7/24/2023

ChE 4755
Particle Technology

Akib Atique Khan Dhrubo

Assistant Professor
Department of Chemical Engineering
Dhaka University of Engineering and Technology

Multiple Particle System

Batch Settling

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Topics
 SUSPENSION OF PARTICLES
 Modified Stokes’ law
 Hindered settling velocity

 BATCH SETTLING
 Richardson-Zaki equation
 Settling flux 𝐔𝐩𝐬 as a function of suspension concentration 𝟏 − 𝛆
 Interface velocity

 BATCH SETTLING TEST

 Type I and type II settling
 Height-time curve and concentration profile
 Particle flux from height-time curve

Akib Atique Khan Dhrubo, AP, ChE 3

Suspension of Particles
 For a suspension of particles, a modified version of the Stokes’ law is assumed to
apply, where
μ
μ = and
f ε
ρ = ερ + (1 − ε)ρ
Where, ε is the voidage.

 The drag coefficient C for a single particle in a suspension can then be expressed
as,
𝟐𝟒 𝟐𝟒 𝛍𝐞
𝐂𝐃 = =
𝐑𝐞𝐩 𝐔𝐫𝐞𝐥 𝛒𝐚𝐯𝐞 𝐱
Where, C = R′ ρ U .

Akib Atique Khan Dhrubo, AP, ChE 4

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Suspension of Particles
 Terminal settling velocity for a suspension of particles:
Under the terminal condition,
gravity − buoyancy − drag = 0

πx πx 1 πx
ρ g− ρ g−C ρ U =0
6 6 2 4
Giving,
𝐱 𝟐 𝛒𝐏 − 𝛒𝐚𝐯𝐞 𝐠
𝐔𝐫𝐞𝐥 𝐓 = = 𝐔𝐓 𝛆𝐟 𝛆
𝟏𝟖 𝛍𝐞

U is the hindered settling velocity (settling velocity of a particle in the presence of

other particles).

Akib Atique Khan Dhrubo, AP, ChE 5

Suspension of Particles
 Superficial velocity is the velocity that doesn’t consider the individual area
occupied by the particles and the fluids. Superficial velocities of the fluids and the
particles can be expressed as,

Q Q
U = ; and U = respectively
A A

 Actual velocity takes the volume occupied by individual particles into

consideration and can be expressed in the following way.

𝐐𝐟 𝐔𝐟𝐬 𝐐𝐩 𝐔𝐩𝐬
𝐔𝐟 = = ; 𝐚𝐧𝐝 𝐔𝐩 = =
𝐀𝛆 𝛆 𝐀 𝟏−𝛆 𝟏−𝛆

Akib Atique Khan Dhrubo, AP, ChE 6

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Batch Settling
 Settling flux as a function of suspension concentration:
In batch settling, there is no net flow,
Q +Q =0
Hence,
1−ε
U = −U
ε
Using U = U − U for hindered settling and combining with the above expression,
𝐔𝐩 = 𝐔𝐓 𝛆𝟐 𝐟 𝛆

U is the hindered settling velocity of particles relative to the vessel wall.

Akib Atique Khan Dhrubo, AP, ChE 7

Batch Settling
Effective viscosity function
𝐑𝐞𝐩 Richardson-Zaki equation
𝐟 𝛆
. U =U ε .
< 0.3 f ε =ε

. U =U ε .
> 500 f ε =ε

In general f ε =ε U =U ε

 The exponent 𝐧 can be found by the following empirical relation for any region,

4.8 − n x .
= 0.043Ar . 1 − 2.4
n − 2.4 D
Here, 𝐱 = 𝐱𝐒𝐕 most preferably.

Akib Atique Khan Dhrubo, AP, ChE 8

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Batch Settling
 𝐔𝐩𝐬 can be referred as volumetric solid settling flux,
U = U 1−ε =U 1−ε ε
Now, the dimensionless particle settling flux,

𝐔𝐩𝐬
= 𝟏 − 𝛆 𝛆𝐧
𝐔𝐓

 The shape of the plot between

𝐔𝐩𝐬
𝐨𝐫 𝐔𝐩𝐬 vs. 𝟏 − 𝛆 can be assumed
𝐔𝐓
by noting that the curve has a maximum
and an inflection point at
𝐧 𝐧−𝟏
𝛆= 𝐚𝐧𝐝 𝛆=
𝐧+𝟏 𝐧+𝟏
respectively.
Show how these points are found.

