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Figure 17. Plot of concentration versus height in a continuous sedimentation device. Curve (1) - low feedrate; Curve (2) - high feed rate.

Sedimentation equipment is designed to perform two operations : to clarify the liquid overflow by removal of suspended solids and to thicken sludge or underflow by removal of liquid. It is the cross section of the apparatus that controls the time needed for settling a preselected size range of particles out of the liquid for a given liquid feed rate and solids loading. The area also establishes the clarification capacity. The depth of the thickener establishes the time allowed for sedimentation (i.e., the solid's residence time) for a given feed rate and is important in determining the thickening capacity. The clarification capacity is established by the settling velocity of the suspended solids. Sedimentation tests are almost always recommended when scaling up for large settler capacities. By means of material balances, the total amount of fluid is equal to the sum of the fluid in the clear overflow plus the fluid in the compacted sludge removed from the bottom of the thickener. The average vertical velocity of fluid at any height through the thickener is the volumetric rate passing upward at that level divided by the unit's cross section. Note that if the particle settling velocity is less than the upward fluid velocity, particles will be entrained out in the overflow, resulting in poor clarification. For those size particles whose settling velocity approximately equals that of the upward fluid velocity, particles remain in a balanced suspension, i.e., they neither rise nor fall, and the concentration of solids in the clarification zone

Figure 17. Plot of concentration versus height in a continuous sedimentation device. Curve (1) - low feedrate; Curve (2) - high feed rate.

increases. This eventually results in a reduction of the settling velocity until the point where particles are entrained out in the overflow.

The thickener must be designed so that the settling velocity of particles is significantly greater than the upward fluid velocity, to minimize any increase in the solids concentration in the clarification zone.

Solids concentration varies over the thickener's height, and at the lower levels where the solution is dense, settling becomes retarded. In this region the upward fluid velocity can exceed the particle settling velocity irrespective of whether this condition exists in the upper zone or not. Figure 17 illustrates this situation, where curve II denotes a higher feed rate. A proper design must therefore be based on an evaluation of the settling rates at different concentrations as compared to the vertical velocity of the fluid. If the feed rate exceeds the maximum of the design, particulates are unable to settle out of the normal clarification zone. Hence, there is an increase in the solids concentration, resulting in hindered settling. The result is a corresponding decrease in the sedimentation rate below that observed for the feed slurry. The feed rate corresponding to the condition of just failing to initiate hindered settling represents the limiting clarification capacity of the system. That is, it is the maximum feed rate at which the suspended solids can attain the compression zone. The proper cross-sectional area can be estimated from calculations for different concentrations and checked by batch sedimentation tests on slurries of increasing concentrations. You will find some problems in the section on Questions for Thinking and Discussing that illustrate the need to check the thickener's calculated area against concentrations at various points in the vessel (including both the clarification and thickening zones)._Figure 18 shows the effect of varying the underflow rate on the thickening capacity. In this example, the depth of the thickening zone (compression zone) increases as the underflow rate decreases; hence, the underflow solids concentration increases, based on a constant rate of feed.

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