Characterization of floc size, strength and structure under various coagulation mechanisms

Flocs generated by various coagulation mechanisms exhibit different size, strength and structure. The properties and fractal dimensions of flocs formed under three common coagulation mechanisms, i.e. charge neutralization, sweep and bridging, were investigated at various hydraulic conditions. The results showed that the floc size decreased with the increasing average velocity gradient G and the stable floc size exponent γ was of the following hierarchy: charge neutralization (0.6107) > sweep (0.5618) > bridging (0.3674). Furthermore, fractal dimensions of flocs were the highest when formed by sweep and the lowest when generated by bridging flocculation. The mass fractal dimensions measured by light scattering were between 2.0 and 3.0 and the floc strength was between 0.01 and 0.58 N m^− 2. An intrinsic unity of the relationship among floc size, fractal dimensions, floc strength under the three coagulation mechanisms was demonstrated.     

Coagulation–bubbling–ultrafiltration: Effect of floc properties on the performance of the hybrid process

A novel hybrid process of coagulation–bubbling–ultrafiltration was proposed to study membrane fouling phenomena by surface water. Relationship of bubbles, flocs and the hollow fibers was explored. When applying less than 20 mL/min gas flow rate, membrane fouling was accelerated with air bubbles introduced. When gas flow rate increased further to 40 mL/min and 60 mL/min, TMP showed a two-stage development trend, which was a fast development in the first few hours followed with a relatively slow development after about 4 h. Unified membrane fouling index (UMFI) increased from 0.00216 (without bubbles) to 0.00274 m²/L (40 mL/min gas flow rate) and 0.00219 m²/L (60 mL/min gas flow rate). As gas flow rate increased, bubble size became bigger, and its distribution range became wider, resulting in higher shear rate in the ultrafiltration column, which led to severe floc breakage. Flocs of small size and compact structure accelerated membrane fouling, resulting in highest UMFI value under 40 mL/min gas flow rate. However, under 60 mL/min gas flow rate, with largest bubbles and highest shear rate examined in this study, concentration polarization was effectively limited. As a result, TMP development slowed down when pore blockage reached equilibrium.     

Comparative study of the effects of experimental variables on growth rates of aluminum and iron hydroxide flocs during coagulation and their structural characteristics

In this study, the dimensions of over six thousand flocs were analyzed to quantitatively and comparatively investigate the effects of several experimental variables on the growth rate of aluminum (Al) and ferric (Fe) hydroxide flocs. Results show that Fe hydroxide flocs have faster growth rate than Al hydroxide flocs; and the average size of the former is larger than that of the latter. Increasing the concentration of the bivalent sulfate ion (SO₄²⁻), initial turbidity, or slow mixing rate, was able to increase the growth rate of both kinds of flocs. On the other hand, steady floc sizes were found to decrease with the increase in SO₄²⁻ concentration, initial turbidity, or shear rate. Fe hydroxide flocs are more prone to be influenced by the changes in the variables than Al hydroxide flocs. While the steady floc sizes became smaller when initial turbidity or slow mixing speed increased, the roundness and smoothness of flocs were found to increase, indicating that higher initial turbidity or larger slow mixing rate produces flocs with more regular and round shape. Furthermore, at a fixed shear rate, Fe hydroxide flocs are stronger than Al hydroxide flocs. However, Fe hydroxide floc sizes are much easier to decrease with the increase in slow mixing intensity.     

Floc model and intrafloc flow

The three-dimensional pore structures in waste activated sludge floc were identified using the fluorescence in situ hybridization (FISH) and confocal laser scanning microscope (CLSM) images. The meshes of the three-dimensional porous configuration of a sludge floc were constructed from the CLSM series images. The intrafloc flow field was simulated for the constructed floc model when it was subjected to a uniform flow field, based on which the Darcy's permeability was estimated. The permeability (k_DL) of original floc was estimated as . Flocculated flocs had higher k_DL due to their large pore size, while the corresponding values of k_DL of the freeze/thawed flocs were lower. The calculated results indicate that a few large pores in the floc determine the permeability. The fractal dimension and compactness, however, are not correlated with the permeability of the flocs.     

