14/10/2020 How to Size a Thickener

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How to Size a Thickener

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Knowing how to size a thickener and determine the capacity required to handle a pre-determined
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tonnage of a certain pulp, by over owing a clear solution and obtaining the desired pulp density of
thickener discharge, depends upon the settling rate of that particular pulp. The settling rate of any
pulp is easily determined by simple laboratory tests such as outlined below:

Laboratory Test Method:

Place a measured quantity of pulp at a known density in a beaker or glass cylinder. Fix a narrow
strip of paper on one side of the container. Mix pulp thoroughly. Draw a line on the paper at the
top of the pulp and mark “0” minutes. For ve minutes, at one-minute intervals, mark the point to
which the solids have settled. This determines the free settling rate of the solids at the initial
density.

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14/10/2020 How to Size a Thickener

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Usually readings should be taken at three different densities of the pulp corresponding
approximately to densities which will exist in the various zones in the thickener.

Decant suf cient clear water or solution to establish a pulp with intermediate density. For instance,
if initial pulp density was 4:1, water to solids, the removal of one-fourth of the water would
establish a density of 3:1. Mix thoroughly. Repeat readings of settlement as above.

Then decant again to obtain a pulp at the third density. The pulp just tested was at 3:1 dilution, so
decanting one- third of the water will give 2:1 dilution, water to solids. Mix thoroughly. Repeat sett
ling measurements at one-minute intervals for ve minutes.

The settling rate per minute should be uniform during the testing at each dilution, until
compression is reached, at which time the amount of settling will decrease during each succeeding
minute. Measure the settling marks in inches, thus determining the settling rate in inches per
minute for each pulp density, and convert this to feet per hour.

Determining Final Density:

Final density is then determined thoroughly mix the pulp remaining after the test at 2:1 dilution
and allow to settle for 19 hours. Mark the position of settled pulp and let stand for a few hours to
see if nal density was reached. If pulp continues to settle, mark its position at hourly intervals
until settling stops. Decant off all clear water or solution. Then determine moisture content of pulp
by weighing and drying.

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Calculating Thickener Area:

Thickener area required is then calculated by

applying above determined data in the following
formula:

A = 1.333 (F – D)/R

A = Thickener area in square feet per ton of dry

solids thickened in 24 hours.
F = Initial density (Parts Water to Solids by weight).
D = Final density to which pulp will settle or density at which you want to discharge pulp from
thickener.

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R = Settling rate in feet per hour.

Usually it is desired to discharge pulp from the thickener at its nal density as shown in the above
test. However, if you want to discharge pulp more diluted than the actual nal density, the density
desired should be used in above formula rather than the nal density to which the pulp will settle.
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Calculations of indicated thickener area from each of the three settling rates obtained in tests will
indicate any change in settling rate in the different zones of the thickener, and the largest area
obtained from the three calculations should be used.

Assume the following data was obtained from the above tests:

At 4:1 dilution R = 0.50 feet per hour

At 3:1 dilution R = 0.30 feet per hour
At 2:1 dilution R = 0.15 feet per hour
Final Density D = 1:1

Applying this data to above formula, you obtain:

A = 1.33 (4 – 1)/0.50 = 7.98

A = 1.33 (3 – 1)/0.30 = 8.86

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14/10/2020 How to Size a Thickener

A = 1.33 (2 – 1)/0.15 = 8.87

Factor of Safety:

Normally a 25 per cent factor of safety is allowed in determining the thickener area size. Thus, in
the above case, 8.87 (largest of three gures) plus 25 per cent factor of safety, equals 11.09 square
feet area required per ton of dry solids fed to the thickener per 24 hours.

If the pulp reached its nal density during the 19 hour test, a standard depth thickener is
considered adequate. However, if additional time was required to reach nal density, the thickener
volume would have to be large enough to retain the pulp for this extra time.

Standard thickener depths are as follows:

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Storage Capacity:

Another factor to be considered is the storage capacity desired in a thickener. For example, it may
be necessary to shut a lter down for repairs and at the same time keep the balance of the mill in
operation. In this case the thickener will act as a storage reservoir. Where storage capacity in a
thickener is of importance such as in many of the non-metallic otation plants, a larger factor of
safety should be applied in calculating the area. Greater depth should not be used unless the lift of
the thickener mechanism can also be increased.

Duplicating Thickener Action:

Many times a pulp standing without agitation will not settle to as low a nal density as when aided
by movement of thickener rakes in actual operation our Laboratory developed a miniature
thickener mechanism which is used in determining nal density under actual operating conditions.

Pulp Calculations for CLASSIFIERS AND THICKENERS

Given percentage moisture (or solids, 100—Moisture) in feed, sands and over ow, and tonnage (dry)
of feed sand or over ow.

Let F, S, and Q be tons (dry) of feed. Sands (spigot) and Over ow, respectively.
Let, f, s, and q be percent of Moisture in Feed, Sands and Over ow, respectively.
S+Q = F and F/100 – f = Q/100-q + S = 100-s
S = F 100-s/100-f x q-f/q-s
Q = F 100-q/100-f x f-s/q-s
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F = Q 100-f/100-q x q-s/f-s = S 100 – f- (a-s)/100 – s-(a-f)

To determine content of any one pulp, the other two moisture contents must be known as well as
all the tonnages.

EXAMPLE:—Tons solid feed per hour 150, Moisture feed 49%, sands 31%, Over ow 82%.
F = 150, f = 49, s = 31, q = 82.
Sand Tonnage S = F 100-s/100-f x q – f/q -s = 150 100-31/100-49 x 82-49/82-31 = 150 69/51 x
33/51 = 131 tons sands.
Q = F 100-q/100-f x f-s/q-s = 150 100-82/100-49 x 49-31/82-31 = 150 81/51 x 18/51 = 18.7 tons
over ow.
Total……………………………………………..149.7 tons O+S = Feed
Error 0.3 tons due to slight inaccuracies in original data.

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Speci c Gravity

DETERMINATIONS

Let W= weight of a given volume of water (1 gram = 1 cc.).

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Ws = weight of an equal volume of dry solids with voids.

Wp= weight of an equal volume of pulp, or by wetting solids to make water level equal.
Gs = speci c gravity of solids= Ws/W – (Wp-Ws)
Gp =speci c gravity of pulp= Wp/W
Ws = Gp-1/Gs-1 x GsW
S=percent of solids in pulp=100 x Gp-1/Gs-1 x Gs/Gp
Weight per cubic foot = Gp/32.038 tons = 62.425 Gp pounds
Cubic Feet per ton=32.038/Gp
Cubic Feet pulp per ton dry solids=32.038 (Gs-1)/(Gp-1) Gs
Per cent water in pulp=100 -S=100 Gs-Gp/(Gs-1) Gp
Tons of dry solids per foot depth for round tanks of diameter.
D (in feet)= D² (Gp – 1) Gs/40.8 (Gs – 1)

Settling Thickening Tanks and THICKENER DESIGN and more Thickener Design.

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By L D Michaud | March 8th, 2016 | Categories: Tools of a Metallurgist | Tags: Small Process Equipment | Comments Off

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