Numerical simulation of water- air flow pattern in a ... · 41 Bozano ECOMIN TriFlo 1 Numerical...
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141 Bozano ECOMIN TriFlo
Numerical simulation of water-air flow pattern in a TriFlo® cylindrical separator
• Girolamo Belardi, Paolo Bozano, Jure Mencinger, Marzio Piler, Gianni Schena
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241 Bozano ECOMIN TriFlo
• hydromechanical processing and
subsequent digestion of bio-wastes,
domestic refuse and miscellaneous of
municipal and industrial wastes and
biomasses
• ore dressing, industrial minerals
• environmental & recycling plants
• steelworks, material handling
• mining, tunneling & civil works
engineering services, assistance to plant operation and strategic consulting in above fields
• renewable energy
Fields of activity
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341 Bozano ECOMIN TriFlo
Dense Medium Cyclone Separators
a) DutchStateMine conical cyclone
b) DynaWhirlPool DWP
c) TriFlo®
d) Larcodem
e) 3-product cyclone
TriFlo®
• cylindrical multistage separator applied in difficult separations or for 3-product separations
• 33 industrial plants16 pilot plants
a) b) c)
d) e)
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441 Bozano ECOMIN TriFlo
Two stages: Why?
• 2nd stage : cleaner > in coal prep
• 2nd stage : scavenger > in min prep
TriFlo® 300 with Dynafeed®
Coal
TriFlo® 500
with Dynafeed®
POTENTIAL APPLICATION FOR CHILE: COPPER PRECONCENTRATION
GANGUE DISCARD• 1st stage : rougher
• Two density cuts (i.e 3 products) and/or 3 stages also possible
Chromite TriFlo® 400
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541 Bozano ECOMIN TriFlo
Advantages of Rougher cleaner and rougher-cleaner with re-circulation
Overload
Second stage always corrects high density tails – very forgiving to feed variations
Possibility of Middlings Recirculation
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641 Bozano ECOMIN TriFlo
Circuits (F = Feed; C = Concentrate; R = Rejects)
1. Rougher 3. Rougher-Cleanerwith Re-circulation
4. Rougher-Scavenger-Cleanerwith Re-circulation
Ep=1.000
SG50=1.600
CF
R
F
R
Ep=0.850
SG50=1.568
F C
R
Ep=0.727
SG50=1.582
F C
R
Ep=0.500
SG50=1.600
Assumptions:- each stage has the same Ep and the same separation cut point d50
- Whiten partition equation- the reported Ep of each circuit has been normalized to the single stage circuit
2. Rougher-Cleaner
C
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741 Bozano ECOMIN TriFlo
Triflo®- CFD study
Ore Inlet
Feed Outlet
Sink Outlet 2
Sink Outlet 1
Medium Inlet 1
Medium Inlet 2
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841 Bozano ECOMIN TriFlo
CFD Set-up
• CFD solver: Ansys-FLUENT ver 14.0
• Mesher: Ansys-ICEM (> 300 000 hexeahedral cells)
• Multiphase: Volume Of Fluids (VOF) model
• Inlet boundaries: prescribed velocity with 5% turbulence
• Outlet boundaries: prescribed back-pressure
• Turbulence: Reynolds-Stress (RSM) model
• Surface tension: Continuum Surface Force (CSF) model
• TriFlo® 100mm ID
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941 Bozano ECOMIN TriFlo
Time required for Semi stationary state
The calculations are time dependant as stationary state can not be found.
