internal dimensions of module
modules available Length, Width, Channel Spacing
cm cm
cm
1 17 4 3.4
2 46 4 3.4
. .
Each of the rectangular modules was designed so that a perspex
spacer plate may be inserted to divide it into two compartments of
equal dimensions. In this way the channel spacing could be varied
from 3.4 cm to 1.5 cm.
"~
LaJrella
separator
116
A magnetic stirrer was installed in the sludge collector to
facilitate the removal of solids in the underf10w stream. The
entire separator was supported between two rigid stands and could
be positioned at any angle between the vertical and the horizontal.
117
Blade-paddle stirrer
Thermostatical y
controlled ~_-!-~~===cooler
heater r-
SP3
Feed tank
,." .
Rotameter
Hach-Turbidimeter
r-~
t
(off-l i ne)
SP2 I
vs
118
5.2.3.3 Experimental procedure
sion liquid. The required quantity of glass beads was then added to
make up the desired concentration of suspension. The total volume
of suspension in the feed tank was about 10 litres. The blade
paddle stirrer was switched on for a brief period to provide some
initial agitation to liberate trapped air from the sample of glass
beads. After the air bubbles had been removed the stirrer was again
switched on, but at a higher speed, to create a homogeneous suspen-
sion. The constant temperature controller in the feed tank and the
magnetic stirrer in the sludge collector were also switched on.
Valve Vl was then opened and the centrifugal pump, Pl, was switched
on to recycle the overflow to the feed tank. The overflow was con-
trolled with V4, which was gradually opened until the desired flow
rate was obtained. The latter was taken as the point at which solids
first appeared in the overflow, and represented the maximum over-
flow capacity of the separator. The presence of solids was detec-
tedbya sudden increase in the turbidity of the overflow which was
measured with a Hach-Turbi.dimeter. The peristaltic pump, P2, was then
switched on and the pump speed was adjusted until a ratio of 1 to 3
119
in the underf10w to the overflow was achieved. The same ratio was
maintained in all the continuous experiments to provide a basis
for comparison of separator performances.
The operation was then kept running for about 1~-2 hours. At
intervals of 10-20 minutes, samples were obtained from SP1, SP2 and
SP3 to determine the solids content in the feed, overflow and under-
flow streams respectively. Material balances based on the solids
were then made to determine the attainment of steady-state condi-
tions, i.e. when" the sol ids fluxes into and out of the separator
were balanced. In most of our experiments steady-state was reached
after about 1 hour. However, in cases where the angle of inclina-
tion of the separator was insufficiently large (i.e. approximately
20 0 from the horizontal), it was impossible to attain steady-state
condition because of the transient behaviour of sludge flow along
the lower inclined surface.
120
5.3 STUDY OF BEHAVIOUR OF SLUDGE FLOW ALONG THE LOWER INCLINED
SURFACE
TABLE 5.2: THE DIFFERENT FULLY DISPERSED SYSTEMS USED IN THE SLUDGE
FLOW EXPERIMENTS
121
(a) Soda glass beads (b) Soda glass beads
.(90-125 m) (355-420 m)
, . ••
The solids listed above were all incompressible by nature and
were narrowly sized using standard sieves. The first set of dis-
persed systems, i.e. those using distilled water, was designed to
study the following parameters which were postulated to have sig-
nificant effects on the sludge flow behaviour:
123
le}
- - - F i n e adjustment rod
-----Vessel
Optica 1_ _ _ _ __
stand
----Plum-line
(b)
Stirrer
---Fine423.d,j ustment
rod
opper-----
FIGURE 5.10: EXPERH1ENTAL RIG FOR THE STUDY OF SLUDGE FLOW BEHAVIOU~ .
124
from 0 to 90 degrees. In addition, a fine control on the increment
to the angle of inclination was provided in the form of a fine
adjustment rod, as shown in Figure 5.l0(b). A contraption consisting
of a pl umb-l ine and a protractor was 'used to measure the angle of
inclination. A stirrer was used in conjunction with a stopper to
create a homogeneous suspension from which a uniform layer of
sludge was formed along the length of the lower inclined surface,
·. except for a short distance of about 10 cm from its base. The
latter provided a free surface for sludge flow.
iii) Using the stirrer the entire mixture was agitated to produce
a homogeneous suspension.
l?<:
v) The stopper and the stirrer were then shifted to the bottom
end of the vessel to leave a free surface for sludge flow
(represented by the shaded area in Figure 5.l0(a)).
vi) The vessel was then gradually but gently inclined until sludge
movement first occurred. The nature of the sludge movement
and the angle at which it occurred were recorded in detail.
vii) After the initial sludge movement had ceased, step (vi) was
repeated until the entire sludge layer was removed.
viii) For every experimental run the entire procedure listed above
was repeated for at least half-a-dozen times to obtain accep-
table average results.
l~
CHAPTER 6
DISCUSSION OF RESULTS
Page No.
6.1 EXPERIMENTAL VERIFICATION OF BATCH INCLINED
SEDIMENTATION MODELS ... 128
127
CHAPTER 6
DISCUSSION OF RESULTS
128
clear liqU~d/
Steady-sta
suspension
t~/.[~~~~~~~'"
interface
129
FIGURE 6.1: COMPARISON BETWEEN THE THEORETICAL AND MEASURED THICKNESSES
OF THE CLEAR LIQUID LAYER ALONG IIiE UPPER INCLINED SURFACE OF
A PARALLEL SIDED BATCH SEPARATOR
Aspect ratio, h/b = 1.13
Angle of inclination, e = 60 0 (from the,vertical)
8 c • • o
7 . c x
•
6 c x •
2 o
~ 1 particle diameter
1 c o
O+-~--~--r-~--~__r-~--~-'---r--~~---r~
o 0.2 0.4 0.6 O. G 1.0 1.2 1. 4 1.6 1.8 2.0 2.2 2.4 2.6 2.8
Thickness of clear liquid layer, 0D(mm)
130
FIGURE 6.2: COMPARISON BETWEEN THE THEORETICAL AND MEASURED THICKNESSES OF
THE CLEAR LIQUID LAVER ALONG IRE UPPER INCLINED SURFACE OF A
PARALLEL SIDED BATCH SEPARATOR
x(cm)
17
20%v/v
5%vlv
30%v/v 10%v Iv Co = 1% v/v
16 0 x A
0 x A
14 Cl ~ A 0
0 x
• A 0
12 0 x
• A 0
Cl x
• A 0
10 Cl x
• A 0
Cl x A 0
8 )\ A
x A
O+-~--~~--~~--,--,--,-~--~~r--r~
o 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 -2.0 2.2 2.4 2.6
Thickness of clear liquid layer, 0D(mm)
111
FIGURE 6~3: C011PARISON BETWEEN THE THEORETICAL AND I1EASURED THICKNESSES
OF THE CLEAR LIQUID LAYER ALONG THE UPPER INCLINED SURFAcE OF
A PARALLEL SIDED BATCH sEpARATOR
Aspect Ratio, h/b = 3.42
e = 300
- - - Theoretical line (Equation 4.16)
x(cm) 30%v/v 20%v/v lO %V/v 5%v/v
18 [] x • /l.
[] • L:. c0 = l%v/v
" 0
16 [] x
• 0
[] ~ • A 0
.. 0 ~ 0
~ A 0
12 x A 0
x
• 0
1 [] x • A 0
8 0
6 0
4 o
O~~--~--+-~--~--~~--~--~~--~~~~~
o 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0 2.2 2.4 2.6 2.8
Thickness of clear liquid layer, 0D(mm)
1 ~?
unexpected since the latter is based on an asymptotic analysis
(i.e. A ~ 00) and hence the predicted thickness should correspond
to a lower limit. Measurement errors are estimated to be small,
since the experimental data for the clear liquid layer thickness
can be accurately obtained from cine-films.
