Polymer Applications Understanding Polymer Activation. Presented by Rich Hopkins February 15, 2011
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1 Polymer Applications Understanding Polymer Activation Presented by Rich Hopkins February 15, 2011
2 Why Polymer? Helping particles settle faster Improving liquid/solid separation
3 Some Applications Clarifiers Primary Coagulation Plate & Frame Press Rotary Drum Thickener Belt Press Drying Beds Gravity Belt Thickener Centrifuges Paper Machines Mining & Metal Processing Paint Booths Enhanced Oil Recovery
4 Settling Rates Diameter of Particle, mm Order of Size Total Surface Area Time Required to Settle 10.0 Gravel sq in 0.3 sec 1.0 Coarse Sand 4.87 sq in 3.0 sec 0.1 Fine Sand 48.7 sq in 38 sec 0.01 Silt 3.38 sq ft 33 min Bacteria 33.8 sq ft 55 hr Colloidal particles Colloidal particles 3.8 sq yd 0.7 acre 7.0 acre 230 days 6.3 yrs 63 yrs Color particles
5 Inorganic Salts Common Name Formula Equivalent weight ph at 1% Availability Alum Al 2 (SO4) 3 * 14H 2 O Lump 175 Al 2 O 3 Liquid 8.5% Al 2 O 3 Lime Ca(OH) Lump as CaO Powder 93-95% Slurry 15-20% Ferric chloride FeCl 3 * 6H 2 O Lump 20% Fe Liquid 20% Fe Ferric sulfate Fe 2 SO 4 * 3H 2 O Granular 18.5% Fe Copperas FeSO 4 * 7H 2 O Granular 20% Fe Sodium aluminate Na 2 Al 2 O Flake 46% Al 2 O 3 Liquid 25% Al 2 O 3
6 Inorganic Salts Advantages Low Cost Disadvantages ph dependent Typically higher dosage and increased sludge volumes No reduction of organic residuals Weak flocs
7 Synthetic Organic Polymers Advantages Strong Stable Floc Improved dewatering No additional sludge volume Effective over wide ph range Can reduce organic molecules Disadvantages Slippery safety hazard Needs proper mixing & activation Handling and proper application effects performance
8 Molecular Weight Low - Coagulant High - Flocculant
9 Polymer Charges Non-ionic = no charge Anionic = negative (-) charge Cationic = positive (+) charge
10 Charge Density
11 Form Coagulant Mannich Emulsion/Dispersion Dry
12 Forms Of Polymers Solution Polymers Primary coagulants 10% - 50% active Low molecular weight 5K - 200K Appearance - clear homogeneous liquid Package - Pails, Drums, Bins, Bulk Easy to dilute Neat product easy to pump Susceptible to Freeze Charge - cationic, anionic
13 Forms Of Polymers MANNICH - Solution Flocculant 4-6% active Low molecular weight segments 5K - 200K Appearance - clear to amber liquid Package - Bulk Can Freeze Viscous can be hard to pump Viscosity temperature dependent Fumes are unpleasant Charge - cationic only
14 Forms Of Polymers Emulsions/Dispersions 25-55% active Appearance - white liquid Medium to High molecular weight - 5M - 10M Appearance - clear homogeneous liquid Package - Pails, Drums, Bins, Bulk Neat product easy to pump but!! Needs Activation Susceptible to Freeze Will settle in neat form Charge - cationic, anionic, non-ionic
15 Emulsion Polymers Water Oil Anionic, Cationic, Nonionic Flocculant 25% to 55% active Polymer gel size 0.1 to 5 um Polymer
16 How Complex Is A Polymer Structure If MW is 10 million 350,000 molecules in a gel One molecule has 150,000 monomers 2.5 microns =
17 Emulsions/Dispersions They Separate in storage Emulsion Polymer Separated Oil Layer Settled Out Polymer
18 Forms Of Polymers Dry Polymers 90% - 95% active All molecular weights to 20M+ Appearance - powder, pellets, granules, beads Package - bags, bulk bags Must be wetted Dusting is safety concern Shelf life in years Charge - cationic, anionic, non-ionic
19 Polymers (Polyelectroylytes) How they work How can we characterize them How to make them work
20 Jar Testing
21 Jar Tests
22 Polymer Selection Type Of Polymer Molecular Weight Charge Density % Active Content Bench Test Performance Evaluations
23 Preparation / Activation Moment Of Initial Wetting Agglomeration / Fragility Rate Of Hydration Charge Site Exposure
24 Rate Of Hydration (The Science) With good dispersion at Moment of Initial Wetting a 1 micron radii polymer particle can fully hydrate in 1 minute swells ~ 6-7 times
25 Rate Of Hydration (Reality) Without good dispersion agglomerations are formed 10 micron agglomeration will fully hydrate in min(s)
26 Rate Of Hydration (Attempt to Correct) Without good dispersion agglomerations are formed 10 micron agglomeration will fully hydrate in 100 min(s) Time increases by the square of the increase in the radius (10 squared)
27 The Art of Aging Aging is a Solution to a Problem not a method or the goal of polymer activation Aging is always required of all improperly mixed polymer solutions Aging is a attempt to gain total polymer activation Too much aging is detrimental to a properly mixed polymer
28 Characteristics of Polymer Dissolution Fragility Agglomeration time
29 How Fragile is It? One gram of free falling water will rupture 1 million carbon-carbon bonds. Proper application of energy is critical
