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Mud Thickening in SRI Clarifiers

Article  in  International Sugar Journal · September 2007

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Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

MUD THICKENING IN SRI CLARIFIERS

By

R.J. STEINDL and B.P. LAVARACK

Sugar Research & Innovation, Queensland University of Technology, Brisbane

r.steindl@qut.edu.au

KEYWORDS: Mud, Density, Viscosity,

Juice Clarifier, Scraper, Rake.
Abstract
THE THROUGHPUT capacity of a clarifier is based on its ability to perform the
two-fold functions of clarifying the juice, and thickening and removing the
settled mud at a rate to match the factory throughput. The high throughput rates
and low residence times that are achievable with the new generation clarifier,
have focussed attention on the need to improve the settling and thickening
characteristics of the mud, and its handling and transport properties in the mud
thickening zone. As juice rates increase, the residence time of the mud must
reduce to maintain satisfactory mud levels in the mud zone. This places more
emphasis on the ability of the mud scraper designs to thicken the mud to an
acceptable consistency and to transport the mud towards the centre mud cone in
a significantly reduced time. The investigations into the factors affecting mud
thickening have been conducted using pilot tests and two factory clarifiers of
similar size. One of the clarifiers was a standard design and the other was a
modified design incorporating the new generation technology. There appears to
be a maximum mud density that can be achieved in the clarifier and this is
achieved within 30 minutes. The final density is not dependent on either the
depth of mud or the addition rate of flocculant. The results obtained with a
settling tube were similar to those obtained directly from the clarifiers. Tests
with the settling tube indicated that final mud densities will be lower if the rakes
extend the full depth of the mud layer and into the juice. The largest increase in
mud density was achieved when a maximum number of rakes was used provided
all rakes remained below the level of the mud-juice interface. The speed of the
rakes did not affect the final mud density.
Introduction
The high throughput rates and low residence times that are achievable with the new
generation clarifier have focussed attention on the need to improve the mud handling and
transport properties in the mud thickening zone. As juice rates increase, the residence time of
the mud must reduce to allow operators to maintain satisfactory mud levels in the clarifier
mud zone. This places more emphasis on the ability of the mud scraper designs to transport
the mud towards the centre mud cone and to thicken the mud to an acceptable consistency in
a significantly reduced time.
The throughput capacity of a clarifier is based on its ability to perform the two-fold
functions of both clarifying the juice, and thickening and removing the settled mud at a rate
to match the factory throughput. The mud solids loading and the depth of the mud zone
control the time allowed for mud thickening and, combined with the scraper design and
speed, determine the thickening capacity.
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Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