133
of using it on a continuous basis. More importantly, no addition
constraint need be imposed on the design to bring about the reali-
sation of steady state because the latter is inherently attainable.
134
FIGURE 6.4: COMPARISON BETWEEN THE PREDICTED AND MEASURED COMPONENTS OF LIQUID
VELOCITY IN THE CLEAR LIQUID LAYER FOR A PARALLEL SIDED BATCH
SEPARAIOR
Aspect ratio, h/b 1.8 ~
45° e ~
------ Predicted thickness of clear liquid layer
•• ••.•. Experimentallydetermined velocity profile
------Predicted velocity profile (Equation 4.l2)
V1
'E- I
~
E
>,
....,
6 I I
.~
u
0 I I
I I
~
(IJ
> 4
"::>
I I
.~
0-
.~
-'
2 I I
I I Position along the
upper inclined
o0 1 2 o 1 .2 surface, x = 8'. cm
8
.0·····~
I
••••• {!j ••• I .. I
:
'. '1 .
: I
.
~ I • I
I
.~
~
u
o
(IJ
4
I
>
.~
I I
::>
0- L
.~
-'
~
I I
I
I I Positiun along the
upper inclined
o0 1 2 o 2 surface, x = 6 cm
Position in the clear Position in the clear
liquid layer, y(mm) 1351iquid layer, y(mm)
FIGURE 6.5: COMPARISON BETWEEN THE.PREDICTEDAND MEASURED LONGITUDINAL
COMPONENIS OF LIQUID VELOCITY-IN lAE CLEAR LIQUID LAVER FOR A
PARALLEL SIDED BATCH SEPARATOR
Aspect ratio, h/b = 3_78
e = 20·
------- Predicted thickness of clear liquid layer
"'-'-' Experimentally determined velocity profile
- - - Predicted velocity profile (Equation 4.12)
Co = 1% v/v Co = 2~% v/v
10
I
8
.. ... 0·.1
I '
I
tu-·'· - -0 .. 1
... I ..
I '
~)
.~
u
"::4
I .:
. I
ClJ
>
I -
:-
I
I :
.-
- I
I
I I Position along
the upper inclined
o ~O------~~----~~ surface, x = 12 cm
1 2 0 1 2
I
~
8 I '-"--~I
VI
...... -.~
"
E
.-0'"
I
I
~
~ 6 • I
.. I
.~
u
~
0
QJ
>
.-- I
I
".
~
"
CT
.~
4
I I
...J
I I Position along
the upper inclined
0
0 1 2 o 2 surface, x = 8 cm
Position in the clear Position in the clear
liquid layer, l(mm) liquid layer, y(mm)
136
that region.
Nevertheless, the verified flow field in the clear liquid layer
will provide a reliable basis for developing a stability analysis
to define the factors responsible for initiating flow instability
at the clear liquid/suspension interface. It is already discussed
in Section 4.2.3 that the effects of flow instability, which is mainly
responsible for the re-entrainment of particles into the supernatant,
is one of the major problems associated with the use of a lamella
separator.
137
TABLE 6.1: EXPERIMENTAL VERIFICATION OF THE POSITION OF
DISCONTINUITY, Xc
15 640 *
20° 41.31 51 1 53 *
5 407 *
"
, , ,
138
practice, difficult to detect the exact position where the discon-
tinuous behaviour first occurs. It is strongly believed that this
uncertainty is largely responsible for the relatively poorer agree-
ment at 2~% v/v {see Table 6.1}.
nQ
FIGURE 6.6: COMPARISON BEHJEEN THE THEORETICAL AND r1EASURED THICKNESSES
OF THE CLEAR LIQUID LAYER ALONG THE UPPER INCLINED SURFACE
OF A PARALLEL SIDED BATCH SEPARATOR
Aspect ratio, h/b = 41.31
e = 70 0
45 o
40 o
35 A o
30 o
25 t:. o
20 t:.
15
o~----~----~----~------~----~~
o 1 2 3 4 5 5.5
Thickness of clear liquid layer, QD(mm)
140
FIGURE 6.7: COMPARISON BETWEEN THE THEORETICAL AND MEASURED THICKNESSES
OF THE CLEAR LIQUID LAYER ALONG THE UPPER INCLINED SURFACE
OF A PARALLEL SIDED BATCH SEPARATOR
Aspect Ratio, h/b = 64
e ,; 45 0
- - Theoretical line (Equation 4.l7)
x(cm)
85 l5%v/v lO%v/v. Co = ~ v/v
80 •
•
70
•
•
"
60 •
" .
50 A
~ 2-particle diameter
40
J o 1 2 3 4 5
141
FIGURE 6.8: COMPARISON BETWEEN THE THEORETICAL AND 11EASURED THICKNESSES
OF THE CLEAR LIQUID LAYER ALONG THE UPPER INCLINED SURFACE
OF A PARALLEL SIDED BATCH SEPARATOR
70
60
'50
~ 2-particle diameter
40
0
T
0 1 2 3, 4 5
142
reached, since the latter is essentially developed for a dilute
settling system.
143
TABLE 6.2: EXPERIMENTAL VERIFICATION OF THE PREDICTED RATE OF BATCH INCLINED SEDIMENTATION USING THE NAKAMURA-
KURODA EQUATION
Low Aspect Ratio Case
* These initial rates are not actually obtained at time zero but at 5 seconds after the commencement of settling.
This brief period allows for the complete dissipation of any residual disturbances induced by ·the agitator when
creating the homogeneous suspension prior to every test run.
i.e. 7.61xl04~<8.47xlO, 0.17<R<2.12, 20 0 <6<60 0 and 1.13< ~ 3.42.
R. = 0(1)
145
N-K equation should, in principle, be adequate for the design
of both batch and continuous separators. It must, however, be
stressed that this assessment is based on the results of experi-
ments using non-flocculated suspension. Before any generalisa-
tion can be made the predictive capability of the N-K equation
will also have to be tested on flocculated suspensions.
146
6.2 BEHAVIOUR OF SLUDGE FLOW ALONG THE LOWER INCLINED SURFACE
6.2.1 Mechanisms of Sludge Flow
i) Layer Movement
* see overleaf
147
In the present analysis the initial sludge layer thickness is
expressed in terms of the number of particle diameters via Co - the
initial concentration of the suspension that is used to create the
sludge layer. For the two sizes of solids used in the experiments
the estimated thicknesses of the initial sludge layer at various
concentrations (co) are tabulated below:
0.1 1 (monolayer)
0.2 1-2
0.3 2-3 Monolayer
0.4 3-4
0.5 4-5
1.0 8-9 2~3
. t-·t,.t ~. ~~t
t~ j-t.:
r
. t·,t i.oS
1'; ",t ~.
I,
t
f/l' . . 1·" 't
' •...t ,t
!..J Nr 't~. tf.~ t f
,"t
,\" K .. ,~t....
"~I t
:' 1 l, i~~t
'
"f"H.tt \ •
\
., ~.. ~..,
~.
t
,..(1
,t··.. i ...t .t
nt
t t
1 t, .-t.i ~ t
l
'.. t
... J
...... t,
t ...'"
~
,~
t \ 1 ' . . ,t
.. ,t ...
.
...... .J_
1'\3IA NV1·d
..--.......... .......