Batch Settling
 Sharp interfaces in sedimentation: Discontinuity may occur in settling of
suspensions between two different concentration region.

 From the diagram, it can be shown that,

U −U C = U −U C
So, the interface velocity can be found as,

𝐔𝐩𝐬𝟏 − 𝐔𝐩𝐬𝟐
𝐔𝐢𝐧𝐭 =
𝐂𝟏 − 𝐂𝟐
i. The velocity of a layer of suspension of concentration C can be found by,
∆𝐔𝐩𝐬 𝐝𝐔𝐩𝐬
𝐔𝐢𝐧𝐭 = 𝐥𝐢𝐦 =
∆𝐂⟶𝟎 ∆𝐂 𝐝𝐂
ii. The velocity of an interface between two different concentrations:

𝐔𝐩𝐬𝟏 − 𝐔𝐩𝐬𝟐
𝐔𝐢𝐧𝐭 = 10
𝐂𝟏 − 𝐂𝟐

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Batch Settling

Akib Atique Khan Dhrubo, AP, ChE 11

Batch Settling
Illustration: A suspension in water of uniformly sized sphere (diameter 𝟏𝟓𝟎 𝛍𝐦,
density 𝟏𝟏𝟒𝟎 𝐤𝐠⁄𝐦𝟑 ) has a solids concentration of 𝟐𝟓% by volume. The suspension
settles to a bed of solids concentration of 𝟓𝟓% by volume.
Calculate:
i. the rate at which the water/suspension interface settles.
ii. the rate at which the sediment/suspension interface rises (assume water
properties: density 𝟏𝟎𝟎𝟎 𝐤𝐠⁄𝐦𝟑 ; viscosity 0.001 Pa s).

Solution:
i. The velocity of the interface between clear water and original suspension is,

U
C −U C
U , = =U
C −C
Here, 𝐔𝐩𝐁 is the hindered settling velocity of the particles relative to the vessel.

Akib Atique Khan Dhrubo, AP, ChE 12

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𝐔𝐩𝐁 can be expressed by the Richardson-Zaki equation by the following manner.

U =U ε
Assuming Stokes’ law, 𝐔𝐓 can be found as,

x ρ −ρ g
U = = 1.717 × 10 m⁄s
18μ
And the validity of the assumption can be checked by evaluating 𝐑𝐞𝐩 .
So, substituting 𝐔𝐓 value and 𝐧 = 𝟒. 𝟔𝟓, we find,

U = 1.717 × 10 0.75 . = 0.45 × 10 m⁄s = 𝟎. 𝟒𝟓 𝐦𝐦⁄𝐬

ii. Do it yourself.

Akib Atique Khan Dhrubo, AP, ChE 13

Batch Settling
 Batch settling test: A suspension of particles are thoroughly mixed in a cylinder to
ensure constant concentration. The positions of the interface are monitored in time.

Based on the initial concentration, two types of settling can be observed.

 Type I settling: Three zones of constant concentration are observed (clear
liquid, suspension of original concentration and sedimentation).

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Batch Settling
A typical height-time plot for the type I settling is as follows,

 Type II settling: Three zones of constant concentration (clear liquid,

suspension of original concentration and sedimentation) and one variable
concentration zone (where the limits are constant) are observed.

The zones during the test and a typical height-time curve for type II settling is
shown in the following page:

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Batch Settling
 Whether type I settling or type II settling occurs can be determined using the flux
plot 𝐔𝐩𝐬 𝐯𝐬. 𝐂 .

 Type I settling occurs if

𝐂𝐁 < 𝐂𝐁 𝟏 ; 𝐨𝐫 𝐂𝐁 > 𝐂𝐁 𝟐
 Type II settling occurs if
𝐂𝐁 𝟏 < 𝐂𝐁 < 𝐂𝐁 𝟐

Akib Atique Khan Dhrubo, AP, ChE 17

Batch Settling
 Particle flux from height-time curve:
For type I settling,
 The velocity of the descending interface between clear liquid and suspension of
concentration C can be found from the height-time curve:
dh h − h
U = =
dt t
 The velocity of the rising interface from the
base can be found as,

h
U =
t
So, the velocity of the particles relative to the
rising plane,
h
U +U =
t
Akib Atique Khan Dhrubo, AP, ChE 18

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Batch Settling
 Now, the volume of the particles passing through the interface is equal to the total
volume of the particles, as the plane is sharing the interface with the clear liquid.
Mathematically,
h
A Ct = C h A
t
And hence,
C h
C=
h

Akib Atique Khan Dhrubo, AP, ChE 19

Batch Settling
Illustration: A height–time curve for the sedimentation of a suspension of initial
suspension concentration 0.1, in vertical cylindrical vessel is shown in the following
figure.

