Data Analysis and Modeling of Constant Pressure Batch Dewatering of Fine Particle Suspensions

The problems of data analysis and modeling of experimental constant pressure batch dewatering of materials forming compressible cakes are considered. Dewatering in these materials is typically completed in two stages, viz. cake formation and cake consolidation. A data representation method especially useful for determining the transition point between the filtration and consolidation stages, as well as for comparing accuracy of model predictions, is illustrated. It is shown that dewatering occurs via one of three qualitatively different pathways. A simplified model for engineering analysis of the process is presented. A time-invariant spatially uniform volume fraction of solids approximation is invoked in the cake formation stage. A time-dependent spatially uniform volume fraction of solids assumption is made in the cake consolidation stage. The two models contain four model parameters and have a common physical basis in Darcy's law. Interrelationships between key process parameters are determined and employed to predict the temporal evolution of dewatering in the cake consolidation stage as well as the end point of dewatering.     

Decreasing Filter Cake Resistance by Using Packing Structures

Packed beds used in absorption columns are evaluated to determine whether they can also be beneficial for cake‐forming filtrations. To assess this, model systems are characterized and separated by using a dead‐end filter cell. Filtrations are conducted with different packings; the filtrate amount over time and resulting turbidity are evaluated. Packings increase the filter cake resistance and the separation time of the cakes formed with approximately incompressible solids. However, they exhibit a positive effect on the filtration of a more complex, compressible substance; the process is not only accelerated, but also the quality of the obtained filtrate is not compromised. These results demonstrate potential in the use of packed beds for the filtration of complex biogenic suspensions.     

Rheology,Sedimentation, and Filtration of TiO2 Suspensions

It is shown that with aqueous suspensions of colloidal oxide and hydroxide particles simple rheometric and sedimentation experiments allow the determination of the optimum pH for filtration and washing. This approach is more practical than zeta potential measurements, as explained by a theoretical review and illustrated by experiments with industrial TiO₂ white pigments of varying surface chemistry. Besides, the solids content of the filter cake and its dependence on pH is correctly predicted from the rheology of the suspension, thus giving an idea of the mechanism of filter cake formation. This follows from a comparison to the results of filtration experiments. There, the influences of filter vacuum as well as of pH and solids content of the pigment feed suspension on filtration capacity and washing efficiency have been studied. The experiments also illustrate an inexpensive method of how to find the optimum set of parameters for an economical drum filter operation in the plant.     

Numerical modelling of fixed-cavity plate-and-frame filtration: Formulation, validation and optimisation

A model of fixed-cavity plate-and-frame filter presses is developed based on the theoretical framework developed by Buscall and White (1987. The consolidation of concentrated suspensions. Part 1. The theory of sedimentation. Journal of the Chemical Society. Faraday Transactions. I, Physical Chemistry in Condensed Phases 83, 873-891) and the piston-driven filtration model of Landman et al. (1991. Dewatering of flocculated suspensions by pressure filtration. Physics of Fluids. A, Fluid Dynamics 3(6), 1495-1509). The model properly accounts for compression of the suspension network structure within a filter cake in one dimension over a fixed cavity and allows for the effect of membrane resistance and ramping pressures. The model is validated by comparing on-site measurements of actual process performance at two water treatment plants with model predictions based on fundamental material properties of the feed slurries, the operating conditions and the press dimensions. The material properties are measured using laboratory based filtration tests. The model is then used to investigate the optimisation of press throughput and cake solids for a ferric water treatment slurry.     

Dynamic cross flow filtration

The dynamic cross flow filtration with the DYNO filter is a very versatile and economic high performance filtration process especially for suspensions with critical separation characteristics. Thickening, washing and clarifying of suspensions but also a classifying sieve filtration can be performed with the DYNO filter in a continuous operation with permanently high throughput rates. The principle of the dynamic high shear filtration ensures almost ideally physical conditions for the separation process. Contrary to classical cross flow filters a repeated recirculation of the suspension is not necessary for attaining the separation target. In the DYNO filter suspensions can be highly concentrated up to the flow limit in only one filtration cycle. In most cases, the concentrate is as dry as a firm filter cake and the filtrate is crystal-clear. Sieve filtration tasks for separating of coarse grain are performed with high concentration factors of up to 1000. Thus, the coarse fraction is obtained highly concentrated.     

