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Hydrofoil Agitator 1
Hydrofoil Agitator 1
G r i f f i t h s
B01ger(~~~)derived a multi-layer floc model from their where d, is the stable floc size,
observed data. Other evidence for multi-level floc C, is the coefficient related to floc strength,
structure is found in the floc density - floc diameter and
relati~nship(~f').However, there appears to be some con- L is the exponent dependent upon the floc
fusion between the researchers as to the exact definition break-up made and size regime of eddies
of some of the levels of the structure. Van de Ven and which can cause disruption.
Hunter(') defined a four-level structure as follows:
To help with the visualization of floc break-up, the
(i) Primary particles; yield stress limit (T~)should be remembered. As
(ii) Flocculi formed from a collection of primary discussed earlier, the bonds holding the flocs together are
particles; elastic and, as such, will break when the yield values are
(iii) Flocs formed from close-packed flocculi; and exceeded. Francois and Van Haute(lo)reworked data from
(iv) Floc aggregates. Tomi and Bagster(") to show a relationship between floc
diameter and largest stress within the bonds (Fig. 2).
However, other researchers consider that the floc is an
aggregation of primary particles and therefore combine
(iii) and (iv). For simplicity, this model will be used. Each
floc will be defined as an aggregate of primary particles
bound together by intermolecular forces and encom-
passing a substantial proportion of fluid within its
framework.
Floc Break-up
Firth and Hunter@)used a Bingham model to describe Dimensions (mm)
the flow of an electrically charged sol. Three parameters - U- Spherical aggregate -x- Length of chain
are of importance, as shown in Fig. 1. zB,the Bingham
yield value, occurs where the flow curve becomes linear Fig. 2. Diameter of spherical aggregates and length
at a value of Go.It was found that this theoretical model
fitted the elastic floc rather than a single particle or a hard of chain vs maximum tension in elastic link between
non-deformable floc model, and the significance of this nodes
theory to mixing will be discussed later.
This shows that the larger the floc, the higher the stress
in the bonds. It therefore follows that to reach the yield
value for the bond, larger flocs will require less shear
input than smaller flocs, which is consistent with
expectations. This also proves the theory behind tapered
flocculation in the sedimentation process, when the
growth of large flocs is an advantage. Higher shear
stresses are important for floc build-up in their early
stages of development to cause the collisions of the
flocculi. T h e effect of slowly tapering down so that yield
stresses are not exceeded as the flocs grow will result in a
larger final floc size which is more easily settled. This
00
theory of a yield stress can be simplified into the form of
Shear rate an equation:
T h e Reynolds number (equation 7) must be dissipation rates will be produced, and hence scales of
considered to evaluate the flow regime of the impeller, i.e. mixing, depending on the particular position of the fluid
laminar, transitional, or turbulent. If it is turbulent, N P in relation to the impeller.
and NQare constants for a given impeller in a given tank. T h e theory of macromixing and micromixing has,
It should be noted that for agitation of water in full and in some cases, been applied to the flocculation process(16).
pilot-scale tanks the viscosity (m) is low while D is high, However, a floc consists of an aggregate of primary
hence keeping the Reynolds number high within the particles bound together by intermolecular forces and
turbulent regime. Bearing this in mind, N P and N Q c a n encompassing a substantial fraction of fluid within its
be regarded as constants, depending upon the type of framework. In other words when a floc has grown, unlike
impeller. Small laboratory-scale test units would have to other more solid particles, it will still be affected by both
be assessed individually, as the small size of the impellers micro and macromixing.