The air core is not static in reality and calculations with VOF model are time dependant
The volume of air core reaches the oscillatory semi-stationary state after 30s
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1041 Bozano ECOMIN TriFlo
Timed Streamline
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1141 Bozano ECOMIN TriFlo
Axial velocity at several cross sections
Upward axial velocity near the wall
Downward axial velocity near the air core
Zero axial velocity in between ( wide zone)
The medium that does not exit at the sinkis subjected to flow reversal and directedto the float outlet
Wide zone of zero axial velocity means favourable condition for high sharpness
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1241 Bozano ECOMIN TriFlo
Y=0
FEED FLOAT
Axial velocitiesCFD vs Experience: Comparison between CFD results and laser Doppler measu-
rements on a transparent acrylic model TriFlo® 100mm ID
Particles close to the wall report to the Sink products by the upward axial velocity
The reversed flow (downard axial velocity) close to the air-core accompanies the Float products at the axial float discharge
STAGE 1 STAGE 2Sink1 Sink2
Medium1 Medium2
X=0
FEED FLOAT
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1341 Bozano ECOMIN TriFlo
Simulation 51cm Counterpressure
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1441 Bozano ECOMIN TriFlo
Simulation Increasing Counterpressure
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1541 Bozano ECOMIN TriFlo
Tangential velocities
The tangential velocity is:
Rather constant along the axis (forced vortex)
one order of magnitudehigher than axial & radialvelocities
FEED
Tangential velocity profiles depend on many factors: geometries, counterpressures, inlet medium velocity
FLOAT
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1641 Bozano ECOMIN TriFlo
Typical plant flowsheet – Graspan RSAtreating rejects from DMS plant with static bath 70x28mm, DMS 28x1mm, spirals <1mm
2 products configuration 3 products configuration
ROM feed
250 t/h
Feed size
70x1mm
Premium
Coal
RSA
Coal
210t/h sink
without affecting
clean coal quality
@220t/h feed
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1741 Bozano ECOMIN TriFlo
Graspan RSA – Coal Washing Plant
Tri-Flo®
Feed Conveyor
D&R Discards screen Middlings
Conveyor
Primary Magsep
D&R Premium &
Middling’s screen
Height 16 m Footprint 76 m2
Average Ep=0.012/17 and very little misplaced materials 0,86%Organic efficiency 98,9% - Near Gravity material (±0.1g/cm3) 27,2%
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1841 Bozano ECOMIN TriFlo
Graspan RSA 700mm TriFlo®
Top sized washed 200x115x65mm
At Tabas CPP 300x190x100mm lumps
have been rejected
Tramp material collected from the
sink discharge – steel bar 800 mm long
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1941 Bozano ECOMIN TriFlo
Graspan RSA Wear conditions after 1,25Mt discards
Very limited and localized wear in the Sink1 head (with Abrasion Index 2.000)
New TriFlo® can be fully ceramic lined
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2041 Bozano ECOMIN TriFlo
Woksop UK - PLASTIC RECYCLING
0
5
10
15
20
25
30
95,0 95,5 96,0 96,5 97,0 97,5 98,0 98,5 99,0 99,5 100,0
purity%
losses %
Line 1 Cyclone Line 2 Cyclone Line 1Tri-Flo
Plastic recycling from automobiles shredding residues 5 t/h – TriFlo® 250
Comparison between conical cyclones and TriFlo®. Definitions: Purity - Wt% of light particles (SG<1.10) in float; Losses -Wt% of light particles (SG<1.10) in sinks
Cylindrical cyclones are more suitable for low density separations;
Cylindrical cyclones are less sensitive to particle shape (flat and elongated particles can not be separated efficiently in traditional conical cyclones);
Double washing in one vessel with higher separation sharpness;
Very forgiving of feed changes Compact layout; Gravity feed of difficult to pump and
abrasive material; Low head plant
Superior results of the TriFlo® technology in plastic separation
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2141 Bozano ECOMIN TriFlo
Brusnengo Italy – Glass recycling Glass recycling from glass cullets 30 t/h – TriFlo® 300
Float
Sink 1
Sink 2
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2241 Bozano ECOMIN TriFlo
Copper PreconcentrationA potential application for increasing ROM Cu % to the
design values of the existing concentration plants
GOAL: EARLY WASTE REJECT
Necessary precondition: Cu enrichment in heavier density fractions in size coarser than 0.5mm
MAIN ADVANTAGES:
1. Savings in grinding and processing costs (energy etc)
2. Savings in water consumption
3. Extended mine life due to lowered cut-off grade
4. Better utilization and higher metallurgical efficiencyof existing plants (feed with design Cu%)
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2341 Bozano ECOMIN TriFlo
CFD Conclusions• Computational Fluid Dynamics is a powerful
tool for a better understanding of the fundamental behaviors of the TriFlo®
• The model has been verified with Laser Doppler experimental data
• Prediction of separation results depending on feed material and operating parameters
• It is a cost-efficient way of achieving better and more accurate designs highly reducing expensive and time consuming prototyping
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2441 Bozano ECOMIN TriFlo
We are your competent partner for:
Tank House Crane Lamella Thickener TriFlo™ Rubber Hoses
Via di Francia 54R16149 – Genova - ITALYECOMIN S.r.l.
QUESTIONS?• ore dressing, industrial minerals, steelworks, environmental &
recycling plants, anaerobic digestion of biowaste, material handling