Numerical simulation of flow characteristics in settler of flash furnace

A computational fluid dynamics （CFD） simulation was carried out with CFX4,3 to investigate the melt flow and temperature distributions in the settler of a flash furnace. Sixteen cases of one slag tap hole adopted with one matte tap hole （1-to-l） and one slag tap hole adopted with two matte tap holes （1-to-2） operation modes were modelled. The simulation results show that the melt flows are similar in both two operation modes, but evident circulations can be found in the case of the 1-to-2 operation mode. The combination modes of the slag and matte tap holes are found to have a significant effect on the temperature distributions of the melt. The melt temperature is more uniform in the case of the 1-to-2 mode. Selection of a matte tap hole farther away from the inlet is more conducive to achieve a uniform distribution of the melt temperature in the settler in nractical tannine oneration

An experimental study of immiscible liquid–liquid dispersions in a pump–mixer of mixer–settler

Drop size distribution(DSD) or mean droplet size(d32) and liquid holdup are two key parameters in a liquid–liquid extraction process. Understanding and accurately predicting those parameters are of great importance in the optimal design of extraction columns as well as mixer–settlers. In this paper, the method of built-in endoscopic probe combined with pulse laser was adopted to measure the droplet size in liquid–liquid dispersions with a pump-impeller in a rectangular mixer. The dispersion law of droplets with holdup range 1% to 24% in batch process and larger flow ratio range 1/5 to 5/1 in continuous process was studied. Under the batch operation condition, the DSD abided by log-normal distribution. With the increase of impeller speed or decrease of dispersed phase holdup, the d32 decreased. In addition, a prediction model of d32 of kerosene/deionized system was established as d32/D = 0.13(1 + 5.9φ)We-0.6. Under the continuous operation condition, the general model for droplet size prediction of kerosene/water system was presented as d32/D = C3(1 + C4φ)We-0.6. For the surfactant system and extraction system, the prediction models met a general model as d32/D = bφnWe-0.6.

Computational fluid dynamics(CFD) simulation of effect of baffles on separation in mixer settler

The main ideas in the development of the solvent extraction mixer settler focused on achieving clean phase separation,minimizing the loss of the reagents and decreasing the surface area of the settlers.The role of baffles in a mechanically agitated vessel is to ensure even distribution,reduce settler turbulence,promote the stability of power drawn by the impeller and to prevent swirling and vortexing of liquid,thus,greatly improving the mixing of liquid.The insertion of the appropriate number of baffles clearly improves the extent of liquid mixing.However,excessive baffling would interrupt liquid mixing and lengthen the mixing time.Computational fluid dynamics(CFD) provides a tool for determining detailed information on fluid flow(hydrodynamics) which is necessary for modeling subprocesses in mixer settler.A total of 54 final CFD runs were carried out representing different combinations of variables like number of baffles,density and impeller speed.CFD data shows that amount of separation increases with increasing baffles number and decreasing impeller speed.

Structural optimization of a settler via CFD simulation in a mixer-settler

This work is aimed at optimizing a settler structure in a mixer-settler.Two different aspects have been considered.Firstly,the flowcharacteristics of a settler have been examined by computational fluid dynamics(CFD)simulation with various agitation speeds of the mixer,as well as organic phase volume fractions ranging from 0.075 to 0.6.The aqueous and organic phase turbulent flow fields were measured by particle image velocimetry(PIV)technique to verify the CFD simulation.Two organic phases with different physical properties were assessed in the CFD simulation to simulate the liquid-liquid systems related to rare earth element extraction,i.e.,0.072 mol·L^-1 P507/kerosene and 1.8 mol·L^-1 P507/kerosene.Secondly,the CFD simulation was carried out in a settler equipped with baffles.The effects of number and location of the baffle in the settler on flow features and entrainments of the aqueous and organic outlet were analyzed.Meanwhile,different settler/mixer volume ratios were also examined.By analyses and comparisons,an optimal design for settler was proposed.CFD can provide a significant guidance to better mixer-settler design.