Spatial and temporal evolution of floc size distribution in a stirred square tank investigated using PIV and image analysis

In this study, non-intrusive measurements were performed in order to determine the spatial and temporal evolution of the floc size distribution in a square 7.3 L tank stirred with an A310 hydro foil impeller. The data was collected in situ using particle image velocimetry. The analysis of the data was done using a connected component labelling technique. It was found that the reproducibility of the system was adequate. The results show that there are large spatial differences in the mean size and the shape of the floc size distribution within the tank. It was found that steady-state was reached when stirrer speed was increased. It was also found that effects of the interaction between flocs and the water surface had substantial influence on the local size distribution. It was determined that the surface was more important for breakage of flocs than the impeller region. Results also showed clear number gradients in the tank. It is clear from this study that any population balance model developed in order to predict floc size distributions should incorporate spatial dependence.     

Modeling spatial distribution of floc size in turbulent processes using the quadrature method of moment and computational fluid dynamics

A study was performed that utilizes the quadrature method of moments (QMOM) to model the transient spatial evolution of the floc size in a heterogeneous turbulent stirred reactor. The QMOM approach was combined with a commercial computational fluid dynamics (CFD) code (PHOENICS), which was used to simulate the turbulent flow and transport of these aggregates in the reactor. The CFD/QMOM model was applied to a 28 l square reactor containing an axial flow impeller and 100 mg/l concentration of 1 μm nominal clay particles. Simulations were performed for different average characteristic velocity gradients (40,70,90, and 150 s^-1). The average floc size and growth rate were compared with experimental measurements performed in the bulk region and the impeller discharge region. The CFD/QMOM results confirmed the experimentally measured spatial heterogeneity in the floc size and growth rate. In addition, the model predicts spatial variations in the aggregation and breakup rates. Finally, the model also predicts that the transport of flocs into the high shear impeller discharge zone was responsible for the transient evolution of the average floc size curve displaying a maximum before decreasing to a steady-state floc size.     

EFFECTS OF DOSING REGIMEN AND AGITATION PROFILE UPON FLOC CHARACTERISTICS

The efficiency of solid-liquid separation processes that employ flocculation and sedimentation mainly depends upon the characteristics of aggregates produced by coagulation. Size and density are foremost, however, most flocculation processes are designed such that many larger floes are formed by floc-floc collisions resulting in the entrapment of large amounts of interstitial water. Thus, as particle size increases, floc density generally decreases. Not only does this affect the achievable rate of sedimentation, but it also contributes to the volume of process sludge that must be dewatered prior to ultimate disposal. The objective of the present work is to examine combinations of flocculant dosing and activation along with shear profile or history that can produce flocs of unusually compact structure, thereby increasing the efficiency of separation and reducing the volume of sludge produced. Four types of batch coagulation experiments were conducted, employing both single and intermittent polymer applications as well as periodic episodes of elevated shear to provide more compact constituent floc structures. A light obscuration method, in which the increase in diode phototube output during sedimentation was used to assess mean aggregate density, was employed throughout the study; it provided a convenient means for comparison of the effects of process modifications upon sedimentation.     

Effects of Fe(III) on floc characteristics of activated sludge

The effects of Fe(III) on floc characteristics of activated sludge were investigated in nine parallel sequencing batch reactors (SBRs). The results showed that Fe(III) improved the quality of organic matters in the effluent of reactors. Concentrations of Fe(III) up to 23.8 mg dm^?3 decreased suspended solids and turbidity in effluent but overdosage resulted in deterioration of these parameters. Activated sludge floc size measurements indicated that Fe(III) led to a shift in the size distribution from large to small flocs. Concentrations of Fe(III) less than 23.8mg dm^?3 did not significantly change the proportion of larger flocs, but overdosage of Fe(III) markedly decreased the fraction of larger flocs and produced a large number of smaller flocs, which may be responsible for the deterioration of effluent suspended solids and turbidity. Scanning electronic microscopic (SEM) observation suggested high Fe(III) concentrations lead to significant changes in floc morphology and reduction of filamentous microorganisms available for the formation of large aggregates. Copyright © 2005 Society of Chemical Industry     

Breakage–reflocculation implemented by two-stage shear for enhancing waste-activated sludge dewaterability: Effects of shear condition and extracellular polymeric substances