~.~--~-------- ~,
ii) Heap Movement
Hence, from a design point of ,view, there are those three possi-
ble flow conditions to consider when sizing a lamella separator
as they will give different rates of sludge discharge. However,
for most practical applications the predominant mode of transport
150
TABLE 6.3: SLUDGE FLOW BEHAVIOUR OF THE DIFFERENT FULLY DISPERSED SYSTEMS
Dispersed System Size Range Sequence of Intermittent Sludge Layer Movements (with Progressive Incr'!ase in a)
of Solids Initial Concentration of Suspension, Cn, from which the Sludge Layer is Formed
Liquid Solids (\lm) 0.1% v/v 0.2% v/v 0.3% v/v 0.4% v/v 0.5% v/v 1.0% v/v 1.5% v/v I
Water Glass 355-420 Bulk Heap Movement-+!3ulk Hovement Layer Hovement-+!3ulk Movement
beads Movement
Water Gl ass. 90-125 Heap + Bulk Layer + Heap + Bulk
beads Hovement Hovement Movement Movement Movement
Water Bronze 90-125 HealBulk Localised HeaprBulk Layer + Heap + Bulk
spheres Move-Hove- Layer Move-~love-
->0 Movement Movement I~ovement
ment ment Movement ment ment
Water Powde- 90-125 Heap Move~nt Localised + Heap Layer + Heap
red Layer Movement Hovement Hovement
glass Movement
Water Zi rcon 90-125 Localised Heap Layer Movement + Heap Movement
Layer ......
Hovement Hovement
Water Lime- 90-125 Loca 1i sed Heap Layer Hovement + Heap Movement
stone Layer -+- Movement
Movement
Reofos 65/ Glass 90-125 Heap Movement + Bulk Movement Layer + Heap + Bulk
Reomol DBP beads Movement Movement Movement
will approximate to layer movement, since the sludge layer is usually
of the order of a few particle diameters in thickness. It is there-
fore believed that for the general purpose of design, a mathematical
model based purely on layer movement should be adequate. This is
substantiated by the fact that in all the experiments where layer
movement prevails, the latter alone accounts for the removal of
about 80-90% of the total sludge layer from the inclined surface.
The subsequent heap and (or) bulk movements •. as indicated in Table
6.3, play only a secondary role in removing the remaining quantity
of sludge. A further justification is provided by the fact that
when matching the batch flow behaviour with the continuous one,
the latter actually approximates to layer movement.
Some relevant parameters for the layer movement have also been
identified to provide the basis for a mathematical model. They
will be discussed in the next section.
152
TABLE 6.4: EFFECT OF SIZE OF SOLIDS ON THE LAYER MOVEMENT
As can be seen, at any given concentration co' the angle at which the
layer movement occurs is evidently lower for the smaller size range.
The reason being that in the latter case there are more overlying
layers of solids present at the same concentration to provide a
stronger impetus for layer movement to occur - see illustrations
below. The whole transport phenomenon resembles a layered chunk
of solids sliding over a thin and almost stationary bottom layer.
Di recti on of
sludge flow
153
Direction of
sludge flow
154
TABLE 6.5: EFFECT OF SOLIDS DENSITY ON THE REQUIRED ANGLE OF
INCLINATION FOR LAYER MOVEMENT
0.5 22 0 17.50
1.0 19 0 17.00
1.5 18.50 ]7 .0 0
155
Initial sludge layer Initial sludge layer
of bronze spheres of gl ass beads
(relatively more (relatively loose)
compact)
156
TABLE 6.6: EFFECT OF LIQUID VISCOSITY ON LAYER MOVEMENT
The required angles of inclination for layer movement using the more
viscous plasticisers mixture are consistently 5-6 degrees higher than
that using d.istilled water. Moreover, the rate of sludge discharge
along the lower inclined surface is observed to be very much slower
in the former case. Unfortunately, no attempt has been made to
measure the actual sludge discharge rate because of time constraint.
Nevertheless the significance of liquid viscosity has been demonstra-
ted.
Furthermore, it is shown by the results in the table that layer
movement appears to be little affected by changes in concentration
(i.e. 0.5-1.5% v/v). This is because any effective increase in the
gravitational acceleration to the sludge layer is counterbalanced
by a corresponding increase in its effective viscosity.
157
6.2.2.4 Shape and Surface Texture of Solids
158
FIGURE 6.10: EFFECT OF SHAPE AND SURFACE TEXTURE OF SLUDGE
SOLIDS ON THE LAYER MOVE~'ENT
35
25
20
15
la
T
o 0.5 1.0 1.5
Initial concentration of sysrension used to create
the sludge layer:,: Co (% v/v)
159
6.3 OPERATING PERFORMANCE OF CONTINUOUS LAMELLA SEPARATOR:
THEORETICAL AND PRACTICAL ASPECTS
6.3.1 Introduction
160
In order to verify the above supposition and also as a step
towards developing an improved procedure for the lamella separator
design, all the present experiments are conducted under controlled
conditions* to suppress the potential causes of discrepancy due to
(I) and (11). In fact, it will be shown in the next section that
under these controlled operating conditions the general level of
agreement between theory and experiments is indeed significantly
much higher than that obtained by previous workers. Where devia-
tions from theory exist in the present analysis, the causes of
discrepancy can now be safely attributed mainly to flow instability
and mixing problems. Photographic evidence is available to sub- .
stantiate this claim.
162
TABLE 6.7: ACCURACY OF THE NAKAMURA-KURODA EQUATION IN PREDICTING
THE MAXIMUM OVERFLOW RATE (Qo) AT Co = 0.5% v/v FOR THE
DIFFERENT MODES OF OPERATION
Channel spacing, b = 3.4 cm
Channel width, W= 4 cm
163
ii) However, substantial deviations from the predicted overflow
rates arise when using the longer channel lengths of 95 cm
and 112 cm. Under these circumstances, the Nakamura-Kuroda equa-
tion is shown to overpredict the maximum overflow rates. Never-
theless, it should be stressed that the level of agreement is
still generally much greater than 80%, and hence the N-K equa-
tion is still adequately applicable.
164
i) an unfavourable velocity field at the vicinity of the clear
liquid/suspension interface which drags part of the suspension
layer along the direction of the clear liquid stream (Figure
6.11a). Reference is made to Section 4.2.3 for a detailed
account on this effect, and
165
FIGURE 6.11{a): RE-ENTRAINMENT OF PARTICLES INTO THE CLEAR LIQUID
LAYER DUE TO UNFAVOURABLE VELOCITY PROFILE
(coUNTERCURRENT fLOW)
--,.
-----.---+ -----~
---. ---.."
,~
---
.-- ---""
I ,
I
' """
166
·,'.~ ,:~
,. .:
'(
, I
..... _-
FIGURE 6.12(a): FORMATION OF ~INTERFACIAL WAVE" DUE TO FLOW INSTABILITY
jCOCURRENT-SUPERCRITICAL MODE)
167
•
(Qo)experimental
Inel ination Channel Aspect (Qo)theoretical
Angle Length Ratio
e (0) (em) of
Separator .L.oeurrent- L.oeurrent- counter-
Supercritica1 Subcritical current
169
flow instability and mixing. A similar conclusion has recently
been obtained by Leung 34 , based on a semi-empirical linear stability
analysis.
i) the predi ct,,,,, capabi 1i ty of the Nakamura and Kuroda equati on,
and
TABLE 6.9: ACCURACY OF THE NAKAMURA~KURODA·EOUATION IN PREDICTING
THE MAXIMUM OVERFLOW· RATE (00) FOR COUNTERCURRENT FLOW
WITH CHANNEL SPACINGS OF 1.5 cm AND 3.4 cm AT Co = ~% v/v
Channel width, W= 4 cm
(Oo)experimental
Inclination Channel Aspect
Ratio (Oo)theoretical
Ang6e Length of
a ( ) (cm) • Separator b = 3.4.
