Tailings flocculation and sedimentation in a lab-scale gravity thickener by CFD modelling

IF 4.7 2区材料科学 Q2 ENGINEERING, CHEMICAL

Particuology Pub Date : 2026-01-01 Epub Date: 2025-11-07 DOI:10.1016/j.partic.2025.10.023

Xuetao Wang , Yuchen Shao , Zhiran Mao , Yulian Wang , Baoyu Cui , Andrew Bayly

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Abstract

This study employed coupled the Computational Fluid Dynamics-Population Balance Model (CFD-PBM) framework and Kinetic Theory of Granular Flow (KTGF) to investigate the flocculation and sedimentation dynamics of polymodal tailings particles in a lab-scale gravity thickener. The Euler-Euler multiphase model and RNG k-ε turbulence model are integrated to simulate solid-liquid interactions and turbulent flow characteristics, while flocculation kinetics, including aggregation and breakage mechanisms, are incorporated to quantify particle size evolution. The influence of feed velocity on flow field characteristics and particle flocculation-sedimentation efficiency was analyzed through visualization. The results indicated that the turbulent energy distribution is highly sensitive to the feed velocity. The optimal velocity range (2.0–2.5 m/s) promotes a balanced aggregation-breakage dynamics of particles, stabilizing the formation of larger flocs and enhancing sedimentation. Excessively high feed velocities (>3.0 m/s) induce stronger turbulence, reducing floc size and impairing sedimentation efficiency. Spatial analysis reveals that fine particles (<50 μm) are widely dispersed, while large flocs (>100 μm) dominate the underflow solid concentration. The impact of floc size and density on sedimentation was also examined. This study identifies a critical threshold for feed velocity to optimize thickener performance, providing a theoretical basis for process intensification in industrial thickeners.

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实验室重力浓缩机尾矿絮凝沉降CFD模拟

本研究采用计算流体动力学-种群平衡模型（CFD-PBM）框架和颗粒流动动力学理论（KTGF）耦合研究了多模态尾矿颗粒在实验室重力浓密机中的絮凝沉降动力学。结合欧拉-欧拉多相模型和RNG k-ε湍流模型，模拟固液相互作用和湍流特性；结合絮凝动力学，包括聚集和破碎机制，量化粒径演变。通过可视化分析了进料速度对流场特性和颗粒絮凝沉降效率的影响。结果表明，湍流能量分布对进给速度高度敏感。最佳速度范围（2.0-2.5 m/s）促进了颗粒的平衡聚集-破碎动力学，稳定了较大絮凝体的形成，增强了沉降。过高的进料速度（>3.0 m/s）会引起更强的湍流，降低絮体尺寸，降低沉降效率。空间分析表明，细颗粒（> 50 μm）广泛分布，而大絮凝体（>100 μm）主导了下流固体浓度。考察了絮体粒径和密度对沉降的影响。本研究确定了优化增稠机性能的进料速度临界阈值，为工业增稠机过程强化提供了理论依据。

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来源期刊

Particuology 工程技术-材料科学：综合

CiteScore

6.70

自引率

2.90%

发文量

1730

审稿时长

32 days

期刊介绍： The word ‘particuology’ was coined to parallel the discipline for the science and technology of particles. Particuology is an interdisciplinary journal that publishes frontier research articles and critical reviews on the discovery, formulation and engineering of particulate materials, processes and systems. It especially welcomes contributions utilising advanced theoretical, modelling and measurement methods to enable the discovery and creation of new particulate materials, and the manufacturing of functional particulate-based products, such as sensors. Papers are handled by Thematic Editors who oversee contributions from specific subject fields. These fields are classified into: Particle Synthesis and Modification; Particle Characterization and Measurement; Granular Systems and Bulk Solids Technology; Fluidization and Particle-Fluid Systems; Aerosols; and Applications of Particle Technology. Key topics concerning the creation and processing of particulates include: -Modelling and simulation of particle formation, collective behaviour of particles and systems for particle production over a broad spectrum of length scales -Mining of experimental data for particle synthesis and surface properties to facilitate the creation of new materials and processes -Particle design and preparation including controlled response and sensing functionalities in formation, delivery systems and biological systems, etc. -Experimental and computational methods for visualization and analysis of particulate system. These topics are broadly relevant to the production of materials, pharmaceuticals and food, and to the conversion of energy resources to fuels and protection of the environment.