The conditioning of waste-activated sludge (WAS) before dewatering is crucial for enhancing sludge dewaterability. The breakage–reflocculation that was implemented by two-stage shear (drastic first-stage shear for breakage and moderate second-stage shear for reflocculation utilizing the bioflocculation function) which was proposed as a novel WAS conditioning method with several advantages (simple operation, lower cost, and none added reagent) compared to traditional methods. Effects of the shear condition and extracellular polymeric substances (EPS) on breakage–reflocculation were orderly investigated. Two equations were developed by response surface methodology for predicting breakage–reflocculation conditioning performance. Analysis of variance (ANOVA) indicated that individual effects of first-stage shear rate (G₁), second-stage shear rate (G₂), second-stage shear time (t₂), and interactive effect of G₁G₂ were significant. More compact WAS flocs with better dewaterability and larger floc size formed through breakage–reflocculation. This was reflected in that the capillary suction time decreased by 16.9% and mean floc size increased by 24% under the optimum shear condition. In addition, the loosely bound EPS was revealed to be closely negatively correlated with breakage–reflocculation conditioning performance, indicating its adverse role in breakage–reflocculation. The breakage–reflocculation could be used as an independent conditioning method with low cost or a part of combined method.     

Effect of Selected Nonionic Surfactants on the Activated Sludge Morphology and Activity in a Batch System

In this study, two nonionic surfactants, one alcohol ethoxylate (AE) and one alkylphenol ethoxylate (APE) were investigated with regard to their influence on the morphology of activated sludge flocs, microbial activity and wastewater treatment efficiency in a laboratory batch system. The experiments were carried out for a range of nonionic surfactants concentrations in wastewater from 5 to 500 mg L⁻¹. Additionally, these results were compared to the data obtained in previous experiments on anionics and performed under the same conditions. Both nonionics tested caused a decrease in the size of activated sludge flocs but they did not affect the shape of the flocs. The circularity index and convexity of flocs remained similar to the control run, containing no surfactant. The presence of nonionic surfactants within the tested concentrations range caused a decrease in biomass activity. In spite of morphological changes of activated sludge flocs and a decrease in microbial activity, only higher concentrations of nonionics in wastewater starting with the level of 50 mg L⁻¹ can induce pinpoint flocs and decrease wastewater treatment efficiency. APE showed a stronger impact on the decrease in floc size and microbial activity than alcohol ethoxylate did. APE was also more difficult to biodegrade than AE. Comparing the efficiency of wastewater treatment (in terms of COD removal) in the presence of nonionic and anionic surfactants at the same concentration of 50 mg L⁻¹, the degree of organic pollutant removal was found to be higher by about 10% for anionics than for nonionics.

Coagulation of bentonite suspension by polyelectrolytes or ferric chloride: Floc breakage and reformation

Coagulation process usually involves different hydrodynamic conditions, in particular when it is followed by a filtration step. In this study, coagulation performance was investigated under a wide range of shear stress. Floc behaviour was followed in-line by laser granulometry to determine size distribution and structure. Synthetic suspension of bentonite in tap water was used as a reference for mineral solids in surface water. Three cationic polymers (polyamine based and polyDADMAC) and ferric chloride were tested using different coagulation reactor geometries. Jar-test indicated coagulation performance under mild hydrodynamic conditions and Taylor–Couette reactors were used to create shear stresses up to 8 Pa. Flocs formed with ferric chloride are not able to grow under middle shear stress like 1.5 Pa. On the contrary, polyelectrolytes lead to large flocs, dense (D_f = 2.6) and resistant to shear stress. A qualitative comparison of floc resistance to shear depending on hydrodynamic conditions and coagulant type is given through the calculation of the strength factor. Fractal dimension measurements indicate a mechanism of particle erosion when flocs are subjected to a higher shear stress in Taylor–Couette reactor. Floc re-growth is also investigated, and breakage appears to be non-reversible regardless of coagulant and conditions experimented.     

Evolution of asphaltene floc size distribution in organic solvents under shear

A mathematical model was developed on the basis of population balance to analyze experimental data on asphaltene floc size distribution in a coagulating suspension. Experiments were carried out in a Couette device under a laminar flow condition. Floc size distributions were measured on-line using optical microscopy and image analysis. The aggregation behavior of asphaltenes was investigated by monitoring the size distribution of flocs for various intensities of agitation (i.e., shear rate, G), solvent composition (i.e., ratio of toluene to n-heptane in the solution, T:H) and particle contents (i.e., volume fraction of particles, ?). The results showed that (i) the floc size distribution can be predicted using a population balance approach, (ii) a steady-state mean floc size is reached for a given shear rate, and (iii) this steady-state floc size increases as ? is increased or T:H is reduced. The relative rates of shear-induced aggregation and fragmentation determine the steady-state size distribution. Similar floc size distributions were obtained at steady state for various shear rates, indicating that the width of the size distribution is independent of shear. However, the experimental observations indicate that the steady-state floc size distribution depends on asphaltene concentration and solvent composition.     