The new generation SRI clarifier has the potential to clarify cane juice at significantly
higher juice rates than previously thought possible. To benefit from this rate potential while
maintaining control of the mud level, achieving adequate thickening in the clarifier and still
maintaining satisfactory performance at the mud filters, it will be necessary to maintain the
density of the mud leaving the clarifier at an acceptably high value. At the higher juice rates
the residence time of the mud underflow must be reduced to maintain a satisfactory operating
mud level in the clarifier without increasing the incidence of juice short-circuiting or ‘rat-
holing’ through the mud cone. This implies that the only opportunity for improved thickening
ability is to investigate the scraper designs.
In the past, the priority has always been to maintain the highest quality of clarified
juice. Mud depths have been controlled to assist with maintaining the quality of the clarified
juice. The focus shifts to the underflow rate when the mud-juice interface rises to the extent
where the quality of the clarified juice is likely to be compromised. Design capacities are
based on achievable settling rates of the flocculated mud rather than underflow consistency or
mud solids concentration.
Feedback from factories with clarifiers incorporating the new generation technology
indicates that they are achieving improvements in mud densities even at higher juice rates.
Computational fluid dynamics (CFD) analysis of the standard SRI design identified high
radial juice velocities immediately above the mud-juice interface (Steindl, 2001). It was
thought that this radial juice flow would not greatly affect the mud density. More recent
experience suggests that the radial juice flows may have more impact on the hindered settling
trajectories and thickened mud density than originally thought.
Much of the published information on hindered settling, thickening and transport of
sediments in clarifiers is concerned with water treatment plants. There are a few articles on
slurry thickening in the mineral processing industries.
There are even fewer articles dealing specifically with the thickening and transport of
mud in cane juice clarifiers. Irrespective of the clarifier duty, the principles of operation are
very much the same. Variations arise from the solids loading in the feed and the physical
properties and characteristics of the settled solids.
Several researchers investigating thickening characteristics (Farrow et al., 1999;
Urrutikoetxea and Garcia-Heras, 1994) selected various forms of a settling tube to model a
vertical segment of a clarifier or thickener. Farrow et al. (1999) investigated the consolidation
behaviour of kaolin slurries with a non-ionic flocculant under different conditions.
They concluded that bed density profile measurements obtained from the
sedimentation column demonstrated that the hydrodynamic conditions prevailing during
flocculation have an important effect on the consolidation behaviour of the sediment and the
underflow density. They highlighted the importance of optimising feedwell design on full
scale clarifiers. Their investigations also demonstrated that thickening of the sediment
achieved by rake action dramatically exceeded that which could be achieved through bed
compression alone and was caused by the removal of intra-aggregate liquor from the
sediment in the rake action.
Most models used to predict the final solids concentration in the underflow from
gravity thickeners require a knowledge of such parameters as the solids flux in the underflow,
the depth of the mud zone, volume fraction of solids, porosity of the mud layer, liquid
viscosity, and the liquid and solid densities. However, no sighted models included any
function to adjust the underflow solids concentration for the thickening actions of rotating
rakes or scraper blades.
To get a better understanding of the factors affecting mud thickening in the standard
and new generation clarifier designs, pilot trials were undertaken using a settling tube fitted
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Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

with a rotating rake arrangement. The results were compared with data collected from both a
standard and a new generation juice clarifier.
Mud thickening in cane juice clarifiers
In the work by Hale and Whayman (1969), attention was given to laboratory batch
settling tests from which estimates of thickening capacity were made by flux plot methods.
Well flocculated muds were shown to thicken considerably faster under mild shear and the
predictions from stirred batch tests gave good agreement with pilot clarifier performance.
Nix (1972a) investigated the mud concentration profile above the scraper zone in a
compartment of a multi-tray clarifier. He concluded that the depth of the mud did not appear
to influence the solids concentration at the bottom of the compartment. He also concluded
that the action of the scraper arms did not affect the concentration of the mud. These findings
were different to those of Hale and Whayman (1969) who demonstrated that stirring of the
mud increased the solids concentration appreciably.
In other work with ATV and RapiDorr clarifiers, Nix (1972b) measured the density
of mud samples over a range of temperatures. He showed that the density of the mud could be
described by equation 1 for all temperatures:
ρM /ρJ = 1.0 + 0.4X (1)
where X = mass fraction of insoluble solids in the mud
ρM = density of mud, kg/m3
ρJ = density of juice, kg/m3
Factory trials
Sample points were inserted in the floor and mud cone of the new generation clarifier
at Farleigh Mill as illustrated in Figure 1. It was planned to sample mud from these points in
conjunction with the mud thickening trials in a batch settling tube. Any short-circuiting of
juice to the underflow pipe should be identifiable by lower density samples taken from #6
compared to samples from #4. Additional trials were conducted at Marian Mill where a
standard design clarifier was being used.

Fig. 1—Location of the sample points on the Farleigh Mill clarifier.

497
Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

Data on mud density profiles collected from across the floor cone of the new
generation clarifier at Farleigh Mill for the same nominal mud depth are shown in Figure 2.
The data indicate:
! the density of the mud increases as it is moved towards the centre of the
clarifier;
! there is no increase in density after about #4; and
! there is a variation in density for mud collected from the same sample point
for each test.

Fig. 2—Mud density profiles across the floor cone of the Farleigh Mill clarifier.