Akib Atique Khan Dhrubo, AP, ChE 20

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Determine:
i. the velocity of the interface between clear liquid and suspension of concentration
𝟎. 𝟏.
ii. the velocity of the interface between clear liquid and a suspension of
concentration 𝟎. 𝟏𝟕𝟓.
iii. the velocity at which a layer of concentration 𝟎. 𝟏𝟕𝟓 propagates upwards from the
base of the vessel.
iv. the final sediment concentration.

Akib Atique Khan Dhrubo, AP, ChE 21

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Solution:
i. This is the slope of the straight portion of the curve.
So,
𝟐𝟎 − 𝟒𝟎
𝐔𝐢𝐧𝐭,𝐀𝐁 = = −𝟏. 𝟑𝟑𝟑 𝐜𝐦⁄𝐬 = 𝟏. 𝟑𝟑𝟑 𝐜𝐦⁄𝐬 𝐝𝐨𝐰𝐧𝐰𝐚𝐫𝐝
𝟏𝟓

ii. The corresponding height for 𝐂 = 𝟎. 𝟏𝟕𝟓 can be found as,

C h
h =
= 22.85 cm
C
The corresponding time for C = 0.175 suspension to interface with the clear liquid is
found by drawing a tangent of the curve from h = 22.85 cm, and the time is t = 26 s.
So,
𝟏𝟓 − 𝟐𝟐. 𝟖𝟓
𝐔𝐢𝐧𝐭,𝐀𝐄 (𝐂 𝟎.𝟏𝟕𝟓) = = −𝟎. 𝟑𝟎𝟐 𝐜𝐦⁄𝐬 = 𝟎. 𝟑𝟎𝟐 𝐜𝐦⁄𝐬 𝐝𝐨𝐰𝐧𝐰𝐚𝐫𝐝
𝟐𝟔

Akib Atique Khan Dhrubo, AP, ChE 23

iii. The upward propagation velocity,

𝟏𝟓
𝐔(𝐂 𝟎.𝟏𝟕𝟓) = = 𝟎. 𝟓𝟕𝟕 𝐜𝐦⁄𝐬
𝟐𝟔

iv. The final sedimentation concentration can be found by,

𝐂𝐁 𝐡𝟎
𝐂𝐬 = = 𝟎. 𝟒
𝐡𝟏𝐬

Akib Atique Khan Dhrubo, AP, ChE 24

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Illustration: For the batch flux plot shown in the following figure, the sediment has a
solids concentration of 𝟎. 𝟒 volume fraction of solids.
i. Determine the range of initial suspension concentrations over which a zone of
variable concentration is formed under batch settling conditions.
ii. Calculate and plot the concentration profile after 𝟓𝟎 𝐦𝐢𝐧 in a batch settling test of
a suspension with an initial concentration of 0.1 volume fraction of solids, and
initial suspension height of 100 cm.
iii. At what time will the settling test be complete?

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Solution:
i. The range of initial concentration for which a region of variable concentration
exists can be found by drawing a tangent to the curve from 𝐂𝐬 = 𝟎. 𝟒, 𝐔𝐩𝐬 = 𝟎.
And the region is found to be
𝟎. 𝟎𝟑𝟔 < 𝐂𝐁 < 𝟎. 𝟐𝟏

ii. The velocities of the interface are The corresponding position of the
determined as, interfaces after 𝟓𝟎 𝐦𝐢𝐧:

U , = 0.166 mm⁄s = 1 cm⁄min AB interface 50.0 cm downwards

U , = −0.111 mm⁄s = −0.66 cm⁄min BE interface 33.2 cm upwards

U , = −0.035 mm⁄s = −0.213 cm⁄min E S interface 10.6 cm upwards

Akib Atique Khan Dhrubo, AP, ChE 26

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100

𝐂𝐀
A

50 𝐂𝐁
Intermediate points
B At C = 0.18, position = 22.0 cm
33.2 𝐂𝐄𝐦𝐢𝐧 At C = 0.2, position = 13.3 cm

E
𝐂𝐄𝐦𝐚𝐱 𝐂𝐒
10.6
S
0.1 0.21 0.4
0.16

Akib Atique Khan Dhrubo, AP, ChE 28

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iii. To solve this portion a height-time

curve is to be constructed.
The straight lines in the curve represent
the interfaces of known constant
concentration (AB, 𝐁𝐄𝐦𝐢𝐧 , 𝐄𝐦𝐚𝐱 𝐒
interfaces) and can be formed from their
corresponding positions after 𝟓𝟎 𝐦𝐢𝐧.
The end time is the time when E S
coincides with the final sediment height.
The final height can be calculated by,

C h
h = = 25 cm
C
So, the end time ~𝟏𝟐𝟎 𝐦𝐢𝐧.