often pushes the flow regime into transitional and even Traditionally, flocculator agitators have been of the
laminar flow regime. gate or picket-fence types. When installed in a tank they
The impeller power number (equation 8), Np, is produce a high tangential velocity (macroscale flow
used to calculate the theoretical power consumption of an circulating around the impeller shaft), and microflow
impeller of a particular size and speed (not including concentrated in alternating vortices at the back of the
gearbox losses, motor losses, etc). This is required for impeller blades. By controlling the rotational speed of the
correct motor and gearbox sizing and is also used to check impeller, the process can be optimized by altering the
the vessel average shear rate or velocity gradient. T h e proportions of micro and macromixing in relation to each
flow number (equation 9) is used to calculate the other (as bulk macroflow varies with rotational speed, and
pumping capacity of the impellers and hence the bulk local shear with rotational speed squared for a given
fluid velocity (BFV) in the tank(”). This is important to agitation system). T h e success of the picket-fence
prevent by-passing or stagnant zones forming in the tank. impeller can be attributed to this controlability. Although
The BFV is defined as the flow produced by the impeller the flow patterns leave a lot to be desired in terms of
divided by the cross-sectional equivalent area of the tank mixing efficiency, bulk flow within the vessel is never
(A’). The equivalent area of a tank is that of a perfect lost. A turbine or hydrofoil impeller, such as the RTF4
square tank, i.e. when the diameter of the vessel equals (Fig. 3), must achieve a minimum agitator speed in order
the fluid depth, and this is defined by the following to maintain the entire contents of the tank in motion. The
equations: successful application of hydrofoils, or any other axial-
flow type of impeller to the flocculation process, will
v2 JI 113
A‘ = __ (10)
4
BFV= -
Q
A’
therefore depend upon them being able to maintain at Table 1 shows an exampIe of this comparison technique.
least a minimum macroscale flow while keeping shear to T h e value of N,8/9,VT1: is first calculated for the picket
an acceptable level. This makes the initial design of the fence, and this value is used to calculate the maximum tip
impeller size and speed very important. speeds of other impellers. This gives an indication of the
In order to investigate the agitation system more required design parameters to maintain a constant tMAX
fully, it is necessary to examine not just the vessel average and hence a constant rate of floc break-up.
shear ( G factor or velocity gradient) but also to obtain an
indication of the maximum shear and to check the bulk
fluid velocity within the vessel. Table 1. Comparison of V,, of various impellers
In a recent paper, Geisler et UP')examined the local using equation 13
shear stress and derived the equation:
Impeller
Picket fence
Pitched blade turbine
This relates the maximum turbulent shear stress Typical hydrofoil 0.35
occurring within the fluid with the tip speed and power RTF4 0.15
number of the impeller. It is well known that there is a
relationship between floc break-up and tip speed, but the
power number relationship is less well known. As an
overall explanation it can be said that the maximum shear As is shown, the initial tMAX values for the picket-
stress will develop at the point in the fluid where the fence impeller enables the maximum allowable tip speed
highest velocity is'applied. In general, this will occur at for the other types of impeller to be specified, which will
the point at which the impeller blade is travelling at its prevent the flocs from being excessively sheared by the
maximum speed, which is at its tip. T h e amount of power action of the impeller blades. Unfortunately, this does not
applied is a function of the blade angle and geometry, and specify the agitation system. As mentioned earlier, for
is usually represented by the power number. Therefore pumping impellers (such as pitched-blade turbine and
the power applied at a single point on the impeller blade hydrofoils), flow must be considered. A minimum value
(and therefore the local velocity gradient) will be a of bulk fluid velocity should be observed or batch control
function of the power number and impeller speed (as will be lost. Using the flow number (equation 9) and
described above). It should be noted that hydrofoils have substituting values for the particular impellers NB it can
a variable angle along the impeller blade, with a small be shown that hydrofoils produce an equal bulk fluid
angle to the plane of rotation at the impeller tip. This velocity with a smaller tMm than pitched-blade turbines.
would mean that the point at which most power is applied Therefore a hydrofoil impeller would be a better choice
may be at a position other than at the tip of the blade. for a flocculation duty than other flow types of impeller.
However, the correlation (which is stated above) will Also, a small increase in impeller diameter will have a
provide a conservative answer in this case, and therefore large effect on the flow produced ( Q a D3).As the tip
would still be a reasonable method of comparison. speed for these impellers is comparatively limited when
Remembering how the elastic floc model has been compared with normal non-shear sensitive duties, large
proven, and knowing that for this to be true the bonds diameters are required to obtain the minimum bulk fluid
must have a maximum yield stress, equation 12 can be velocities required. Fig. 4 illustrates this point by
used not only to compare dissimilar agitators, but showing that a given flowrate can be obtained with a
potentially to predict floc size - although this will be an smaller tMAX using larger impellers.
