Simulation of a semi-industrial pilot plant thickener using CFD approach

Thickeners are important units for water recovery in various industries. In this study, a semi-industrial pilot plant thickener similar to the tailing thickener of the Sarcheshmeh Copper Mine was simulated by CFD modeling. The population balance was used to describe the particle aggregation and breakup. In this population balance, 15 particle sizes categories were considered. The Eulerian–Eulerian approach with standard k–ε turbulence model was applied to describe two phases of slurry flow in the thickener under steady-state condition. The simulation results have been compared with the experimental measurements to validate the accuracy of the CFD modeling. After checking the numerical results, the effect of important parameters such as, feed flow rate, solid percentage in the feed, and solid particle size on the thickener performance was studied. The thickener residence time distribution were obtained by the modeling and also compared with the experimental data. Finally, the effects of feedwell feeding on the average diameter of aggregate and turbulent intensity were evaluated.     

Application of response surface methodology and central composite rotatable design for modeling the influence of some operating variables of the lab scale thickener performance

This study discussed the application of response surface methodology (RSM) and central composite rotatable design (CCRD) for modeling and optimization of the influence of some operating variables on the performance of a lab scale thickener for dewatering of tailing in the flotation circuit. Four thickener operating variables, namely feed flowrate, solid percent, flocculant dosage and feedwell height were changed during the tests based on CCRD. The ranges of values of the thickener variables used in the design were a feed flowrate of 9–21 L/min, solid percent of 8%–20%, flocculant dosage of 1.25–4.25 g/t and feedwell height of 16–26 cm. A total of 30 thickening tests were conducted using lab scale thickener on flotation tailing obtained from the Sarcheshmeh copper mine, Iran. The underflow solid percent and bed height were expressed as functions of four operating parameters of thickener. Predicted values were found to be in good agreement with experimental values (R² values of 0.992 and 0.997 for underflow solid percent and bed height, respectively). This study has shown that the RSM and CCRD could efficiently be applied for the modeling of thickener for dewatering of flotation tailing.     

Effect of the column height on the performance of liquid–solid fluidized bed for the separation of coarse slime

A liquid–solid fluidized bed separator, used for the separation of coarse slime, was developed. Test particles sized in the range from 0.25 to 0.5, 0.5 to 1.0, and 0.25 to 1.0 mm were separated in the liquid–solid fluidized bed. Beds with column heights of 1200, 1500, and 1800 mm were tried. The clean coal and the tailings were subsequently analyzed by float–sink testing. The results showed that the ash and yield of clean coal both decreased with increasing column height, for all three size fractions, and that the ash of the clean coal obtained from tests on the broader size fraction was less than that from the narrower sized fractions. The separation density decreased with increasing column height. The lowest E value was seen for a column height of 1500 mm, for which conditions the separation density was 1.45 g/cm³. The E value was 0.084 for the 0.25–0.5 mm fraction but the corresponding separation density was 1.48 g/cm³, and the E value 0.089, for the broader 0.25–1.0 mm fraction.     

Effect of agitation on the characteristics of air dense medium fluidization

In order to study the effect of agitation on the characteristics of air dense medium fluidization, we designed and constructed an agitation device. Analyses were then conducted on the fluidization characteristics curves, the bed density stability and the average bubble rise velocity Uaunder different agitation conditions. The results indicated that a lower bed pressure drop(without considering lower gas velocity in a fixed bed stage) and higher minimum fluidized velocity are achieved with increasing agitation speed.The height d(distance between the lower blades and air distribution plate) at which the agitation paddle was located had a considerable effect on the stability of the bed density at 9.36 cm/s U 10.70 cm/s. The higher the value of d, the better the stability, and the standard deviation of the bed density fluctuation r dropped to 0.0364 g/cm~3 at the ideal condition of d = 40 mm. The agitation speed also had a significant influence on the fluidization performance, and r was only 0.0286 g/cm~3 at an agitation speed of N = 75 r/min. The average bubble rise velocity decreased significantly with increasing agitation speed under the operating condition of 1.50 cm/s U–U_(mf) 3.50 cm/s. This shows that appropriate agitation contributes to a significant improvement in the fluidization quality in a fluidized bed, and enhances the separation performance of a fluidized bed.     

