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Mechanical Unit Operations in Waste Treatment
Mechanical Unit Operations in Waste Treatment
2002
1. Introduction ......................................................................................................................2
2. Particles and disperse systems .......................................................................................6
2.1 Particles and particle size distributions.......................................................................6
2.2 velocity of sinking particles, gravity ...........................................................................8
2.3 velocity of sinking particles with centrifugal forces ....................................................9
3. Dewatering.....................................................................................................................10
3.1 Sedimentation tank clarifier ...................................................................................10
3.2 Sedimentation with centrifugal force centrifuge and hydrocyclone ........................11
3.3 Filtration ...................................................................................................................15
3.4 Conclusions for dewatering .....................................................................................15
3.4 Conclusions for dewatering .....................................................................................16
4. Classification and sorting ...............................................................................................16
4.1 Classification Screening / Sieving / Sighting ............................................................16
4.2 Sorting Density sorting / Magnetic sorting / Sink-float ..........................................18
5. Mixing ............................................................................................................................23
6. Comminution..................................................................................................................24
6.1 General ....................................................................................................................24
6.2 Technical machines..................................................................................................26
6.3 Size Reduction with Shredders ................................................................................29
6.4 Energy Requirements of Shredders .........................................................................31
7. Impressum .....................................................................................................................32
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 1
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
1. Introduction
Steady state: balancing equations with flows (kg/min; kJ/h) at any point of time.
Batch: balancing equations with summarized flows for a time interval.
e.g.
Mass-balance
Energy balance
(III) Hflows into system Hflows out of system + Ein - Eout Estorage + Epos.heat of reaction = 0
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 2
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Tab. 1.1 Some data about Solid Waste
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 3
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Table 1.2 Summary of Techniques Used for Processing Solid Wastes
Storage and Storage and transfer of wastes to Open storage pits for unprocessed
transfer be processed wastes, storage bins and silos for
processed wastes;
transfer equipment: front-end loaders,
metal and rubber belt conveyors,
vibratory conveyors with unprocessed
wastes; pneumatic conveyors and screw
conveyors with processed wastes
Chemical volume Reduction of volume of solid Mass-fired incinerators, with and without
reduction wastes through burning heat recovery, for unprocessed wastes;
rotary kilns for hazardous/containerized
(incineration) and bulk/sludge waste
Mechanical size Alteration of size and shape of Hammer mills, shredders, roll crushers,
and shape solid-waste components grinders, chippers, jaw crushers, rasp
mills, and hydropulpers
alteration
Drying and Removal of moisture from solid Centrifuge and filtration used to dewater
dewatering wastes treatment-plant sludge,
Convection, conduction and radiation
dryers used for solid wastes and sludge
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 4
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Table 1.3 Mechanical Methods for Separating Solid-Waste Components
Method Function Equipment , facilities,
applications
Screening Separate components by size Trommels and horizontal and
vibrating screens for unprocessed
and processed wastes;
Disk screens with processed
wastes
Air separation Separate light (organic) Zig-zag air, vibrating-air, rotary-air,
materials from heavy and air-knife classifiers used with
(inorganic) material processed wastes
Jig separation Separate light and heavy
materials by means of density
separation
Pneumatic Separate light and heavy
separation (stoners) materials
Optical sorting Separate plastics
Sink-float, flotation, Separate light and heavy
Inclined table, materials
shaking table
Separation Mixing
Classification Homogenization
Screening / sieving Stirring
Clarification Mixing of solids
Sedimentation Kneading
Filtration Dispersing
Centrifugation / Decanting Emulsification
Removal of dust Spraying
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 5
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
2. Particles and disperse systems
2.1 Particles and particle size distributions
* sampling
* how to measure the size?
* shape of particles
a lot of technical particles do not have not perfect spherical shape and complicated size
distributions.
sphericity = surface of sphere (identical volume)
real surface
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 6
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 7
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
2.2 velocity of sinking particles, gravity
sink velocity v
Figure
drag coefficient
(also named cw) vs.
Re number
for spherical particles
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 8
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
2.3 velocity of sinking particles with centrifugal forces
radius r0
In technical applications the particles are usually very fine ->laminar flow regime
for laminar flow: vsink (r) = dp2 (p-l) r 2 / 18 (eq.13)
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 9
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
3. Dewatering
shape -> multiply sink velocity with sphericity (e.g. cubes = 0.81)
high solids -> hindering of sedimentation, equations with special parameters
e.g. multiply sink velocity with ~ 0.5 for a solid content of 5-10%
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 10
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
technical design: e.g.