Reynolds number-dependent permeability of wastewater sludge flocs

Most theoretical models assume constant permeability of wastewater sludge floc. This work shows that, at creeping flow limit with small intrafloc Reynolds number, the permeability of floc can not only be affected by floc structure, but also by the external flow condition. The three-dimensional structure of flocs using the fluorescence in situ hybridization (FISH) and the confocal laser scanning microscope (CLSM) was firstly probed. Then, the volumetric grid models for sludge flocs were constructed. We noted that the floc permeability could keep unchanged, increased, or decreased at increased Reynolds number (Re). Flow redistribution among channels of various sizes contributes to the noted Re-dependent permeability of flocs.     

Floc breakage in agitated suspensions: Effect of agitation rate

A population balance equation that governs the floc size distribution in turbulent flow, incorporating both the splitting and erosion mechanisms of floc breakage has been presented in previous studies[6,7]. Experiments have been conducted in which transient floc size distributions of dilute suspensions of Kaolin-hydrous ferric-oxide flocs undergoing breakage in agitated batch system are obtained over turbulent microscale shear rates ranging from 60 to 400 sec^?1. Floc size distributions over a range of floc diameters from about 1 to 100 μ m are measured by overlapping techniques, including computerized optical scanning of photographs and rapid electronic sizing of individual flocs using a light blockage transducer. The experimentally determined size distributions are then fit to those computed from the population balance equation, using constrained nonlinear least squares. The splitting frequency of parent flocs is found to vary as the 0.33 power of the parent floc volume and 0.71 power of the shear rate. The average number of daughter fragments produced upon splitting of individual flocs is found to be about 2.5. The mean and standard deviation of the daughter fragments produced upon splitting are found to be in fixed ratio to one another, independent of the parent floc size and shear rate. An appropriately nondimensionalized coefficient characterizing floc erosion has been found to be independent of shear rate.     

Interaction between wastewater-sludge floc and moving ice front

Freeze/thaw treatment is an effective sludge-dewatering technique. The efficiency of dewatering of freeze/thawed sludge declines as the approaching ice front engulfs flocs at a high freezing rate. The forces exerted on a wastewater-sludge floc by the approaching ice front and the surrounding fluid field determine whether the ice front engulfs the floc. Two wastewater flocs of sizes 2170 and were hung on a cantilevered beam which underwent constant-speed freezing (5 or ). Beam deflection and the shape of sludge floc were recorded to estimate the force exerted by the ice and the elasticity of the sludge flocs. The force exerted by an approaching ice front on the floc ranged from 1.6 to , and was attributable primarily to the interaction between the gas bubbles formed between the floc and the ice front. When the ice had partly engulfed the floc, the corresponding force continuously increased as freezing continued, compressing the unfrozen part of the floc and pulling apart the network of the frozen part of the floc. The change in floc shape was tracked to estimate the interior elasticity of , and the elongation coefficient of for the flocs herein.     

Instrument for ceramic particle dispersion II: Computational fluid dynamics analysis

A planetary-type mixer using a container equipped with stainless steel mesh has been developed. For various slurries (Al₂O₃ in water), each modeled as Newtonian fluid, the shear stress was calculated using computational fluid dynamics (CFD) under various mixing conditions and with different equipment properties. The meshed-geometry included more than 100,000 nodes with hexahedral cells in one zone, with quadrilateral cells in the remaining zones. The fluid viscosity, rotation rate, and mesh opening affected the maximum shear stress. The shear stress increased concomitantly with increasing fluid viscosity. The container rotation rate and the maximum shear stress share a proportional relation. For a fluid with 9.2 mPa s, the shear stress was 134 Pa or more for a 0.81 mm and larger mesh opening, as observed at the bottom of the container. Mesh having an opening smaller than 0.81 mm generated high shear stress on the mesh surface. The maximum shear stress increased with decreasing mesh opening size. The particle size distributions of the Al₂O₃ particles in the slurries after treatment by the mixer were estimated under conditions similar to those of the calculations. Results show peaks in the particle size distributions of the Al₂O₃ particles in the slurries before treatment at 0.2 and 2-70 μm because of the primary particle size and agglomerates. The amounts of the agglomerate decreased concomitantly with the decreased mesh opening size. When slurries pass through the small mesh openings, high shear stress is generated. That achieves the good dispersion of the sub-micron sized Al₂O₃ particles in the slurry.     