CFD simulation of an industrial hydrocyclone with Eulerian–Eulerian approach: A case study

In the present study, a three-dimensional computational fluid dynamics simulation together with experimental field measurements was applied to optimize the performance of an industrial hydrocyclone at Sarcheshmeh copper complex. In the simulation, the Eulerian–Eulerian approach was used for solid and liquid phases, the latter being water. In this approach, nine continuous phases were considered for the solid particles with different sizes and one continuous phase for water. The continuity and momentum equations with inclusion of buoyancy and drag forces were solved by the finite volume method. The k–ɛ RNG turbulence model was used for modeling of turbulency. There was a good agreement between the simulation results and the experimental data. After validation of the model accuracy, the effect of inlet solid percentage, pulp inlet velocity, rod inserting in the middle of the hydrocyclone and apex diameter on hydrocyclone performance was investigated. The results showed that by decreasing the inlet solid percentage and increasing the pulp inlet velocity, the efficiency of hydrocyclone increased. Decreasing the apex diameter caused an increase in the hydrocyclone efficiency.     

Study on kinetics of thermal decomposition of low LOI goethetic hematite iron ore

In the present study, the kinetics of thermal decomposition of hydrated minerals associated in natural hematite iron ores has been investigated in a fixed bed system using isothermal methods of kinetic analysis. Hydrated minerals in these hematite iron ores are kaolinite, gibbsite and goethite, which contribute to the loss on ignition(LOI) during thermal decomposition. Experiments in fixed bed have been carried out at variable bed depth(16, 32, 48 and 64 mm),temperature(400-1200 ℃) and residence time(30,45, 60 and 75 min) for iron ore samples. It is observed that beyond a certain critical bed depth(16 mm), 100% removal of LOI is not found possible even at higher temperature and higher residence time. Most of the solid-state reactions of isothermal kinetic analysis have been used to analyze the reaction mechanism. The raw data are modified to yield fraction reacted "α" versus time and used for developing various forms of "α" functions.f(α) is the inverse of first derivative of g(α) with respect to α. The study demonstrates that decomposition of hydrated mineral in hematite follows the chemical kinetics.The estimated activation energy values in all the experimental situations are found to high, of the order of 60 kJ/mol, reinstating that the reactions are indeed controlled by moving phase boundary and random nucleation.     

Characteristics of fluidization and dry-beneficiation of a wide-size-range medium-solids fluidized bed

Wide-size-range medium-solids are used in a modularized coal beneficiation demonstration system with a gas-solid fluidized bed. The characteristics of fluidization and dry-beneficiation of the medium solids were studied. The numerical simulation results show that 0.15–0.06 mm fine magnetite powder can decrease the disturbances caused by the bubbles. This is beneficial to the uniformity of the gas-solid interactions and thus to the uniformity and stability of the bed density and height. The experimental results show that, with an increase in the fine coal content in medium solids, both the fluidization quality and the beneficiation performance of the bed decreased gradually. When the fine coal content was no more than 13%, a relatively high superficial gas velocity increased the beneficiation efficiency. When the content was more than 13%, part of the fine coal was separated, leading to product layers. The separation efficiency was therefore gradually decreased. The models for predicting the bed density standard deviation and the probable error, E, value were both proposed. The E value can reach to 0.04–0.07 g/cm~3 under the optimized experimental parameters. This work provides a foundation for the adjustment of the bed density and the separation performance of the modularized 40–60 ton per hour dry coalbeneficiation industrial system.     

CFD model simulation of bubble surface area flux in flotation column reactor in presence of minerals

Bubble surface area flux(S_b) is one of the main design parameter in flotation column that typically employed to describe the gas dispersion properties, and it has a strong correlation with the flotation rate constant. There is a limited information available in the literature regarding the effect of particle type,density, wettability and concentration on Sb. In this paper, computational fluid dynamics(CFD) simulations are performed to study the gas–liquid–solid three-phase flow dynamics in flotation column by employing the Eulerian–Eulerian formulation with k-e turbulence model. The model is developed by writing Fortran subroutine and incorporating then into the commercial CFD code AVL FIRE, v.2014.This paper studies the effects of superficial gas velocities and particle type, density, wettability and concentration on Sband bubble concentration in the flotation column. The model has been validated against published experimental data. It was found that the CFD model was able to predict, where the response variable as indicated by R-Square value of 0.98. These results suggest that the developed CFD model is reasonable to describe the flotation column reactor. From the CFD results, it is also found that Sb decreased with increasing solid concentration and hydrophobicity, but increased with increasing superficial gas velocity. For example, approximately 28% reduction in the surface area flux is observed when coal concentration is increased from 0 to 10%, by volume. While for the same solid concentration and gas flow rate, the bubble surface area flux is approximately increased by 7% in the presences of sphalerite.A possible explanation for this might be that increasing solid concentration and hydrophobicity promotes the bubble coalescence rate leading to the increase in bubble size. Also, it was found that the bubble concentration would decrease with addition of hydrophobic particle(i.e., coal). For instance, under the same operating conditions, approximately 23% reduction in the bubble concentration is predicted when the system was working with hydrophobic particles. The results presented are useful for understanding flow dynamics of three-phase system and provide a basis for further development of CFD model for flotation column.     