area for future work. Also, interestingly, equation 12 can An alternative and simpler method of comparing
be combined with equations 8 and 9, to show that a set the local shear produced by an impeller is to evaluate the
value of t M A X can be achieved with different power head produced by the agitation system. This can be
inputs, and bulk fluid velocities, with a change only in the achieved utilizing the same equations which are
size or type of impeller. This may mean that (a) there are commonly used to calculate the performance of pumps.
potential savings in power to be achieved, (b) shorter The head difference can be thought of as the difference
residence time tanks could be used, or (c) removal in pressure between the upper and lower sides of a flow-
efficiency could be increased simply by changing the type producing impeller. T h e difference in pressure will cause
or size of impeller on the flocculator. For instance, using the fluid to flow at a certain velocity, and the differences
a large, lower power number impeller at an increased tip in velocity caused by the variation in actual speed at
speed would be likely to improve the collision rate while points across the impeller diameter will give a velocity
maintaining the rate of the floc break-up, thus giving an gradient at the impeller; this will be the highest found
overall improvement in performance. locally within the agitation system. T h e equation which
Equation 12 is also a useful method for the is used for this calculation method can be derived from
comparison of agitation systems. If the system has the simple relationship:
existing picket-fence agitators operating at known tip
speeds, and the impeller power number is known or can P = QpgAH (14)
be obtained from the manufacturer, a comparison can be
made using relationship: Substituting the power number and flow number
(equations 8 and 9) into P and Qrespectively, and then
simplifying, gives the equation:
,,
,
,,
,
,
,
-3’
.c
J
I
1 --
100
10
.1
.01
0 .5 1 1
Tip speed ( d s )
I3 .15 -x- .3 -0-.5 -#-I -4-3
Fig, 5. Maximum shear stress vs tip speed for various impeller po wer numbers
Care should be taken when examining an existing standard impeller which was used in the past for
flocculator, as it is often tempting to multiply out flocculation, i.e. the gate or picket fence, by the
equation (2) so that: . specification of a maximum tip speed. This also
has the effect of setting maximum shear stress
%MAX = f{Pa,Nb, D") levels.
(iii) New hydrofoil-type impellers offer many advan-
Therefore, by taking a reading of the power drawn from tages for the flocculation process, but do not
the agitator and knowing the impeller diameter and necessarily fit the G factor and tip speed
speed, tMAX can be estimated. This should not be done, as parameters which were used in the past. There-
the power consumption would include gearbox, motor fore a more general design parameter is required
and other losses which may be relatively large, and would to predict floc break-up.
therefore lead to inaccurate results. T h e manufacturer of (iv) Although no specific design value recommen-
the agitator should be asked for details of the theoretical dations have been given, Geisler's equation for
power draw from the impeller, or estimations can be maximum shear stress has been recommended
made from equations 7 and 8. as an easy method of comparing the break-up of
flocs, and hence the overall performance
produced in an agitated tank. Reworking of
Use o f Hydrofoils for Flocculation previous test data has shown this method to be
reliable.
Any flow-inducing type of impeller has a considerable (v) T h e bulk fluid velocity has been defined and
advantage over a gate or picket-fence agitator, in that they recommended as an essential design parameter
are applicable to any shape of tank. The impellers mix by for flow-producing impellers. A minimum value
inducing flow within the tank rather than having to travel should be used in order to prevent stagnant areas
through the liquid. Therefore, for tanks with width to and by-passing in the tank, and higher values
length ratios of 2: 1, only one agitator would be required. should be used to increase the collision rate of
Hydrofoil impellers not only have the advantage of particles in the tank.
producing lower shear stresses when sized correctly, but (vi) Hydrofoils and high-efficiency impellers have
also of very high bulk flow per unit of power invested. the advantage of producing a high bulk flow with
This reduces the chances of by-passing and makes the a low shear stress, compared with other axial-
residence time distribution curve narrow and therefore flow impellers.
more ideal for the process. (vii) In general, to keep within shear stress limits
Mixing efficiency will be significantly increased by equivalent of a picket fence while maintaining a
using hydrofoil impellers due to the pumping action minimum bulk fluid velocity, a large hydrofoil
which is produced. Therefore the time taken for a given impeller at a relatively low tip speed (for this
number of collisions will be reduced. Potentially, this type of impeller) would be required.