Akib Atique Khan Dhrubo, AP, ChE 29

Continuous Settling
 Settling of a suspension in a flowing fluid:
A solid suspension of concentration (1 − ε ) or C is fed and withdrawn continuously
at same volumetric flow rate Q.
Q= U +U A

At any position, the relative velocity can be

written as,
U U
U = − = U εf ε
1−ε ε

Eliminating U from the above two equations, we get

𝐐(𝟏 − 𝛆)
𝐔𝐩𝐬 = + 𝐔𝐓 𝛆𝟐 (𝟏 − 𝛆)𝐟 𝛆
𝐀
Or,
𝐒𝐨𝐥𝐢𝐝 𝐬𝐞𝐭𝐭𝐥𝐢𝐧𝐠 𝐟𝐥𝐮𝐱 = 𝐟𝐥𝐮𝐱 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐮𝐥𝐤 𝐟𝐥𝐨𝐰 + 𝐟𝐥𝐮𝐱 𝐝𝐮𝐞 𝐭𝐨 𝐬𝐞𝐭𝐭𝐥𝐢𝐧𝐠 (𝐛𝐚𝐭𝐜𝐡 𝐟𝐥𝐮𝐱)
Akib Atique Khan Dhrubo, AP, ChE 30

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Continuous Settling
A similar analysis can be performed for upward flow,

𝐐(𝟏 − 𝛆)
𝐔𝐩𝐬 = 𝐔𝐓 𝛆𝟐 𝟏 − 𝛆 𝐟 𝛆 −
𝐀
Or,
𝐒𝐨𝐥𝐢𝐝 𝐬𝐞𝐭𝐭𝐥𝐢𝐧𝐠 𝐟𝐥𝐮𝐱 = 𝐟𝐥𝐮𝐱 𝐝𝐮𝐞 𝐭𝐨 𝐬𝐞𝐭𝐭𝐥𝐢𝐧𝐠 𝐛𝐚𝐭𝐜𝐡 𝐟𝐥𝐮𝐱 − 𝐟𝐥𝐮𝐱 𝐝𝐮𝐞 𝐭𝐨 𝐛𝐮𝐥𝐤 𝐟𝐥𝐨𝐰

Akib Atique Khan Dhrubo, AP, ChE 31

 The bulk flow flux line is drawn with a

slope of 𝐐⁄𝐀.
 Total continuous downward flux is
determined by adding bulk flow flux
line with the batch flux line.
 Corresponding concentration inside the
thickener 𝐂𝐁 is found by horizontal
movement.

 The bulk flow flux line is drawn with a

slope of −𝐐⁄𝐀.
 Total continuous downward flux is
determined by subtracting bulk flow
flux line from the batch flux line.
 Corresponding concentration inside the
thickener 𝐂𝐓 is found by horizontal
movement.

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Thickeners
 In a practical thickener, the “up flow’ and the “downflow” sections are to be
considered simultaneously.

 A suspension of concentration 𝐂𝐅 is fed at a

rate of 𝐅 at an intermediate point.
 An underflow is drawn off at the base at a
rate of 𝐋 and concentration of 𝐂𝐋 .
 An overflow of rate 𝐕 and concentration of 𝐂𝐕
flows out at the top.

 A simple total and particle material balance gives:

𝐅 = 𝐕 + 𝐋; 𝐅 𝐂𝐅 = 𝐕 𝐂 𝐕 + 𝐋 𝐂 𝐋
The mean particle concentration in the bottom and the top is 𝐂𝐁 and 𝐂𝐓 respectively.

Akib Atique Khan Dhrubo, AP, ChE 33

Thickeners
 Based on the feed flow rate and concentration, thickeners can be loaded in any of
the following three ways:
 Critically loaded thickeners: 𝐂𝐅 is equal to the critical concentration giving rise
to a feed flux equal to the continuous flux that the downflow section can
deliver.

 Underloaded thickeners: 𝐂𝐅 is less than the critical concentration giving rise to

a feed flux less than the continuous flux that the downflow section can deliver.