Filtration of Colloidal Suspensions – MRI Investigation and Numerical Simulation

The principle mechanisms of solid‐liquid separation processes are sedimentation and filtration, both including the formation and compression of a liquid‐saturated bulk. The compressive properties of the bulk determine the operating parameters of solid‐liquid separation devices and the achievable separation results. Information about the solids volume fraction of the bulk is essential for a better understanding of the physical mechanisms and precise modeling. A numerical model for the calculation of the local solids volume fraction during formation and compression of filter cakes and sediments was developed. The calculated results are compared with experimental NMR data.     

Filtration Behavior of Suspensions of Uniform Polystyrene Particles in Aqueous Media

Abstract

Cake filtration experiments of suspensions of polystyrene particles, of uniform morphology, through Nuclepore membranes having uniform pores were carried out. The effects of particle properties (size and surface charge), suspension properties (particle concentration and ionic strength), and applied pressure were determined. The results were analyzed in terms of the conventional Darcy-Ruth filtration equation. Plots of resistance versus weight of solids in the cake revealed two distinct regions with a transition occurring early on in the filtration process at a cake thickness of the order of 1 mm. The initial portion has a lower average slope (specific resistance) than that of the second region. It is by only plotting this second region (i.e. ignoring the initial stages of the filtration process) that apparent negative values for the medium resistance are obtained.

The specific cake resistance obtained from the slope of the second region, which spans at least 90% of the filtration time, was correlated with particle and dispersion properties. The specific filtration resistance was essentially independent of slurry concentration and of the total applied pressure. Specific cake resistance measured at constant pressure and slurry concentration showed an inverse dependence on ionic strength.     

A spatially resolved model for pressure filtration of edible fat slurries

A spatially resolved one dimensional pressure filtration model was developed for a slurry of edible fat crystals. The model focuses on the expression step in which a cake is compressed to force the liquid through a filter cloth. The model describes the local oil flow in the shrinking cake modeled as a porous nonlinear elastic medium existing of two phases, viz. porous aggregates and interaggregate liquid. Conservation equations lead to a set of two differential equations (vs. time and vs. a material coordinate ω) for two void ratios, which are solved numerically by exploiting a finite-difference scheme. A simulation with this model results in a spatially resolved cake composition and in the outflow velocity, both as a function of time, as well as the final solid fat contents of the cake. Simulation results for various filtration conditions are compared with experimental data collected in a pilot-plant scale filter press.     

Gravitational drainage of compressible organic materials

A model was developed to simulate drainage of compressible particle suspensions, and study how cake compression and volumetric load influence the process. The input parameters were settling velocity, cake resistance and compressibility. These parameters were found using a new experimental method. Dextran‐MnO₂ particle suspensions were drained as these resemble organic waste slurries with respect to settling and compressibility. It was demonstrated that cake compressibility must be taken into account to obtain adequate simulations. This implies that pressurized filtration resistances cannot be used for drainage simulations. In the filtration step, a distinct increase of dry matter from top to bottom of the cake was observed. During the subsequent consolidation, the cake compressed and a uniform dry matter profile was found. The final dry matter content of the cake increased with feed concentration and volumetric load. The drainage time increased proportionally with feed concentration and, more importantly, proportionally with squared volumetric load. © 2010 American Institute of Chemical Engineers AIChE J, 2010     

Effect of cake layer structure on colloidal fouling in reverse osmosis membranes

A series of reverse osmosis (RO) membrane filtration experiments was performed systematically in order to investigate the effects of various hydrodynamic and physicochemical operational parameters on a cake layer formation in colloidal and particulate suspensions. Bench-scale fouling experiments with a thin-film composite RO membrane were performed at various combinations of trans-membrane pressure (TMP), cross-flow velocity (CFV), particle size, pH, and ionic strength. In this study, silica particles with two different mean diameters of 0.1 and 3.0 μm were used as model colloids. Membrane filtration experiments with colloidal suspensions under various hydrodynamic operating conditions resulted that more significant permeate flux decline was observed as TMP increased and CFV decreased, which was attributed to the higher accumulative mass of particles on the membrane surface. Results of fouling experiments under various physicochemical operating conditions demonstrated that the rate of flux decline decreased significantly with an increase of the ionic strength as well as particle size, while the flux decline rate did not vary when solution pH changed. The experimentally measured cake layer thickness increased with a decrease in particle size and solution ionic strength. Furthermore, the model estimation of cake layer thickness by using a cake filtration theory based on the hydraulic resistance of membrane and cake layer was performed under various ionic strength conditions. The primary model parameters including accumulated mass and specific cake resistance were calculated from the cake layer resistance. This result indicated that the formation of cake layer could be closely related with solution water chemistry. The model estimated cake layer thickness values were in good agreement with the experimentally measured values.     