Artificial neural network approach for rheological characteristics of coal-water slurry using microwave pre-treatment

Detailed experimental investigations were carried out for microwave pre-treatment of high ash Indian coal at high power level(900 W) in microwave oven. The microwave exposure times were fixed at60 s and 120 s. A rheology characteristic for microwave pre-treatment of coal-water slurry(CWS) was performed in an online Bohlin viscometer. The non-Newtonian character of the slurry follows the rheological model of Ostwald de Waele. The values of n and k vary from 0.31 to 0.64 and 0.19 to 0.81 Pa·sn,respectively. This paper presents an artificial neural network(ANN) model to predict the effects of operational parameters on apparent viscosity of CWS. A 4-2-1 topology with Levenberg-Marquardt training algorithm(trainlm) was selected as the controlled ANN. Mean squared error(MSE) of 0.002 and coefficient of multiple determinations(R~2) of 0.99 were obtained for the outperforming model. The promising values of correlation coefficient further confirm the robustness and satisfactory performance of the proposed ANN model.     

Numerical simulation of flocculation and settling behavior of whole-tailings particles in deep-cone thickener

Rapid dewatering and thickening of whole-tailings with ultrafine particles is one of the most important processes for the whole-tailings paste preparation. Deep-cone thickener, a kind of such process for the flocculation and settling of whole-tailings, is particularly necessary to study. However, there exist many problems in observing the flocculation and settling process of whole-tailings, as well as the particle size distribution(PSD) of whole-tailings floccules in deep-cone thickener. Population balance model(PBM) is applied to predict the PSD in deep-cone thickener, and LUO model and GHADIRI model are employed to study the aggregation and fragmentation mechanism of the whole-tailings particles, respectively. Through three-dimensional numerical simulation on the whole-tailings flocculation and settling in deep-cone thickener using computational fluid dynamics(CFD)-PBM, the distribution of density and turbulent kinetic energy in deep-cone thickener were obtained, at the same time the spatio-temporal changes of whole-tailings floccules particle size distribution are analyzed. Finally, the major flocculation position in deep-cone thickener is found and the flocculation settling rules of whole-tailings are achieved.     

Identification of large-scale goaf instability in underground mine using particle swarm optimization and support vector machine

An approach which combines particle swarm optimization and support vector machine (PSO–SVM) is proposed to forecast large-scale goaf instability (LSGI). Firstly, influencing factors of goaf safety are analyzed, and following parameters were selected as evaluation indexes in the LSGI: uniaxial compressive strength (UCS) of rock, elastic modulus (E) of rock, rock quality designation (RQD), area ration of pillar (S_p), the ratio of width to height of the pillar (w/h), depth of ore body (H), volume of goaf (V), dip of ore body (α) and area of goaf (S_g). Then LSGI forecasting model by PSO-SVM was established according to the influencing factors. The performance of hybrid model (PSO + SVM = PSO–SVM) has been compared with the grid search method of support vector machine (GSM–SVM) model. The actual data of 40 goafs are applied to research the forecasting ability of the proposed method, and two cases of underground mine are also validated by the proposed model. The results indicated that the heuristic algorithm of PSO can speed up the SVM parameter optimization search, and the predictive ability of the PSO–SVM model with the RBF kernel function is acceptable and robust, which might hold a high potential to become a useful tool in goaf risky prediction research.     