, cm. .b ".1.5 cm
171
TABLE 6.10: ACCURACY OF THE NAKAMURA-KURODA EQUATION IN PREDICTING
THE MAXIMUM OVERFLOW RATE (Qo) FOR COUNTERUCRRENT FLOW
WITH CHANNEL SPACINGS OF 1.5 cm AND 3.4 cm AT Co = 2% v/v
Channel width, W= 4 cm
,.
172
ii) the causes of deviation, from theory, of the actual achievable
maximum overflow rates under different operating conditions.
173
Maximum overflow rate (Q )
o
® CD
.: ..
Region I
Regi on II
Regi on I II
175
FIGURE 6.13: EFFECT OF SEPARATOR ASPECT RATIO ON THE ACTUAL MAXn·;UM
OVERFLOW RATE FOR THE COUNTERCURRENT FLOW WITH
Co = 0.5% v/v, b = 3.4 cm AND e = 200 -600
Inclination angle (eo)
60°
o 45°
x 30°
o 20°
600
5 10 15 20 25 30 35
Aspect ratio of separator (h/b)
176
FIGURE 6.14: EFFECT OF SEPARATOR ASPECT RATIO ON THE ACTUAL MAXIMUM
OVERFLOW RATE FOR THE COCURRENT-SUBCRITICAL MODE WITH
Co = 0.5% v/v, b = 3.4 cm AND e = 20 0-60 0
Inclination angle (e)
60°
45°
x 30°
o 20°
o 5 10 15 20 30 35
177
FIGURE 6.15: EFFECT OF SEPARATOR ASPECT RATIO ON THE ACTUAL MAXIMUM
OVERFLOW RATE'FOR THE COCURRENT-SUPERCRITICAL MODE WITH
c,0 = 0.5% v/v, b'='3.4'cm AND e = 20 0 -60 0
inclination'angle (e)
60 0
o 45°
)( 30°
o 20°
600
500
400
300
o
200 o
100 '
5 10 15 20 25 o
Aspect Ratio of Separator (h/b)
178
FIGURE 6.16: EFFECT OF SEPARATOR ASPECT RATIO ON THE ACTUAL MAXIMUM':
OVERFLOW RATE FOR THE COUNTERCURRENT FLOW WITH
Co = 2% v/v, b = 3.4 cm AND 8 = 20 0-600
Inclination·angle (8)
600
500
400
300 c
200
100
o 5 10 15 20 25 30 35
Aspect Ratio of Separator (h/b)
179
FIG:URE 6.17: EFFECT OF SEPARATOR ASPECT RATIO ON THE ACTUAL MAXrr·1UM
OVERFLOW RATE FORTHECOCURRENT-SUBCRITICAL MODE WITH
Co = 2% v/v, b = 3.4 cm AND 6 =20 0-600
o
x
600
500
5 10 15 20 25 30 35
Aspect Ratio of Separator (h/b)
180
FIGURE 6.18: EFFECT OF SEPARATOR ASPECT RATIO ON THE ACTUAL MAXIMUM
OVERFLOlf RATE FOR THE COCURRENT -SUPERCRITICAL MODE WITH
Co = 2% v/v, b = 3.4 cm AND 8 = 20 0-60 0
c
x
o
600
500
400
o
300
200 o
100
o ~----~----~----~------~----~----~----~
o 5 10 15 20 25 30 35
Aspect Ratio of Separator (h/b)
181
Co (% v/v) (h/b)UL
0.5 25-30
2.0 15-22.5
182
6.3.3 Sludge Thickening Performance
183
solids concentration, c u' in the underf10w stream. The influence
of different flow patterns are also investigated based on the
countercurrent flow and the cocurrent subcritica1 and supercriti-
ca1 modes. For details of the experimental procedure, reference
is made to Section 5.2.3.3.
184
FIGURE 6.19: EFFECT OF INCLINATION ANGLE ON THE CONSISTENCY OF THE
SOLIDS cOiICENTRATlON IN TRE UNDERFlOW STREAII FOR COUNTERCURRENT
nor! ImH THE INITIAL FEED CONCENTRATION. Co ~ 0.5% v/v
Inclination angle
-Svr.1bol
- et e Separator dimensions:
a 70° 20°
L ~ 56 cm; b ~ 3.4 e[.1;
0 60° 30°
\I ~ 4 cr.1
x 45° 45°
~ 30° 60°
0
0 20° 70
3.0
2.5
2.0
1.5
1.0
0.5
O~~~~~ __L--L__L--L__L--L__L--L__ ~~
185
FIGURE 6.20: EFFECT OF INCLINATlO1i ANGLE ON THE COr~SISTENCY OF THE
SOLI9S CONCENTRATION IN THE UNDERFLo\j STREAM FO~ THE
COCURRENT--SUBCRITICAL MODE WITH THE INITIAL FEED CONCEN-
TRATION, Co 0.5% v/v
)( 45° 45°
30° 30°
•
•Solids cone. (% v/v) in underflol1 stream, e
u
3.5
3.0
2.5
OL-~~~~__~~~~~~~~~~~~
o
20 40 50 30 100 120 140 150 180 200 200
Operating Time (mins)
186
FIGURE 6.21: EFFECT OF INCLINATION ANGLE ON THE CONSISTENCY OF THE
SOLIDS COt~CEIHRATloN IN THE UtlDERFLOW STREAM FOR THE
COCURRENT-SUPERCRITICAL MODE WITH TRE INITIAL FEED CONCEN-
TRATIO~, Co = 5% v/v
0 50 0 ".~Oo L 66 cm;
= b = 3.4 cm;
45 0 W = 4 cm
)(
45 0
30 0 60 0
•
Solids conc. (% v/v) in underf1o~1 strear.1, Cu
.. 3.5
3.0
2.5
2.0
1.5
1.0
05
OL-~~--J-~ __~~__~~__~-L__L-~~.
o 20 40 60 80 100 120 140 160 180 200 220 240 260
Operating Time (r.1ins)
137
FIGURE 6.22: EFFECT OF INCLINATION ANGLE ON THE AVERAGE "STEADY-STATE" ..
SOLIDS CONCENTRATION IN THE UNDERFLOW STREAM FOR THE
DIFFERENT FLOW pATTERNS HITH Co - 3.5% v/v
Separator dimensions:
o Cocurrent-su~ercritical mode
Cocurrent-subcritical mode
o Countercurrent flow
2.5
2.0
1.5
1.0
0.5
188
whi ch the sludge layer accumulates suffi cient gravi tati ona 1
mass to overcome the additional viscous resistance imposed
by the countercurrent stream. The cocurrent flow, on the
other hand, by virtue of its sameness of flow direction
actually reinforces the sludge transport, thus producing
a smoother discharge. This explains the greater consis-
tency in cu'
From the present results, the use of a countercurrent flow
is therefore to be avoided in situations where a high consis-
tency in cu is demanded. For such a requirement, either the
cocurrent subcritical or supercritical mode should be used
instead. However, the overriding "consideration for the
choice between the two is the actual achievable solids con-
centration, cu ' in the underflow stream. This will be the
next subject of discussion.
bi} That between the inclination angles (a) of 30 0 and 550 *, the
supercritical mode gives considerably higher average 'steady-
state' underflow concentrations than the other two operating
modes. Moreover, its concentration versus a curve, as shown
in Figure 6.22, passes through a maximum at an approximate
optimum inclination angle of 45 0 - the existence of which has
been predicted during the earlier discussion. The ability to
achieve underflow concentration at a lower inclination angle
is another proof that the supercritical mode is a more superior
189
design for lamella separators.