30 Methods Of Preparation / Activation In-Line Activation Batch Tank
31 Activation Measures Polymer Activation Research Credit of Yong H. Kim Ph.D.
32 Charge Site Exposure
33 Uniformity Of Mixing Energy
34 Mixing Zones Conventional Mixing
35 The Major Players Siemens/Stranco/W&T Polyblend Neptune Dynablend Komax Semblex Jet Wet (Dyna-Jet) Acrison Norchem Velodyne ProMinent Fluid Controls
36 PB the original
37 PB the original Turbine blade Baffle plate
38 H-Series HydroForce
39 H-Series HydroForce
40 M-Series
41 M-Series High speed open vane impeller Secondary mixing zone
42 3-Stage Mixing Chamber 3 Distinct mixing zones 3 Different mixing blades to deliver proper energy 1 st Zone Blade delivers high shear at precise point of polymer injection, creating immediate dispersion before agglomeration takes place. Induced back mixing eliminates short circuiting ProMix Chamber
43 3-Stage Mixing Chamber 2 nd Zone Induces a vortex and draws solution down from zone 1 and forces solution to cylinder sides and into zone 3. 3rd Zone This zone gently blends the active polymer solution before it exits the chamber. ProMix Chamber
44 3-Stage Mixing Chamber Energy Profile Zone 1 Zone 2 Fragility Zone 3 Agglomeration time
45 Mixing, Mixing, Mixing Good Mixing = Better Control = Optimization = Chemical Savings
46 Dry Polymer Feed System % Polymer. Turn-Key Automatic Control High Accuracy Feeder Step-by-Step Mixing Sys. Vacuum Conveyor No Dust.
47 Polymer Activation Factors High TDS makeup water Low temperature makeup water High molecular weight polymer Low charge density High or low surfactant With anionics, low ph and/or high hardness (ideal 7-9) With cationics, high ph makeup water (ideal 6-8) Chlorine levels
48 Other Factors Influencing Optimization Discharge Piping Minimize Fluid Velocity Eliminate High Shear Pumping Systems Multiple Points Of Injection Evaluate System Piping Downstream Of Polymer Injection Determine Optimal Feed Concentrations
49 An Inescapable Conclusion Polymer feed systems must meet the needs of different polymers and different applications. This requirement calls for flexibility of all the variables of polymer feed and preparation. Programmable Simple Reliable Repeatable
50 Right Energy / Right Time NOT ENOUGH ENERGY Agglomerations Waste Polymer Decrease Performance TOO MUCH ENERGY Damage The Chain Decrease Performance
51 Conclusions Survey your system needs for improvement Evaluate costs for improvement vs. savings as result of the improvement Be aware of new technologies & strategies that will help you be more efficient
52 The Cost of Poor Activation & Inefficiencies 50 lbs / Day Polymer X $2.25 / lb X 365 Days / Year = $41,062 in polymer cost If you could be 25% more efficient with your polymer usage, you would realize $10,265 / year in polymer savings Value of polymer savings over the life of equipment 10 8% / year = $141,821
53 Polymer Process Improvements Higher dry solids Lower sludge disposal costs Lower energy costs Lower operational costs Longer filter runs Higher clarity Less sludge returns Lower chemical costs Less labor
54 Properly Designed Polymer Feed System Full range of sizes to meet any application Peristaltic pump models for low dosage applications Customized controls Open design for easy maintenance Integrated with manufactured pumps and components Unique injection check valve with easy access Can be used online or as make-down system Precise delivery of activated polymer solution
55 Properly Designed Polymer Feed System MORE Performance LESS Operating Cost MORE Reliability LESS Maintenance MORE Simplicity LESS Headaches MORE Controls LESS Attention
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