Performance of a novel vertical-flow settler: a comparative study

By increasing particle concentration and G value （root-mean-square velocity gradient） to enhance flocculation, a novel vertical-flow settler was designed to increase sedimentation effectiveness, and to simultaneously improve operational stabilization. Due to the gradual decrease in upward flow-rate of raw water, a floes blanket would form and suspend in the middle section of the settler, not at the bottom as in a conventional clarifier. Enough large floes, resulted from flocculation or fltration, would continuously settle out of the floes blanket, and simultaneously, the floes in raw water or those forming above the blanket would ceaselessly enter the floes blanket. As a result, the floes concentration in the blanket could keep a dynamic balance. The hydrodynamic shear in the blanket was improved by flow separation, which was induced by the abrupt change in flow channel. Due to the floes blanket and improved hydrodynamic shear, flocculation would be enhanced, which was helpful for removing fine particles in raw water. A comparative study showed that the novel vertical-flow settler had a much better performance in the removal of the particles in raw water than a conventional one, when they treated kaolin suspensions of different concentrations （500, 100 and 50 mg/L, respectively） coagulated by polyaluminum chloride（PAC1） at the up-flow rates of 1 and 2 mm/s, respectively.

The Influence of Geometry on the Fluid Dynamics of Continuous Settler

Settlers are broadly used by industries for separating components with different densities, because they show operational facilities and high efficiency. As they use the action of gravity, they can treat great quantities of effluents with lower energy expenditure. However, the performance of the settler depends on the streamlines inside the equipment, which, in turn, are influenced by the characteristics of the suspended solids, the geometry, and dimensions of the tank. In this paper, the effect of the settler geometry properties on the hydrodynamic in a vertical circular cylindrical tank was investigated. The evaluated parameters were the feed pipe design, the dimensions of the piece of equipment, and the structure of settler bottom. The numerical simulations were performed using the package ANSYS-CFX 16.0. It was considered a turbulent, isothermal, and stationary flow. The Euler-Euler multiphase model and BSL-RSM model turbulence were applied. The recirculation zones were influenced by the separation tank geometrical form. The modification of the feed pipe in the original project reduced the mixture inside the feedwell. The increase of the sedimentation tank diameter improved the performance of water and solid separation, elevating the efficiency by 10.48%, whilst the increase of the tank depth reduced the separation efficiency by 16.72%, in comparison to the original project.

从高钙富硼老卤中提硼研究

以青海某高钙富硼老卤为研究对象开展了提硼研究。结果表明,合适的萃取条件为:磺化煤油为稀释剂、异辛醇用量50%、萃取相比1.0、萃取混合时间15 min;合适的反萃条件为:反萃剂为pH=1的稀盐酸、反萃相比1.5、反萃混合时间15 min。以此条件在5级混合澄清槽中完成了连续逆流萃取—反萃运转试验,连续运转45 h,硼萃取率为95.49%,硼与钾、钠、钙、镁的分离效果较好;硼反萃率为99.59%,反萃液中硼含量达17.17 g/L。采用“溶剂萃取—反萃—高温蒸发—低温冷却结晶—重溶—冷却结晶—过滤洗涤—干燥”工艺高效分离提取硼,硼总回收率为92.33%,制备出的硼酸产品达国家标准(GB/T 538—2018)要求。

萃取装备在烯草酮连续化生产中的应用

连续化是化工生产发展方向,以烯草酮生产中涉及的液-液萃取分离过程为对象,针对液-液萃取分离体系中杂质种类、含量及分离特性,详细探究两相流动及传质特性,开发了高效萃取塔、管式萃取器和油水聚结分离材料等,并成功应用于烯草酮生产萃取分离工段,实现了其连续自动化生产。基于高效萃取装备解决了传统釜式生产存在的密闭性差、产品质量不稳定、废水量大、能耗高、安全性差等问题,推动了我国农药化工生产技术水平持续提升。

Simple model of sludge thickening process in secondary settlers

In wastewater treatment plants （WWTPs）, a secondary settler acts as a clarifier, sludge thickener, and sludge storage tank during peak flows and therefore plays an important role in the performance of the activated sludge process. Sludge thickening occurs in the lower portions of secondary clarifiers during their operation. In this study, by detecting the hindered zone from the complete thickening process of activated sludge, a simple model for the sludge thickening velocity, us = aXb （ a =0.9925SSFI3.5, b = - 3.5411n（ SS VI3.5 ） ＋12.973）, describing the potential and performance of activated sludge thickening in the hindered zone was developed. However, sludge thickening in the compression zone was not studied because sludge in the compression zone showed limited thickening. This empirical model was developed using batch settling data obtained from four WWTPs and validated using measured data from a fifth WWTP to better study sludge thickening. To explore different sludge settling and thickening mechanisms, the curves of sludge thickening and sludge settling were compared. Finally, it was found that several factors including temperature, stirring, initial depth, and polymer conditioning can lead to highly concentrated return sludge and biomass in a biologic reactor.