Underf10w concentration, C
u (% v/v)
190
The initial increase in u along A, up to the optimum point,
C
Finally, the upturn along C occurs because all the solids now
have sufficient gravitational acceleration to move spontaneously.
It is believed that at this stage the mechanism of sludge flow has
reverted from layer movement to the bulk movement (refer Section
6.2.1).
191
shows a consistent increase with increasing inclination angle.
It appears that the additional resistance to sludge flow, provi-
ded by the feed stream, has 'ironed' out the occurrence of
optimum conditions created by the varying degree of layer move-
ment at different inclination angles and which characterise the
subcritica1 and supercritical modes of operation. Because of
the additional resistance to flow and its lower solids handling
capacity, the countercurrent flow operation - between the incli-
nation angles (a) of 30 and 55 degrees - is shown to produce
much lower underflow concentrations than the supercritica1 mode.
For example, to achieve the same maximum Cu obtained with the
supercritical mode at 45 0 , the countercurrent flow will have to
be operated at approximately 70 degrees. This means a reduction
to the total projected settling area of about 50% - once again
indicating the vast potential improvement that can be made to the
current commercial design using the supercritical mode.
192
FIGURE 6.23: EFFECT OF INCLINATION ANGLE ON THE CONSISTENCY OF THE SOLIDS
CONCENTRATION IN THE DNDERFLOW sTREAf1 FOR COON1 ER CURRENT FLOW
WITH THE INITIAL FEED CONCENTRATION, Co - 2.0% v/v
Separator dimensions:
.
L = 66 cm; b = 3.4 cm; H = 4 cm
7.0
6.0
Symbol Inclination Angle
" e
5.0 A 70 0 20 0
c 60 0 30 0
4.0 x 45 0 45 0
0
30 0 30 0
3.0
2.0
1.0
o 20 40 60 80 100 120
Operating Time (mins)
193
FIGURE 6.24: EFFECT OF INCLINATION ANGLE ON THE CONSISTENCY OF THE
"SOLIDS CONCENTRATION IN TRE UNDERFLOH STREAM FOR THE
COCURRENT -SUBCRITICAL tlODE UITH THE INITIAL FEED CONCEN-
TRATION, Co - 2.0% v/v
Separator dimensions:
L = 66 cm; b = 3.4 cm; W= 4 cm
x 45 0 45 0
3 0 30 0 60 0
1.
o
o 20 40 60 SO 100 120
Operating Time (mins)
194
FIGURE 6.25: EFFECT OF INCLINATION ANGLE ON THE CONSISTENCY OF SOLIDS
CONCENTRATION IN THE UNDERFLOVl STREAf1 FOR THE COCURRENT-
SUPERCRITICAL flODE HITH THE INITIAL FEED CONCENIRATIoN,
= 2% v/v
c0--';":""';-
Separator dimensions:
.11
6
Symbol Inclination Angle
e
"
5 Il. 70° 20 0
0 60° 300
4 X 45° 45°
0 30° 300
o o
o 20 40 60
Operating Time (mins)
195
FIGURE 6.26: EFFECT OF INCLINATION ANGLE ON THE AVERAGE "STEADY-STATE"
SOLIDS CDrICENTRATION IN THE UNDERFLO\~ STREAr! FOR THE DIFFERENT
FLOIj PATTERNS WITH Co = 2% v/v
Separator dimensions:
8.5
8.0
7.5
7.0
"6.
Cocurrent-subcritica1 mode
5.5
5.0
ot 20 0 30°
I
40°
I I
500
I
60 0 70°
I I
80° (,,0)
196
operation. The reason being that at such a high feed concen-
tration, the effective increase in the solids loading to the
separator, results in the sludge movement becoming predominantly
gravity controlled. As such the influence of different flow
patterns on the sludge transport becomes masked by the gravita-
tional effects on the layer movement. For the same reason, the
concentration profiles (Figure 6.26) merely shows an upward
• trend without exhibiting any maximum or minimum turning points.
Interesti ng1y, the countercurrent fl ow once agai n see",,,, to
produce generally higher average "steady-state" underflow con-
centrations than both the subcritica1 and supercritica1 modes.
Unfortunately no satisfactory explanation has been found to
account for this result.
197
CHAPTER 7
CONCLUSIONS
198
7.2 For inclined sedimentation in a high aspect ratio separator,
i.e. h/b =0(10 2 ), the essential steady-state conditions are
not .inherently attainable. There may be constraints on the
dimensions and design of the separator that need to be
satisfied before steady-state can be achieved.
As aO design guideline, the following constraint on the
channel spacing for the lamella separator can be used:
192 tanS . V0 \l X
i . e.
199
concentration of 0.5 percent solids by volume, such an
optimum inclination angle (approximately 45°) exists for
both the cocurrent subcritical and supercritical modes of
operation. However, the actual maximum underflow concen-
tration that is achieved with the latter is greater by
about 35 percent, hence sho~ling itself as being of a
superior design •
•
Co (% v/v) (h/b)UL
0.5 25-30
2.0 15-22.5
200
7.6 The Nakamura and Kuroda equation is shown to be capable
of predicting very accurately the maximum overflow rate
of a lamella separator. This is on the precondition that
201
CHAPTER 8
RECOMMENDATIONS FOR FURTHER WORK
8.1 All the solid-liquid systems that have been used in the
experiments in this thesis are fully dispersed in nature.
Hence, the various design guidelines that have been derived
from the present research findings are strictly applicable
only to such systems. It is suggested, therefore, that
alongside the proposed further experiments using the fully
dispersed systems. similar analyses be made on 'real' suspen-
sions. The latter will include f10ccu1ated suspensions and
sludges of deformable particles.
Only then, perhaps, can more general guidelines be established.
202
optimum separator aspect ratio which will contribute towards
the development of an optimisation procedure for the lamella
separator design.
203
APPENDICES
Page No.
204
Page No.
Tables A.37-A.44
Maximum overflow rates for the different
modes of operation 249
205 .
APPENDIX A.1
Details of suspension
Glass beads:
Size range = 90-125 ~m (spherical)
Particle density = 2460 kgm- 3
Suspension liquid:
*Reofos 65 (25.5% v/v) and Reomo1 DBP (74.5% v/v)
Liquid density @ 25 0 C = 1079.5 kgm- 3
Liquid viscosity @ 25 0 C = (22.2528 x 10- 3 ) Nsm- 2
Verti ca1 batch sett1 ing velocity of suspensi on:
* Manufacturer: Ciba-Geigy.
206
A.l.2 Experimental Verification of Inclined Sedimentation ~'odels
by Acrlvos and Rerbolzhelmer
A.l.2.1 Low aspect ratio case
The theoretical predictions for the steady-state thickness of
the clear liquid layer that is formed beneath the upper inclined sur-
face and the velocity field in the clear liquid layer itself have
been verified experimentally. The respective predictive equations
are given below:
_3_Xrt_a_n_e_v...;o::..,-ll )y.,
oD = ( ~ and
g (p p - p) Co
_ y2/2}
207
A.l.2.2 High Aspect Ratio Case
b3 g (p - p) c
p 0
192 tane Vo 11
i.e.