Assessing floc strength using CFD to improve organics removal

Floc characteristics play a major role in the removal of contaminants from water in physico-chemical treatment processes. The efficiency of the main removal processes is a function of floc size, strength and density. Changes in these parameters affect floc removal and hence the removal of adsorbed organic matter. Coagulation and flocculation efficiency and floc strength are often assessed using a jar tester. Here, CFD was used to model the flow field within a standard jar test apparatus and, using a Lagrangian particle trajectory model, to study the effects of turbulence on individual flocs. Combining numerical and experimental data, velocity gradient values at which floc breakage occurs are postulated for three different floc suspensions. Although the threshold values are determined using jar test and CFD data in combination, they are based on the flocs’ resistance to induced velocity gradients. This is a significant result, as previous breakage thresholds have been expressed in terms of mixing speed and cannot be applied at full scale. The results shown here can be adopted for use in other situations and can be used to assess the performance of existing flocculators or to design new installations.     

Aggregation and breakage kinetics of fresh cement paste

The influence of shear-induced forces on the microstructure of fresh cement pastes was studied. Aggregation and breakage kinetics of the paste matrix are highly influenced by the shear history. It was found that the kinetics of re-aggregation is relatively slow, and time scale for recovery is longer than the time needed for breakdown. When the aggregation kinetics dominates, network interactions among particles develop and the average floc size increases. When the breakage kinetics dominates, network interactions among particles are broken and are accompanied by a decrease in the average floc size. The results suggest that there is a limiting size to floc growth. Minor additions of clays can significantly impact the structural network development and result in a more flocculated structure. The flocs produced by the clays were highly stable flocs with strong interparticle bonds that were able to oppose floc breakage and floc erosion.     

A comparison of the results obtained from grinding in a stirred media mill lignite coal samples treated with microwave and untreated samples

Various studies have been carried out on the effect of microwave-treatment on grinding different types of coal. However, the effect of microwave treatment on grinding coal samples −3.35 mm in size which can be considered to be fine is still under investigation. The purpose of this paper is to make contributions to these studies conducted. In the study, lignite coal samples with pyritic sulphur and 25% structural moisture were crushed below −3.35 mm particle size using jaw and cone crushers and then classified into three different mono size groups by Russel sieve. For a complete removal of the structural moisture from the lignite coal, a microwave application with 600 W needs approximately 35% more energy consumption than that with 850 W. The untreated coal samples and the ones treated with microwave at 850 W were ground for 5, 15, 30, 60, 120 s in a stirred media mill. The breakage rates of microwave-treated coal increased and accordingly the ground products of microwave-treated coal yielded finer particles than −106 μm as compared to untreated coals. The untreated and microwave-treated feed coals of −3350 μm and −1180 μm particle sizes were ground for 2 min in the stirred media mill. It was found that the increases in the rate of weight percentages for −106 μm particle size fraction after 2 min of grinding of untreated and microwave-treated feed coals of −3350 μm and −1180 μm were found to be 15.81% and 2.69%, respectively. Moreover, Hardgrove Index (HGI) test results of lignite coal showed that the HGI index value increased by approximately 23% after microwave treatment with 850 W.     

Understanding the role of restructuring in flocculation: The application of a population balance model

The effect of shear on floc properties was observed through population balance to comprehend the mechanisms of flocculation, in particular the role of restructuring. Little fundamental attention has been given before to the shear influence responsible for creating compact aggregates, while the floc characteristics might differ in other conditions. It is crucial to understand how aggregates evolve to steady state, if their properties are to be ‘tailored’ to suit subsequent solid-liquid separation. From a previous experimental study (Langmuir 18(6) (2002) 1974), restructuring was observed to occur extensively in the flocculation of latex particles in couette-flow, and was proposed to be responsible for the decrease in floc size on their transition to equilibrium. On the other hand, flocs of larger primary particles were more susceptible to breakage, with densification occurring as a result of fragmentation and re-aggregation. Denser flocs were found when structural deformation dominated, particularly in the initial stage of the process, while comparatively tenuous ones were observed when formation and breakage kinetics were the governing mechanisms. The distinct manners in which aggregates of different primary particle sizes evolved with time, were replicated with a population balance that incorporated the floc structural variation; verifying that restructuring indeed played a crucial role under certain flocculation conditions.