Determination of the desiccation behavior of clay slurries

The main objective of this study was to determine the desiccation behavior of clay slurries. A clay slurry with high water adsorption capacity(W_L = 180%,W_P 60%,W_s = 20) was used to determine the soil water characteristic curve(SWCC), shrinkage curve, and hydraulic conductivity. The last parameter was determined similar to the Instantaneous Profile Method using evaporation tests. Results indicated that the clay slurry had an air entry value(AEV) of 1000 kPa and a residual suction of 5000 kPa that occurred at the plastic limit and the shrinkage limit, respectively. The discrepancy between theoretical and measured shrinkage limit was due to the gradual increase in clay particle contact. Unlike soils, the saturated hydraulic conductivity varied by two orders of magnitude(4×10 ~10 m/s at 20 kPa to 3 x 10 ~12 m/s at AEV). The unsaturated k further decreased to 10 ~14 m/s at 6 x 10~4 kPa beyond which vapor flow took place.     

Evaluation of reduction roasting and magnetic separation for upgrading Mn/Fe ratio of fine ferromanganese

Low grade ferromanganese tailing was subjected to different mineralogical techniques, reduction roasting and magnetic separation to establish whether commercially acceptable manganese qualities and high Mn/Fe ratio could be obtained, and also to determine the best processing route for beneficiating this ore. The main manganese mineral within the feed sample is birnessite, with minor amounts of pyrolusite and todorokite. Size by assay analysis conducted presented a result with a yield of about 35.75% and Mn grade of 27.63% to coarse (?3.35 + 1 mm) and yield of 20.24% and Mn grade of 27.71% to (?1.18 + 0.50 mm) fraction. Two-stage high induced magnetic separations at 16,000 and 11,000 G produces Mn grades with similar grade to that obtained from the ferromanganese feed sample. Reduction roasting followed by magnetic separation on ?1.18 + 0.50 mm at 1000 G recovered 72.31% Mn with a grade of 58.44% Mn, 2.52% Fe and 3.29% Si at Mn/Fe ratio of 23.22. This study reveals the influence of roasting in converting the hematite and goethite to magnetite and the response of the roasted fraction to magnetic separation.     

液固循环流化床预分布器附近流体动力学的数值研究

在液固循环流化床(LSCFB)内,分别以水、玻璃珠为液相和固相,应用2种不同结构的分布器,在室温常压下,考察了分布器结构对预分布器区及换热管内流体动力学的影响。利用商用计算流体力学(CFD)软件Fluent 6.2,选用欧拉模型(Eulerian),系统研究了不同分布器结构和不同表观液速对换热器的预分布器区固体颗粒和局部液体速度径向分布的影响。模拟结果表明:应用变孔径预分布器与均匀孔径预分布器相比,变孔径预分布器能更好地改善固体颗粒和局部液体径向速度分布的均匀性;在低表观液速下,固含率径向分布的计算值与实验值吻合良好,误差随表观液速增大而增大。     

Strength behaviour of sandstone subjected to polyaxial state of stress

The paper presents an experimental investigation on the strength behaviour of natural rock subjected to polyaxial state of stress. The polyaxial tests were conducted on cubical specimens of sandstone obtained from the Shivpuri district in Madhya Pradesh state of India, The specimens having nominal dimensions of100 mm x 100 mm x 100 mm were tested using a polyaxial testing machine. Twenty-five combinations of intermediate and minor principal stresses were applied and the specimens were loaded till failure occurs. It was observed that the intermediate principal stress has a substantial effect on the strength of the Shivpuri sandstone. A database of rock strength under various combinations of σ_2 and σ_3 was obtained for the Shivpuri sandstone. The database was used to study the predictability of five most commonly used strength criterion. Root mean square error(RMSE), average absolute relative error percentage(AAREP) and coefficient of accordance(COA) were used as indices for the measure of goodness of fit. It was observed that the least error in the prediction was shown by modified Mohr Coulomb criterion followed by modified Weibols and Cook criterion. A probability analysis of the error in prediction was also done.     

Determination of consolidation behaviour of clay slurries

The main objective of this study was to determine the consolidation behaviour of clay slurries.A finegrained clay with high consistency limits(W_L = 180%,w_P= 120%) was investigated using conventional oedometer and bench-top centrifuge tests.Results indicated that the slurry had an apparent preconsolidation(due to initial conditions,electrochemical interactions,tortuous drainage,and thixotropic strength) from e = 5.7 to e = 5.5 followed by virgin compression.Likewise,the low hydraulic conductivity(10~(-10)-10~(-12) m/s) was due to low porosity(small pore throats) and high tortuosity(long flow paths).Unlike consolidation of soils,the c_v and m_v decreased with increasing σ' but increased with increasing e and k.The data from the two tests correlated well in the range of σ' = 10-65 kPa,e = 5.5-3.86,k= 1.7 × 10~(-10)-5×10~(-11) m/s,F_c = 1-40 MN.New equations were developed to correlate the consolidation parameters(e,σ',k) with F_c.The deviation of k beyond 40 MN(e = 4.65) was due to deviation from the initial straight line portion of the settlement curve in the centrifuge test.     