208
A.1.3 Experimental Verification of Inclined Sedimentation Model
oy Nakamura and Kuroda
= v (1 + h Sina) b
o b Cos a
209
------
--=- = .=-..=-
~
+ + + +
dh
____Jt
at
Wid h
, ------
Area of clear
liquid layer, A
t Settling time, t
A = Vertical area of clear
liquid layer at time t
212
TABLE A.2
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
213
TABLE A.3
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
215
TABLE A.5
216
TABLE A.6
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
fLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
Aspect Ratio, ho/b : 3.42
e : 20 0
c : 1% v/v
0
11
0
: 6.97 x 10 5
Ro : 2.12
217
TABLE A.7
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
Aspect Ratio, ho/b : 3.42
a 20 0
5% v/v
5.32 x 10 6
1.39
Position along Predicted thick- Measured thi ck- Predi cted thi ckness
upper incl ined ness of clear ness of clear ~leasured thl ckness
surface, x(cm) liquid layer, liquid layer,
50 (mm) (5 D)m' mm
218
TABLE A.8
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
Aspect Ratio, ho/b 3.42
e 20 0
Co : 10% v/v
Ao : 1.20 x 10 7
Ro : 1.23 ...
Position along Predicted thick- Measured thick- Predi cted thi ckness
upper inclined ness of clear ness of clear Measured thlckness
surface, x(cm) liquid layer liquid layer,
0D (mm) (oD)m' mm
1 0.30 - -
2 0.38 0.43 0.88
3 0.43 0.49 0.88
4 0.47 0.51 0.92
5 0.51 0.54 0.94
6 0.54 0.54 1.00
7 0.57 0.59 0.97
8 0.60 0.59 1.02
9 0.62 0.65 0.95
10 0.64 0.70 0.91
11 0.66 0.76 0.87
12 0.68 0.81 0.84
13 0.70 0.86 0.81
14 0.72 0.97 0.74
15 0.74 . 1.03 0.72
16 0.75 1.03 0.73
219
TABLE A.9
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
~LEAR LIQUID LAYER THICKNESS
Lo\~ Aspect Rati 0 Case
Aspect Ratio, ho/b 3.42
a 20 0
Co 20% v/v
Ao 3.59 x 107
Ro 0.82
Position along Predi cted thi ck- Measured thi ck- Predicted thickness
upper inclined ness of clear ness of clear Measured thl ckness
surface, x(cm) liquid layer, liquid layer,
0D (mm) (oD)m' mm
1 0.21 - -
2 0.26 0.32 0.81
3 0.30 ·0.36 0.83
4 0.33 0.40 0.83
5 0.35 0.43 0.81
6 0.38 0.46 0.83
7 0.40 0.47 0.85
8 0.41 0.48 0.85
9 0.43 0.50 0.86
10 0.45 0.51 0.88
11 0.46 0.53 0.90
12 0.47 0.54 0.87
13 0.49 0.56 0.88
14 0.50 0.59 0.85
15 0.51 0.62 0.82
16 0.52 0.65 0.80
17 0.53 0.67 0.79
220
TABLE A.10
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
1 0.16 - -
2 0.20 - -
3 0.22 - -
4 0.25 - -
5 0.27 - -
6 0.28 0.23 1.22
7 0.30 0.27 loll
8 0.31 0.31 1.00
9 0.32 0.35 0.91
10 0.34 0.38 0.90
11 0.35 0.40 0.88
12 0.36 0.41 0.88
13 0.37 0.43 0.86
14 0.38 0.45 0.84
15 0.38 0.48 0.79
16 0.39 0.48 0.81
17 0.40 0.51 0.78
221
TABLE A.11
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
1 0.90 - -
2 1.13 - -
3 1.30 1.83 0.71
4 1.43 1.89 0.76
5 1.54 2.01 0.77
6 1.63 2.07 0.79
7 1. 72 2.13 0.81
8 1.80 2.20 0.82
9 1.87 2.26 0.83
10 1.94 2.32 0.84
11 2.00 2.43 0.82
12 2.06 2.44 0.84
13 2.11 2.44 0.87
14 2.17 2.49 0.87
15 - 2.22 2.49 0.89
16 2.27 2.56 0.89
17 2.31 2.56 0.90
222
TABLE A.12
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
Aspect Ratio, ho/b 3.42
e : 300
5% v/V
: 5.32 x 10 6
1.39
.
Pos iti on along Predicted thick- r1easured thi ck- Predicted thickness
upper inclined ness of clear ness of clear Measured thl ckness
surface, x(cm) liquid layer, 1iquid layer,
oD (mm) (oD)m' mm
1 0.46 - -
2 0.58 - -
3 0.66 0.68 0.97
4 0.72 0.81 0.89
5 0.78 0.87 0.90
6 0.83 0.93 0.89
7 0.87 0.99 0.88
8 0.91 1.09 0.84
9 0.95 1.12 0.85
10 0.98 1.18 0.83
11 1.01 1.18 0.86
12 1.05 1.22 0.86
13 1.07 1.24 0.86
14 1.10 1.26 0.87
15 1.13· 1.28 0.88
16 1.15 1.30 0.89
17 1.17 1.33 0.88
18 1.20 1.35 0.89
??1
TABLE A.13
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
Aspect Ratio, ho/b 3.42
a 30 0
c 10% v/v
0
1\0 1.20 x 10 7
Ro 1. 23
Position along Predi cted tili ck- Measured thick- Predicted thickness
upper inclined ness of clear ness of clear Measured thlckness ,
surface, x(cm) liquid layer, liquid layer,
oD (mm) (oD)m' mm
1 0.35 - -
2 0.44 - -
3 0.50 0.55 0.91
4 0.56 0.57 0.95
5 0.60 0.63 0.95
6 0.63 0.68 0.93
7 0.67 0.73 0.92
8 0.70 0.77 0.91
9 0.72 0.77 0.94
10 0.75 0.79 0.95
11 0.77 0.82 0.94
12 0.80 0.82 0.98
13 0.82 0.84 0.98
14 0.84 0.86 0.98
15 0.86 0.90 0.96
16 0.88 0.93 0.95
17 0.89 1.05 0.85
18 0.91 1.11 0.82
224
TABLE A.14
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
Aspect Ratio, h/b 3.42
e : 30 0
c' 30% v/V
0
3.59 X 10 7
.. 110
Ro 0.82
225
TABLE A.15
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
Low Aspect Ratio Case
Aspect Ra ti 0, ho/b 3.42
e 30 0
Co 30% v/V
Ao 8.47 x 10 7
.-. Ro 0.52
1 0.18 - -
2 0.23 - -
3 0.26 - -
4 0.29 - -
5 0.31 - -
6 0.33 - -
7 0.35 - -
8 0.36 0.32 1.13
9 0.38 0.34 1.12
10 0.39 0.34 1.15
11 0.40 0.39 1.03
12 0.42 0.42 1.00
13 0.43 0.46 0.94
14 0.44 0.48 0.92
15 0.45 0.51 0.88
16 0.46 0.51 0.90
17 0.47 0.54 0.87
18 0.48 0.54 0.89
226
TABLE A.16
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio, ho/b : 1.80
e : 45 0
c 1% v/v
0
Ao : 1.93xlOs
Ro 1.13
ILocation of measurement
}Osrtlor ~OSltl on Predi cted Predicted Measured Predicted velocity
along in clear thickness velocity velocity Measured ve loci ty
upper 1iqui d of clear at (x,y) at (x,y) , . .
incline( layer liquid
surface, normal layer at
x (cm) to x X,8 (I11I11) mm S-1 mm s-l
y (mm) D
227
TABLE A.17
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio, h/b 1.80
e 45 0
c 2~% v/v
0
Ao 6.07 X 105
Ro .• 0.89
Location of measurement
Posltlon Position Predi cted Predicted Measured Predicted velocity
along in clear thickness veloci ty velocity Measured velocity
upper 1iqui d of clear at (x ,y) at (x,y)·
inclined layer liquid
surface, normal layer at
x (cm) to x x,oD(mm) mm s-1 mm S-1
y (mm)
228
TABLE A.1B
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Location of measurement
Positi on Position Predicted Predi cted Measured Predicted velocitl
along in clear thi ckness velocity velocity Measured velocity
upper 1iqui d of clear at (x,y) at (x,y)
inclined layer 1iqui d
surface, normal layer at
x (cm) to x x,oD(mm) mm 5- 1 mm S-1
y (mm)
229
TABLE A.19
EXPERII-1ENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio, ho/b : 3.42
e: 200
Co : 1% v/v
Ao •• 6.97 x 10 5
Ro .• 2.12 . .