1. V0 should be known (needed throughput)
2. mass balances (no solids in V1), calculate:
V1 = V0 (0/1) (1-c0/c2) = m2/1 (c2/c0 1) (eq.16)
V2 = V0 (0/2) (c0/c2) (eq.17)
3. fix needed dp,crit and calculate sink velocity vsink (dp,crit )
4. calculate necessary cross sectional area A = vsink / V1
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 11
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Table 3.1 Data of some centrifugal separators
b)
c) a)
Hydrocyclone
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 12
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
the liquid rotates in a stationary casing
a pump presses the liquid through the hydrocyclone and hydrostatic energy is
transformed to kinetic energy
a primary eddy flow forms, the particles are transferred to the inner wall and the bottom
of the hydrocyclone;
the apex nozzle at the bottom is closed except for an small sludge opening
the liquid flow is reversed at the bottom and a secondary eddy forms underneath the dip
pipe- called vortex finder
centrifugal force ac = v0 2 / R
K = 4 p /( D) (eq.18)
g
p pressure drop [Pa]
density of liquid [kg/m3 ]
V1 ~ D2 p0.5 (eq.20)
dp,crit ~ D0.5 p0.25 (eq.21)
advantages
disadvantage
limitations
pressure drop p
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 13
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 14
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
3.3 Filtration
Filtration is separation of solid particles from suspensions with help of a porous filter
medium. The separated solids form a filter cake.
A density difference between liquid and solid is not necessary.
Driving force is the pressure difference p between suspension and filtrate.
two types: cake filtration, depth- or filter medium filtration (precoat filter)
V12 + 2 V1 A C1 = C2 A2 t (eq.24)
scale-up:
1. test filtration with a hand filter
(leaf test, vacuum test)
2. two exp. data points -> determine
C1 and C2
3. design technical filter with these
values
4. problematic: filter cake properties
are not constant
Other filter types:
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 15
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
3.4 Conclusions for dewatering
coarse
Bild fraction
fine fraction
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 16
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Fig. Trommel screen Fig. Screen with vibration
(not typical for waste)
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 17
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
4.2 Sorting Density sorting / Magnetic sorting / Sink-float
density sorting
principle: usually wet sorting under gravity
1. pulsating water stream; min.density difference 1200 kg/m3
2. float-sink separation: use of a separation liquid with
suitable density (1300- 3000 kg/m3) between the density of
the two fractions;
with fine particles (min3-5 mm): low sink velocity.
for even finer particles: hydrocyclone
magnetic sorting
electrosorting
new technique and still in development
separation of electric conductors from non-conductors
principle: high voltage field with 15-40 kV direct current, all
particles receive a negative charge and are attracted to a positive
charged rotating drum, conductors are discharged faster and fall
off earlier
iron, steel and iron-oxides, -sulfides and -silicates
optimum particle size: 1-10 mm
optical sorting
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 18
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
flotation
principle: sorting of very fine particles in a suspension with the help of air bubbles, the
formed foam (froth) carries certain particles and floats to the upper region of the apparatus
the wetability depends on the materials and added chemicals
used for minerals
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 19
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 20
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 21
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 22
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
5. Mixing
a) mixing of liquids or dispersion of gases and solid particles in a liquid:
various stirrer types, needed energy principle of similarity, ReM-number and Ne-
number
ReM = n d2 / (eq. 25)
Ne = P /( d5 n3) (eq. 26)
p power requirement [W] d diameter stirrer
n rotational speed [1/s]
Ne = function (ReM) - manufacturer diagramms
static mixers
b) kneading of viscous or plastic components: e.g. with screws
c) mixing of solids,
characterization of mixing quality: standard deviation of the content xi of a certain
component in a defined number of samples N
standard deviation = [(1/(N-1) (xi xM)]0.5 (eq. 27)
median content xM = 1/N (xi) (eq. 28)
problematic are dry mixtures with large size and density
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 23
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
6. Comminution
6.1 General
types
compactors Definitions
Void ratio = Vvoid / Vsolids
milling / grinding
Porosity = Vvoid / (Vsolids+ Vvoid)
cutting / slicers
mechanisms of comminution:
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 24
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Influence of pressure on compaction:
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 25
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
6.2 Technical machines
Roll crusher
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 26
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Hammer mills (Shredders)
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 27
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Shear Shredders
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 28
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
6.3 Size Reduction with Shredders
Fig. Size reduction of various municipal solid waste components after shredding
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 29
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
Fig. Explanation Particle size distribution
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 30
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
6.4 Energy Requirements of Shredders
Fig. Experimental data 1983. Degree size reduction = (dfeed dafter mill) / dfeed
Source Significance of Size Reduction in Solid Waste Management Vol.3. Effect of Machine parameters on Shredder Performance
M.Savage, J.Tuck, P. Gandy, G. Trezek, Cal Recovery Systems, Inc. 1983
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 31
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg
7. Impressum
to contact lecturer
Arne Pietsch
Eurotechnica Ingenieurbro GmbH
An den Stcken 55
D 22941 Bargteheide, Germany
Lule Tekniska Universitet Unit operations for mechanical and biological waste treatment 32
Mechanical Waste Treatment
Dr.-Ing. Arne Pietsch Nov. 2002, Hamburg