could lead to a reduction in the residence time required
in the tanks, and thus a higher throughput in a given tank,
or smaller tanks for a given throughput. T h e increased Acknowledgements
number of collisions could also lead to an improved
performance of the flocculators, as more collisions will be The author wishes to acknowledge the contribution to
caused at, potentially, a lower level of maximum shear. this paper of Chemineer in the UK and US, without
Hydrofoil-type flocculator agitators are often whose time and training this paper would not have been
cheaper in capital cost because of the lower torque written.
requirements for the gearbox and shaft system. Although
hydrofoils are expensive to manufacture due to their
complex shape, the cost of this item usually compares Nomenclature
favourably with a picket fence because of its much smaller
physical size. A' = Equivalent area of tank (m2)
BFV = Bulk fluid velocity (m/s)
B = Break-up constant
Conclusions C, = Floc-strength coefficient
D = Impeller diameter (m)
1. Although, in the past, the concept of 'velocity d = Floc diameter (m)
gradient' has been proven to be a successful method dS = Stable floc diameter (m)
of specifying flocculator agitators, recent papers have G = Velocity gradient (5')
indicated that for new, more efficient impeller g = Acceleration due to gravity (m/s2)
systems the normal design procedure is not valid. h = Coefficient depending on strength of floc bonds
This paper has attempted to give an alternative KA = Aggregation constant
procedure which is easy to use. In summary: KB = Break-up constant
(i) Camp and Stein's velocity gradient concept L = Coefficient depending on break-up mode and
assumes a perfect distribution of shear within size regime of eddies
the vessel. This can never be the case in a m = Coefficient depending on size regime of eddies
mechanically agitated system. Nl,f = Number of contacts of primary particles (l),
(ii) The G factor has been adapted to fit the and flocs (Q
N = Impeller speed (sd) (4) MICHAELS, A. S., AND BOLGER, J. C. lnd. €ng. Chem. Fund., 1962, (l),
n = Number concentration of primary particles (l), 24-33.
and flocs (0 (5) MICHAELS, A. S., AND BOLGER, J. C. lnd. Eng. Chem. Fund., 1962, (l),
N, = Reynoldsnumber 153-1 62
NP = Powernumber (6) LAGVANMA, A. L., AND GEMMEL,R. S. J. Am. Wat. Wks.Assoc.,1968,(9),
N, = Flow number 1040-1046.
P = Power (watts) (7) VAN DE VEN, T. G., AND HUNTER, R. J. Rhocel. Acta., 1977,16,534-543.
Q = Flowrate (m3/s) (8) FIRTH,B. A., AND HUNTER, R. J. J. COll. lnterf. Sci., 1976,57,248-275.
R = Radius of floc particles (m) (9) SPEILMAN, L. A. Hydrodynamic aspects of flocculation. In The Scientific
r = Radius of primary particles (I), and flocs (f), Basis of Flocculation. (Ed. K. Ives.) Sijthoff and Noordhoff, 1978.
( 4 (10) FRANCOIS, R. J., AND VAN HAUTE,A. A. Floc strength measurements
T = Tankdiameter (m) giving equipment support for a four level hydroxide floc structure.
T' = Mean residence period (s) KatholiekeUniversiteitLeuven, Inst. of Indust. Chem de Craylaan2 B-
Trrnax = Largest force in structure 3030 Heverlee, Belgium, 1983.
u = Velocity (m/s) (11) TOMI,D., AND BAGSTER, D. F. Chem. Eng. Sci., (1975) 30,269-278.
V = Volume(m3) (12) Chemineer Inc., American Chemical Engineering. McGraw-Hill, Inc.,
VTp = Impeller tip speed (m/s) New York, N.Y.
AH = Impeller head difference (m) (13) BOURNE, J. F., AND RAVINORANATH, K. Comparison of finite difference and
p = Viscosity (Nm/s2) collection methods for micromixing calculations. Technisch-
z = Shear stress (N/m2) Chemisches Lab. E TH, CH-8092 Zurich. 1978.
k l = Force proportionality constant (14) OLDSHUE,J. Y. Fluid Mixing Technology. McGraw Hill Inc. New York.
p = Density(kg/m3) 1983.
(15) VAN DEN AKKER. H. E., AND BAKKER,R. A. A computational study of
chemical reactors on the basis of micromixing models. In froc. of8th
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