Location of measurement
P051tlon 1'OS1 t1 on Predicted Predicted Measured Predicted velocitl
along in clear thi ckness velocity velocity Measured velocity
upper 1iquid of clear at (x,y) at (x,y)
inclined layer 1i qui d
surface, normal layer at
x (cm) to x x'''D(mm) mm S-l mm S-l
y (mm)
?,"
TABLE A.20
EXPERH1ENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Location of measurement
Position Position Predicted Predicted Measured Predicted velocity
along in clear thickness velocity velocity Measured veloclty
upper 1i qui d of clear at (x,y) at (x,y)
incl ined layer liquid
surface, normal layer at
x (cm) to x x,oD(mm) mm S-l mm S-l
y (mm)
231
TABLE A.21
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio, h/b . 3.42
9 20 0
Co 5% v/v
Ao 5.32 x 10 6
Ro 1.39
Location of measurement
Positi on Position Predicted Predi cted Measured Predicted velocit~
along in clear thickness velocity velocity Measured veloclty
upper liquid of clear at (x,y) at (x,y)
inclined layer li qui d
surface, normal layer at
x (cm) to x x,oD(mm) mm S-l mm S-l
y (mm)
232
TABLE A.22
EXPERmENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Co 1% v/v
Ao 6.97 x 10 5
Ro 2.12
233
TABLE A.23
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio, ho/b : 3.42
e : 300
c o .• 2~% v/v
Ao 2.19xl0 6
Ro : 1.68
Location of measurement
Position Position Predicted Predicted r,leasured Predicted velocitr
along in clear thickness velocity velocity Measured veloclty
upper 1i qui d of clear at (x,y) at (x,y)
inc1 ined layer liquid
surface, normal layer at
x (cm) to x x,oD(mm) mm s-l mm 5- 1
y (mm)
4 0.5 ,
0.97 4.77 5.19 0.92
234
TABLE A.24
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio, ho/b .. 3.42
e : 300
Co : 5% v/v
Ao 5.32 x 10 6
•R
o
: 1.39
Location of measurement
Position Position Predicted Predicted Measured Predicted ve10citl
along in clear thickness velocity velocity Measured ve 1oei ty
upper liquid of clear at (x,y) at (x,y)
inclined layer liquid
surface, normal layer at
x (cm) to x, x,oo(mm) mm s-l mm s-l
y (mm)
235
TABLE A.25
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio. ho/b : 3.78
.e : 20 0
Co : 1% v/v
Ao : 8.52 x 10 5
Ro .• 2.34
Location of measurement
Position Position Predicted Predicted Measured Predicted velocity
along in clear thickness velocity velocity Measured velocity
upper liquid of clear at (x,y) at (x.y)
inclined layer liquid
surface, normal layer at
x (cm) to x. x.oD(mm) mm 5- 1 mm 5- 1
y (mm)
236
TABLE A.26
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio, ho/b 3.78
e 20 0
2~% v/v
2.67 x 106
1.86
Location of measurement
Position Positi on Predicted Predicted Measured Predicted velocity
along in clear thickness velocity velocity Measured ve locl ty
upper liquid of clear at (x,y) at (x,y)
inclined layer 1i qui d
surface, normal layer at
x (cm) to x, x,oD(mm) mm s-l mm 5- 1
y (mm)
237
TABLE A.27
EXPERIMENTAL VERIFICATION OF PREDICTED
VELOCITY FIELD IN THE CLEAR LIQUID LAYER
Low Aspect Ratio Case
Aspect Ratio, h/b 3.78
e 20 0
Co 5% v/v
Ao 6.50 x 10 6
Ro •. 1.53
Location of measurement
Position Position Predicted Predicted Measured Predicted velocity
along in clear thickness velocity velocity l1easured velocity
upper 1i qui d of clear at (x,y) at (x,y)
inclined layer 1i qui d
surface, normal layer at
x (cm) to x, x,oD(mm) mm s-l mm S-l
y (mm)
238
TABLE A.28
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
High Aspect Ratio Case
239
TABLE A.29
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
High Aspect Ratio Case
240
I~
TABLE A. 30
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
High Aspect Ratio Case
241
TABLE A.31
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
High Aspect Ratio Case
242
TABLE A.32
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
High Aspect Ratio Case
Aspect Ra ti 0, h/b 64
e 45 0
Ci
0
.. 5% v/v
110 1 X 10 8
Ro 6.01
Position along Predicted thick- Measured thi ck- Predi cted thi ckness
upper inclined ness of clear ness of clear Measured thickness
surface, x( cm) liquid layer, liquid layer,
oD (mm) (oD)m' mm
243
TABLE A.33
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
High Aspect Ratio Case
40 1.67 - -
50 1.83 1.48 1.23
55 1.90 1.62 1.18
60 1.97 1.80 1.10
65 2.03 2.00 1.01
70 2.10 2.20 0.96
75 2.17 2.40 0.90
80 2.23 2.53 0.88
85 2.29 . 2.83 0.83
244
TABLE A.34
EXPERIMENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER·THICKNESS
High Aspect Ratio Case
245
TABLE A.35
EXPERH1ENTAL VERIFICATION OF PREDICTED STEADY-STATE
CLEAR LIQUID LAYER THICKNESS
High Aspect Ratio Case
246
TABLE A.36 .
Ro 8.57
247
APPENDIX A.2
Glass beads:
Size range = 90-125 ~m (spherical) ,.- ...
Suspension" liqUid:
Reofos 65 (25.5% v/v) &Reomol DBP (74.5% v/v)
Liquid density @ 25°C = 1079.5 kg m- 3
Liquid viscosity @ 25 0 C = (22.2528 x 10- 3 ) Ns m- 2
0.005 0.0287
0.02 0.0243
248
A.2.2 Maximum handling capacity for the pure clear liquid overflow*
TABLE A.37
Maximum Overflow Rate for Countercurrent Flow
Feed concentration, Co = 0.5% v/v
Number of settling channels = 1
Channel spacing, b = 3.4 cm
Channel width, W = 4 cm
Inclination Channel Aspect A Ro Maximum overflow rate "Efficiency"
0
Angle (eO): Length Ratio of Qo (cc/min) ratio,
measured (cm) Separator
from the (h/b) (Qo)expt
vertical (Qo)expt (Qo) theo t (Qoltheo
.
TABLE A.45
Solids concentration in the underflow (sludge) stream as a
function of the operating time for Countercurrent Flow
Feed concentration, Co = 0.5% v/v
Number of settling channels = 1
Channel length, L = 66 cm
Channel spacing, b = 3.4 cm
Channel width, W = 4 cm
N
......