 Overloaded thickeners: 𝐂𝐅 is greater than the critical concentration giving rise

to a feed flux greater than the continuous flux that the downflow section can
deliver.

Akib Atique Khan Dhrubo, AP, ChE 34

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In a critically loaded thickener,

 The upflow flux is zero.

 The feed intersects the total continuous

downward flux at feed concentration.
So,
𝐂𝐅 = 𝐂𝐁

 As there is no overflowing, the feed

flux is equal to the underflow flux and
𝐂𝐋 can be found by moving
horizontally.

 The concentration in the upflow section

can either be zero or,
𝐂𝐓 = 𝐂𝐅 = 𝐂𝐁

35

In an underloaded thickener,
 The upflow flux is again zero.

 𝐂𝐁 and 𝐂𝐋 both can be found by moving

horizontally from the feed flux line.

As there is no overflowing, the feed flux

is equal to the underflow flux. 𝐂𝐓 and
𝐂𝐕 are both zero.

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In an overloaded thickener,
 The upflow flux is the excess flux found
as the difference between the feed flux
and the total continuous flux.

 𝐂𝐁 is found from the intersection and

𝐂𝐋 by moving horizontally from the
intersection.

 Applying the excess flux to the upflow

section 𝐂𝐓 is found and 𝐂𝐕 is found by
moving horizontally to the overflow
flux line. upflow flux = overflow flux .

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Illustration: Use the following batch flux data

Solid suspension Solid suspension

Settling flux 𝐦𝐦⁄𝐬 Settling flux 𝐦𝐦⁄𝐬
concentration concentration
0 0 0.2 0.013
0.025 0.01 0.225 0.012
0.05 0.018 0.25 0.0112
0.075 0.02 0.275 0.0105
0.1 0.0185 0.3 0.01
0.125 0.0175 0.325 0.01
0.15 0.016 0.35 0.01
0.175 0.014

to answer the following:

i. Graphically determine the limiting feed concentration for a thickener of area
𝟏𝟎𝟎 𝐦𝟐 handling a feed rate of 𝟎. 𝟎𝟏𝟗 𝐦𝟑 ⁄𝐬 and an underflow rate of 𝟎. 𝟎𝟏 𝐦𝟑 ⁄𝐬.
Under these conditions what will be the underflow concentration and the
overflow concentration? 38

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ii. Under the same flow conditions as above, the feed concentration is increased to
0.2. Estimate the solids concentration in the overflow, in the underflow, in the
upflow section and in the downflow section of the thickener.

Solution:
i. A simple material balance on the process gives the overflow rate.
F = V + L; V = 0.009 m ⁄s
The slopes of the fluxes are found as,

F L V
= 0.19 mm⁄s ; = 0.10 mm⁄s ; = −0.09 mm⁄s
A A A
From these extracted information; feed flux, overflow flux, underflow flux and total
continuous downward fluxes for below feed and above feed can be plotted and the
overall graphs are shown in the next page.

Akib Atique Khan Dhrubo, AP, ChE 39

0.04
Feed flux

0.03
Downward flux for
below feed
0.02
𝐔𝐩𝐬

Underflow
flux
0.01
The following results
Batch flux
are obtained
0.174
0
𝐂𝐅 = 0.174
0 0.1 0.2 0.3 0.33 0.4 𝐂 𝐂𝐋 = 0.33
𝐂𝐕 = 0
0.02

0.01

𝐂
𝐔𝐩𝐬

Downward flux for

-0.01
above feed
-0.02
Overflow
-0.03 flux

-0.04

Akib Atique Khan Dhrubo, AP, ChE 40

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0.04
Feed flux

0.03
Downward flux for
below feed
0.02
𝐔𝐩𝐬

Underflow
flux
0.01
The following results
Batch are obtained:
0.174 flux
0 In the downflow
0 0.1 0.2 0.3 0.33 0.4 𝐂 section:
𝐂𝐁 = 𝟎. 𝟐
0.02
𝐂𝐋 = 𝟎. 𝟑𝟑
0.01 In the upflow section:
𝐔𝐩𝐬

0.044 0.2 𝐂 𝐂𝐕 = 𝟎. 𝟎𝟒𝟒

0
𝐂𝐓 = 𝟎. 𝟐
Downward flux for
-0.01
above feed
-0.02
Overflow
-0.03 flux

-0.04

Akib Atique Khan Dhrubo, AP, ChE 41

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