Numerical simulation of influence of Langmuir adsorption constant on gas drainage radius of drilling in coal seam

To determine reasonable distance of gas pre-drainage drillings in coal seams, a solid–gas coupling model that takes gas adsorption effect into account was constructed. In view of different adsorption constants,the paper conducted the numerical simulation of pre-drainage gas in drillings along coal seam, studied the relationship of adsorption constants and permeability, gas pressure, and effective drainage radius of coal seams, and applied the approach to the layout of pre-drainage gas drillings in coal seams. The results show that the permeability of coal seams is on the gradual increase with time, which is divided into three sections according to the increase rate: the drainage time 0–30 d is the sharp increase section;30–220 d is the gradual increase section; and the time above 200 d is the stable section. The permeability of coal seams is in negative linear and positive exponent relation with volume adsorption constant VLand pressure adsorption constant PL, respectively. The effective drainage radius is in negative linear relation with VLand in positive exponent relation with PL. Compared with the former design scheme, the engineering quantity of drilling could be reduced by 25%.     

Surface magnetization of siderite mineral

Surface self-magnetization of siderite is achieved by generating ferromagnetic substance on the surface of siderite by adjusting slurry temperature, pH value, stirring rate and reaction time. No addition of any iron-containing reagent is required. The temperature of 60 °C, NaOH concentration of 0.10 mol/L; stirring rate of 900 r/min and the reaction time of 10 min are the optimal conditions. The results show that the siderite recovery in magnetic separation increased from 26.9% to 88.8% after surface magnetization. Magnetization kinetic equation is expressed as 1 ? [1 ? (? ? 0.269)]^1/3 = Kt. Activation energy for the magnetization reaction is 4.30 kJ/mol. VSM, SEM and XPS were used to characterize the siderite, and results show that the saturated magnetization (σ_s) of siderite increased from 0.652 to 2.569 A m²/kg, the magnetic hysteresis was detected with a coercive force of 0.976 A/m after magnetization; Fe2P3/2 electron binding energy changed which reflects the valence alteration in iron on the surface and the formation of ferromagnetic Fe₃O₄.     

Modeling and process optimization for microbial desulfurization of coal by using a two-level full factorial design

The microbial sulfur removal was investigated on high sulfur content (1.9%) coal concentrate from Tabas coal preparation plant. A mixed culture of ferrooxidans microorganisms was isolated from the tailing dam of the plant. Full factorial method was used to design laboratory test and to evaluate the effects of pH, particle size, iron sulfate concentration, pulp density, and bioleaching time on sulfur reduction. Statistical analyses of experimental data were considered and showed increases of pH and particle size had negative effects on sulfur reduction, whereas increases of pulp density and bioleaching time raised microbial desulfurization rate. According to results of designing, and regarding statistical factors, the optimum values for maximum sulfur reduction were obtained; pH (1.5), particle size (?180 μm), iron sulfate concentration (2.7 mmol/L), pulp density (10%) and bioleaching time (14 d), which leaded to 51.5% reduction from the total sulfur of sample.     

Motion behavior of particles in air–solid magnetically stabilized fluidized beds for separation

In order to study the settling mechanism of particles in an air–solid magnetically stabilized fluidized bed (MSFB) for separation, we carried out free settling and quasi-zero settling tests on the tracing particles. The results show that the main resistance forces as the tracing particles settled in an air–solid MSFB were motion resistance force and yield force. The motion resistance and yield forces greatly hindered the free settling of the particles by greatly decreasing the acceleration for settling process of the particles. The acceleration decreased from 3022.62 cm/s² to zero in 0.1 s, and in the end, the particles stopped in the air–solid MSFB. The yield force on particles increased with increasing the magnetic field intensity, resulting in decrease of the quasi-zero settling displacement. However, the yield force on particles decreased with increasing the fluidized air velocity, leading to increase of the quasi-zero settling displacement. When the structure and operating parameters of the air–solid MSFB were set up, the yield stress on particles stopped in an air–solid MSFB was a function of diameter and density of particles. The settling displacements of equal diameter particles increased with increasing their densities, and the settling displacements of equal density particles increased with increasing their diameters.