The Role of Polysaccharide on the Filtration of Microbial Cells

The role of polysaccharide on the “dead-end” microfiltration of microbial cells is studied. Yeast and blue dextran are used as typical samples of microbial cells and polysaccharide, respectively. The filter cake becomes more compressible in the early periods of filtration and exhibits much higher filtration resistance when dextran molecules co-exist in the cake structure. A cake compression mechanism is proposed to explain the pressure effects on the cake structure and filtration resistance. For the two-component cakes, the dextran molecules deform easily even under a pressure as low as 30 kPa, while significant yeast deformation is observed when pressure is higher than 100 kPa. It is attributed to the depletion of most solid compressive pressures by deformed dextran molecules. The cake porosity data indicate that the cake compressibility is higher under low filtration pressure, and blue dextran plays a significant role on the cake structure and occupies a considerable volume in the cake. A resistance model is also derived for understanding the relationship between the average specific cake filtration resistance and filtration pressure. The cake filtration resistance is determined by the effective volume fraction of each component in cake and nearly the same as that of blue dextran under low pressure.     

Effect of membrane morphology on rising properties of filtration resistance in microfiltration of dilute colloids

The effect of membrane morphology on the flux decline behaviors in dead‐end unstirred microfiltration of very dilute colloids of polystyrene latex was examined using mixed cellulose ester and cellulose acetate membranes with interconnected tortuous pores and track‐etched polycarbonate membranes with uniform straight cylindrical pores. The plots of reciprocal filtration rate against the filtrate volume per unit membrane area for the former two membranes exhibit concave downward curves in the initial period when the membrane pore blocking is significant, whereas the plot for the latter shows a concave upward curve in that period. The former results were described by a serial resistance model consisting of the initial membrane pore blocking followed by filter cake growth, and the latter was represented by a parallel resistance model in which the pore blocking and cake growth develop simultaneously from the beginning of filtration. © 2017 American Institute of Chemical Engineers AIChE J, 63: 3511–3522, 2017     

Optimization Study of Municipal Sludge Conditioning,Filtering, and Expressing Dewatering by Partial Least Squares Regression

The effect of different conditioner doses and different applied pressures on the dewaterability of municipal sludge during the filtration and expression stage was assessed using a series of experiments referred to as a uniform design. The relative importance of conditioner dose and applied pressure on the dewatering characteristics of municipal sludge was evaluated with a quadratic model using partial least squares (PLS) regression analysis. It was shown that the developed quadratic model was able to accurately predict the dewatering characteristics during the whole process. It was further shown that lime as a physical conditioner had the most significant impact on filtration rate, expression rate, cake dry solids content, net sludge solids yield, and total cycle time. Aluminum polychloride as the inorganic flocculant had a quite complex effect although not as significant as lime. Filtration pressure had only a slight effect on dewaterability of the municipal sludge, though higher feeding pressure was needed in order to enhance the total feeding amount. Furthermore, expression pressure was only of benefit to cake dry solids content and expression rate and failed to improve other dewatering characteristics of the municipal sludge.     

Variations in backwash efficiency during colloidal filtration of hollow-fiber microfiltration membranes