U1
Inclination Operati ng Temperature t~aximum Underflow Turbidity Concentrati on
Angle Time (0C) Overflow Rate (sludge) Rate level in of solids in
(eO) (mi ns) (Qo)expt. (Qu)expt. the overflow underfl ow, Cu
cc/min* cc/min* (NTU) % v/v
* A constant ratio of 3:1 for the overflow rate to the underflow (sludge) rate is maintained throughout the experiment
TABLE A.46
Solids concentration in the underf10w (sludge) stream as a
function of the operating time for Countercurrent Flow
Feed concentration, Co = 0.5% v/v
Number of settling channels = 1
Channel length, L = 66 cm
Channel spacing, b = 3.4 vm
Channel width, W = 4 cm
30 0 0 24.8 258 84 6
(Background value) 0
20 25.0 258 84 7.0 1.47
30 25.0 258 84 7.2 1.66
45 24.9 258 84 7.2 1.66
65 25.0 258 84 7.3 2.04
90 24.8 258 84 7.0 2.52
120 24.9 258 84 7.0 2.50
135 25.0 258 84 7.2 2.36
150 25.0 258 84 7.0 2.41
165 24.9 258 84 7.0 2.41
TABLE A.49
Solids concentration in the underflow (sludge) stream as a
function of the operating time for Countercurrent Flow
Feed concentration. Co = 0.5% v/v
Number of settling channels = 1
Channel length. L = 66 cm
Channel spacing. b '= 3.4 cm
Channel width, W = 4 cm
Inclination Operating Temperature Maximum Underflow Turbidity Concentration
Angle Time (oC) Overflow Rate (sludge) rate level in of solids in
( eO) (mins) (Qo)expt. (Qu)expt. the overflow underfl ow, Cu
(NTU) % v/v '
cc/min cc/min
6
60 0 0 24.9 430 143.3 (Background value) 0
35 24.9 430 143.3 7.0 1.28
50 25.0 430 143.3 7.0 1.49
80 25.0 430 143.3 7.0 1.57
90 25.0 430 143.3 7.0 1.62
110 25.0 430 143.3 7.0 1.56
130 24.9 430 143.3 7.0 1.60
145 25.0 430 143.3 7.0 1.60
TABLE A.51
Solids concentration in the underflow (sludge) stream as a
function of the operating time for Cocurrent-Subcritical Flow
Feed concentration, c = 0.5% v/v
Number of settling chRnnels = 1
Channel length, L = 66 cm
Channel spacing, b = 3.4 cm
Channel width, W = 4 cm
Inclination Operating Temperature Maximum Underflow Turbidity Concentrati on
Angle Time (0C) Overflow Rate (sludge) rate level in of solids in
N
( eO) (mins) the overflow underflow, Cu
'"
W (Qo)expt. (Qu)expt.
(NTU) % v/v
cc/min cc/min
60 0 24.9 146 6 0
0 440 (Background value)
40 25.0 440 146 7.1 1.60
60 24.B 440 146 7.1 1.57
80 25.0 440 146 7.1 1.57
120 24.9 440 146 7.1 1. 73
140 24.9 440 146 7.1 1.90
160 25.0 440 146 7.1 1.91
180 24.9 440 146 7.0 1.90
195 25.0 440 146 7.0 1.90
TABLE A.55
Solids concentration in the underflow (sludge) stream as a
fUnction of the operating time for Cocurrent-Supercritical Flow
Feed concentration, Co = 0.5% v/v
Number of settling channels = 1
Channel length, L = 66 cm
Channel spacing, b = 3.4 cm
Channel width, W = 4 cm
Inclination Operating Temperature Maximum Underflow Turbi di ty Concentration
Angle Time (OC) Overflow Rate (sludge) rate level in of solids in
(eO) (mins) (Qo)expt. (Qu)expt. the overflow underfl ow, cu
cc/min cc/min (NTU) %v/V
6
20 0 0 25.0 190 62.5 (Background value) 0
50 24.9 190 62.5 7.1 1. 78
70 25.0 190 62.5 7.1 2.02
85 24.8 190 62.5 7.0 2.07
100 24.9 190 62.5 7.0 2.02
120 24.9 190 62.5 7.1 2.22
140 24.9 190 62.5 7.0 2.22
160 24.8 190 62.5 7.0 2.28
175 24.9 190 62.5 7.0 2.25
TABLE A.58
Solids concentration in the underf10w (sludge) stream as a
function of .the operating time for Countercurrent Flow
Feed concentration, Co = 2% v/v
Number of settling channels = 1
Channe 1 1ength, L = 66 cm
Channel spacing, b = 3.4 cm
Channel width, W = 4 cm
45 0 0 25.0 297 99 . 6
(Background value) 0
20 24.8 297 99 7.0 6.40
40 24.9 297 99 7.0 7.45
60 25.0 297 99 7.1 7.40
80 25.0 297 99 7.0 7.75
100 25.0 297 99 7.2 7.80
TABLE A.50
Solids concentration in the underflow (sludge) stream as a
function of the operating time for Countercurrent Flow
Feed concentration, Co = 2% v/v
Number of settling channels = 1
Channel length, L = 66 cm
Channel spacing, b = 3.4 cm
Channel width, W = 4 cm
0
0 25.0 145 48 6 0
20 (Background value)
20 25.0 , 145 48 7.0 7.75
40 24.9 145 48 7.0 7.99
55 24.9 145 48 7.0 8.20
70 25.0 145 48 7.0 8.27
85 24.8 145 48 7.0 8.00
100 25.0 145 48 7.1 8.35
.
TABLE A.62
Solids concentration in the underf10w (sludge) stream as a
function of the operating time for Cocurrent-Subcritica1 Flow
Feed concentration, Co = 2% v/v
Number of settling channels =1
Channel length, L = 66 cm
Channel spacing, b = 3.4 cm
Channel width, W = 4 cm
20 0 0 25.0 150 50 6
(Background value) 0
20 25.0 150 50 7.0 8.01
40 25.0 150 50 7.0 7.88
60 24.9 150 50 7.2 7.79
80 24.9 150 50 7.0 7.91
100 25.0 150 50 7.0 7.88
TABLE A.66
Solids concentration in the underf10w (sludge) stream as a
function of the operating time for Cocurrent-Supercritica1 Flow
Feed concentration, Co = 2% v/v
Number of settling channels = 1
Channe 1 1ength, L = 66 cm
Channel spacing, b = 3.4 cm
Channel width, W = 4 cm
....,
N
Inclination Operating Temperature Maximum Underf10w Turbidity Concentration
co Angle Time (OC) Overflow Rate (sludge) rate, level in of sol ids in
(e ) (mins) (Qo)expt. (Qu)expt. the overflow underf10w, Cu
cc/min cc/min (NTU) %v/v
N
Inclination Opera ting Temperature Maximum Underf10w Turbidity Concentration
...... Angle Time (0C) Overflow Rate (sludge) rate. level in of solids in
'" ( eO) (mins) (Qo)expt. (Qu)expt. the overflow underflow, Cu
cc/min cc/min (NTU) %v/v
N
rncl ination Operating Temperature Maximum Underflow Turbidity Concentration
00
~
Angle Time. (OC) Ove rfl ow ra te , (sludge) rate, 1eve 1 in of solids in
(eO) (mins) (Qo)expt. (Qu) expt. the overflow underflow, C u .
cc/min cc/min (NTU) % v/v
282
Symbo~ Description Dimensions
time T
particle residence time in settling T
channel
T dimensionless time
u longitudinal component of velocity in LT-l
clear liquid layer
u dimensionless longitudinal component of
velocity in clear liquid layer (i.e.
along the direction of the upper
inclined surface)
v vertical settling velocity of particles
in suspension
v dimensionless velocity component in
clear liquid layer normal to the upper
inclined surface
w width of lamella plate L
283
Symbo~ Description Dimensions
Pp density of particles
284
Symbo~ Desaription Dimensions
p(~) effective density of suspension
divided by that of the pure fluid
density difference between the sus-
pension and pure fluid
local particle concentration divided
by that of the initial concentration
of suspension, Co
Subscript
•.
110" denotes initial value
Superscript
denotes stretched variables
285
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