Preparation of high-purity neodymium chloride by solvent extraction in the mixer-settlers： A pilot-scale investigation

A novel purification process based on mixer-settlers for high-purity NdClwas developed. Acidic solution and pure NdClsolution were compared to scrub the less-extractable rare earths(REs)(La, Ce, and Pr)from loaded organic phase. The extractant with low-degree saponification was evaluated to remove the more-extractable element(Sm). Then the RE impurities(La, Ce, Pr, and Sm) in Nd were purified by an integrated process. Furthermore, effect of smuggling behavior on the purification of NdClin mixersettlers was studied. Based on the investigation mentioned above, the pilot-scale purification process for NdClwith a purity of 99.999% was developed, and the total recovery was about 99%.

催化裂解装置反应系统结焦原因分析及应对措施

针对某石化企业2.2 Mt/a催化裂解装置反应系统结焦问题,根据结焦机理和装置实际运行情况分析认为:原料雾化效果不佳,油剂接触不均匀和存在未汽化油是造成提升管结焦的主要原因,并对后续系统结焦造成影响;油气停留时间长,反应程度深,热裂化缩合反应增加,同时油浆回炼量过大,导致油气中稠环芳烃、胶质、沥青质等结焦前身物较多;当温度低于该重组分露点温度时,就会凝析出液滴,重油液滴和催化剂会在油气静止区域、油气流体流动变化较大的区域向器壁或内构件黏附,并进一步发生脱氢缩合反应,逐渐固化累积形成较大的焦块。通过采取严控原料品质、控制反应深度、降低油浆回炼量、提升催化剂性能、提高反应注汽量等工艺优化措施,并采取脱气罐优化改造、增加中压防焦蒸汽环、旋风分离器优化改造等技术改造措施,有效缓解了反应系统结焦,保证了装置安全长周期运行。

铜闪速熔炼多相流模型化研究进展

铜闪速熔炼具有高处理量、高富氧浓度、高冶炼效率和低环境污染的优势,已在世界范围内广泛推广应用,深入研究闪速熔炼过程中的物理化学现象和原理具有重要意义。然而,闪速炉内多相流间相互作用及熔炼动力学行为受到多方面因素的共同影响,仅依靠生产经验、试验观测和理论分析难以全面解析炉内多相流传质传热过程、获取流体流动特性、揭示气固多相流相互作用规律,阻碍了闪速炉冶炼效能的进一步提升。当下计算流体力学数值模拟发展迅速,正为预测和分析闪速炉内多相流问题提供了高效、准确、直观的帮助。本文在介绍铜闪速炉结构、冶炼原理、理论模型的基础上,阐述了近年来铜闪速熔炼动力学反应机理、炉内流动特性方面模型化的研究成果及发展趋势,全面综述了铜闪速炉在喷嘴、沉淀池、上升烟道、锅炉优化方面的研究成果,为闪速炉生产优化及设计改进提供指导。

混合澄清槽中硝酸传质对分散相存留分数的影响

混合澄清槽是一种重要的液-液萃取设备,分散相存留分数是混合澄清槽混合室中的一个重要水力学参数。传质条件下分散相存留分数的变化情况是一个重要的研究方向。针对2套不同尺寸的混合澄清槽开展了水力学和硝酸传质实验。获得了水力学条件下泵轮转速、两相流比、料液停留时间对于分散相存留分数影响的实验结果。在传质条件下,发现2套混合澄清槽的级效率均>90%。该研究条件下传质通量集中在10-5~10-4数量级,在该数量级上传质通量很难对水力学性能产生影响,上述计算结果解释了传质条件下分散相存留分数未出现明显变化的根本原因。

FCC装置沉降器结焦原因分析及防范措施

针对某120 Mt/a重油催化裂化装置沉降器频繁结焦问题进行分析,不同位置的焦块组成分析表明,结焦的主要组成为催化剂细分和未汽化油,从结焦机理分析该装置的焦炭类型属于软焦。从工艺参数和设备结构两方面总结影响结焦的主要因素,包括原料性质不稳定、反应温度大幅度波动造成未汽化油增多、预提升干气用量不足、预提升套筒脱落以及粗旋出口和顶旋入口的软连接失效等。从优化原料性质和操作条件等方面提出一系列防结焦措施,可为催化裂化装置的长周期运行提供理论指导。