A series of filtration experiments was performed systematically to investigate physical and chemical factors affecting the efficiency of backwashing during microfiltration of colloidal suspensions. In this study, all experiments were conducted in dead-end filtration mode utilizing an outside-in, hollow-fiber module with a nominal pore size of 0.1 μm. Silica particles (mean diameter = 0.14 μm) were used as model colloids. Using a flux decline model based on the Happel's cell for the hydraulic resistance of the particle layer, the cake structure was determined from experimental fouling data and then correlated to backwash efficiency. Modeling of experimental data revealed no noticeable changes in cake layer structure when feed particle concentration and operating pressure increased. Specifically, the packing density of the cake layer (1-cake porosity) in the cake layer ranged from 0.66 to 0.67, which corresponds well to random packing density. However, the particle packing density increased drastically with ionic strength. The results of backwashing experiments demonstrated that the efficiency of backwashing decreased significantly with increasing solution ionic strength, while backwash efficiency did not vary when particle concentration and operating pressure increased. This finding suggests that backwash efficiency is closely related to the structure of the cake layer formed during particle filtration. More densely packed cake layers were formed under high ionic strength, and consequently less flux was recovered per given backwash volume during backwashing.     

Experimentelle und theoretische Untersuchungen zur Filtration mit überlagerter Sedimentation in Drucknutschen

Sedimentation superimposed on industrial cake filtration leads to longer filtration times and often has a detrimental effect on subsequent process steps such as washing and demoisturing. The influence of sedimentation is seldom recognised in laboratory filtration experiments. Methods are presented for evaluation of pressure filter experiments with superimposed sedimentation which avoid the error made in the usual evaluation methods. For the case of zone sedimentation the article presents a graphical evaluation and a numerical method of modelling permitting scale up to any desired cake height. In superimposed classifying sedimentation simultaneous measurement of filtrate volume and cake height provide information about local variation in filter cake resistance. It is shown for a model system that, owing to sedimentation, the cake resistance shows a minimum at mean cake height and increases rapidly towards greater heights. The local cake resistance corelates with particle size distributions measured for layers of a horizontally cut filter cake. The method of evaluation presented permints determination of the flow resistance of the uppermost layers of a cake and hence estimation of the gas pressure necessary for demoisturing. The profiles of local filter cake resistance show that the relative cake layering is largely independent of the level of suspension filling. A scale-up model is presented for use in those cases where classifying sedimentation cannot be suppressed.     

A model analysis on the reasons for unstable operation of jet-pulsed filters

Various physically based models are available to describe an uneven distribution of the filter cake on the filter area of jet-pulsed bag filters. Such an uneven distribution is intrinsically present, when only segments of the filter are cleaned at a time but not the entire filter. Moreover, also patchy cleaning causes an uneven filter cake loading, since only a fraction of a filter cake is removed by a jet pulse while the other fraction remains basically intact on the filter cloth. Unstable filter operation can be defined by a continuous or periodic reduction of the filtration time per cleaning pulse. The operation of a jet-pulsed filter was mathematically simulated and, by systematically altering model parameters, unstable operation was obtained. Three situations were investigated: a continuous increase of the filter cake resistance parameter, a continuous increase of the filter cloth resistance parameter, and a particular cake detachment function where, after a filter cake survived some filter cycles, it can hardly be removed. The transient pressure difference simulation results reveal characteristic patterns: Taking normal stable operation as a reference, an increase of the filter cake resistance leads to shorter filtration and somewhat longer cleaning intervals (i.e., more cleaning pulses). An increase of the filter cloth resistance causes longer filtration and also considerably more cleaning pulses. Deficient filter cleaning gives shorter filtration periods and extremely long cleaning intervals. A comparison between model simulations and pilot plant results shows that there, the experimentally observed unstable operation can most likely be attributed to problems with cake detachment. Hence appropriate measures for avoiding unstable operation were successfully introduced.     

Nanocolloid cake properties determined from step‐up pressure filtration with single‐stage reduction in filtration area

A sophisticated method was developed for evaluating simultaneously and accurately both the average specific resistance and average porosity of the filter cake formed in unstirred dead‐end ultrafiltration of nanocolloids such as protein solution and nanosilica sol. In the method, a step‐up pressure filtration test was conducted by using a filter with a single‐stage reduction in the effective filtration area. The influence of the pressure drop across the cake on not only the average specific cake resistance but also on the average cake porosity of highly compressible filter cake was evaluated using only flux decline data in one dead‐end filtration test, taking advantage of the decrease in the cake thickness caused by the pressure increase. As a result, the cake properties were easily determined for a variety of nanocolloids. Constant pressure dead‐end ultrafiltration data obtained under various pressures and concentrations were well evaluated based on the method proposed. © 2015 American Institute of Chemical Engineers AIChE J, 61: 4426–4436, 2015