旋浮吹炼炉冷修及改造实践

根据某厂悬浮吹炼炉生产运行情况,结合冷修时发现的反应塔水套、沉淀池渣线区耐火砖以及上升烟道顶部侵蚀严重的情况,介绍了该厂悬浮吹炼炉第一次冷修期间针对反应塔、沉淀池、上升烟道进行的结构优化措施,并提出了后续该厂悬浮吹炼炉可以进行的进一步优化措施。

过硫酸铵代替锰矿粉作为氧化剂的研究与实践

本文阐述了湿法炼锌黄钾铁矾除铁工艺过程中,通过在锌浸出系统单独以锰矿粉作为氧化剂对生产产生不利的影响,提出了在浸出系统过程中添加过硫酸铵作为氧化剂的新思路,经过实验研究验证了该技术的优越性,并通过科学合理加入应用于生产实践中取得良好的效果。

全逆流混合澄清槽中萃取体系料液流场CFD模拟研究

为了研究全逆流混合澄清槽内气-液(水相)-液(有机相)三相流体在微观层面的行为,本文采用CFD方法,以全逆流混合澄清槽为对象进行了研究。结果表明,搅拌会在混合室内产生一个V型液位分布,桨叶后方出现负压区域,且上部会出现空化现象;正方形混合室的四角方向会出现压力滞止死区;混合室内有机相会出现围绕搅拌轴的包覆层,水相主要从桨叶正下方吸入后与有机相在桨叶区域进行混合;混合室内存在多个局部速度旋涡场,桨叶下部是四周液体向桨叶正下方汇集,桨叶上部则是先向上后向旋转轴汇集;两相的混合与液滴的破碎与并聚主要发生在桨叶处及混合室附近壁面上。

拜耳法赤泥沉降工序工艺指标对生产的影响

对影响赤泥沉降工序的混合效率、沉降槽底流固含、洗水量、滤饼含水率、赤泥压滤液及细种子苛化液加入点等工艺指标分别进行计算,分析识别影响沉降工序处理能力因素。研究发现,分离及洗涤沉降槽底液液固比降低、混合效率提高、滤饼含水率降低、洗水量增加,都能够使赤泥的碱附损量降低。因此,可通过改进沉降槽、静态混合器、压滤机等来进一步优化生产指标;同时,赤泥压滤液及细种子苛化液的最佳加入点应为矿浆碱浓度高于且最接近洗水浓度的那一级沉降槽。

基于ANSYS的高效沉降槽支腿结构有限元分析及结构优化

本文主要阐述了氧化铝生产中大型沉降设备(高效沉降槽)支腿结构有限元分析计算及其优化方案。高效沉降槽是氧化铝生产过程中结构比较复杂的核心设备,设备整体重量约几百吨左右,在保证设备制造经济性的前提下确保其安全性至关重要。本文以某氧化铝厂Φ20 m高效沉降槽为例,应用有限元分析对该设备支腿进行有限元分析,优化支撑结构形式,重点对支腿强度、稳定性进行了分析计算,并提出了一套新的支腿布局方案,减少支腿部件整体重量,降低设备投资。与现有结构形式相比,将排料筒悬空,可有效解决排料不畅,大大降低积料及结疤的产生,降低维修成本。

泥层界面仪在氧化铝厂沉降生产过程控制中的应用

泥层界面仪的使用为氧化铝厂赤泥沉降分离洗涤工序的优化过程控制提供了有效的在线检测手段。介绍了氧化铝厂沉降工序的控制现状,分析了采用泥层界面仪的必要性。简述了目前市场上的主流泥层界面仪的基本原理和主要功能。通过泥层界面仪的使用,测量出沉降槽泥层、过渡层以及清液层的液位,建立起基于进料量的前馈与泥层高度反馈的串级优化控制策略,有效的控制了底流泵的出料量,稳定了沉降槽的泥层液位高度。仿真实验结果证明,该策略能够合理控制沉降槽泥层和清液层高度,有效实现絮凝剂精准添加,减少絮凝剂单耗,稳定末洗底流的附碱,减少系统碱损失,最终实现提升沉降槽产能,使沉降工序的设备高效运行、实现生产指标平稳优化。