Figure 3 illustrates that the mud density profile across the clarifier floor is not
dependent on the mud depth.

Fig. 3—Mud density profiles for different mud depths (measured at the outer
wall) in the Farleigh Mill clarifier.
498
Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

The mud depth nominated for each series in Figure 3 is the mud depth at the wall of
the clarifier. If it is assumed that the mud-juice interface is essentially horizontal, then an
increase in mud depth of 0.7 m does not result in any increase in mud density, even at #1
where the mud depth has increased threefold.
The data also support the observation made from Figure 2 that the mud density does
not increase in the mud cone. The juice processing conditions and mud settling characteristics
were consistent during the time these tests were conducted.
Data collected from Marian Mill exhibited similar trends to those from Farleigh Mill,
although the Marian densities were more variable and densities were lower overall.
Mud thickening
A batch settling tube apparatus was fabricated from 1600 mm of 150NB steel pipe
(Figure 4). A polycarbonate window was fitted down one side of the apparatus so that the
mud-juice interface could be tracked. Ten sample points were located at 150 mm intervals
along the side of the tube to allow a density profile through the depth of the mud to be
determined for each set of conditions. The diameter of the settling tube was made as large as
possible to minimise wall effects but was limited by practical constraints on the volume of
flocculated juice that could be prepared in a batch.

Fig. 4—Photograph of the settling tube and rake stirrer arrangement.

Flocculated mud was prepared in an elevated reservoir and then fed into the bottom
of the settling tube.
The tube could be topped up with flocculated mud through a second feed line at the
top of the tube. As soon as the filling procedure was completed, the timer and the rake motor
were started. Samples of 100 mL were then collected at appropriate intervals from selected
sample points.
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Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

The following effects on thickening rate and final density of the mud were
investigated:
! depth of the mud;
! flocculant dose rate;
! mud rake configuration (number and length of rake components); and
! mud rake rotational speed.
Overall, the results were variable. In some cases, quite good agreement between tests
using similar conditions was obtained while, in other cases, the results appeared to be
influenced more by the properties of the mud flocs than by the actual test conditions. Because
the properties of the mud flocs were a significant factor in determining the results for each
series of tests, every effort was made to use batches of juice with similar mud flocculating
and settling characteristics. Previous experience has shown that using a bulk supply of mud is
not feasible as the mud can deteriorate relatively quickly if the temperature is not maintained
at close to 100°C.
Depth of mud
Batch tests were undertaken in the settling tube by filling the tube with different
initial depths of mud. The rake was switched on as soon as the mud transfer to the tube was
completed. The results supported the observations made from the factory clarifiers that the
final mud density was not dependent on the mud depth. Figure 5 shows the consolidation of
the settled mud as a function of time for the same rake configuration. After the rake
commenced rotating, there was an initial period of consolidation or thickening which lasted
about 20–25 minutes before the mud depth stabilised. Figure 6 provides the densities of the
mud samples for the same tests. There was no significant increase in density after about 30
minutes.
The final mud density of about 1065 kg/m3 was similar to the mean of the mud
densities measured in the underflow pipe at Marian Mill where the residence time of the mud
in the clarifier was between 80 and 120 minutes and the mud depth was about 2.5 m.

1.6

1.4 Test 2
Test 3
1.2
Test 7
MUD DEPTH, m

1.0

0.8

0.6

0.4

0.2

0.0
0 15 30 45 60
TIME, minutes

Fig. 5—Consolidation of the flocculated mud in the settling tube for three initial
mud depths.
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Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

1100

1090

3 1080

1070
MUD DENSITY, kg/m

1060

1050

1040

1030 Test 2
1020 Test 3
Test 7
1010

1000
0 10 20 30 40 50 60 70
TIME, minutes

Fig. 6—Mud density of samples taken 0.2 m above the bottom of the settling
tube apparatus.
Flocculant dose rate
Most batch thickening tests were conducted using 3 ppm on juice of Superfloc
A2120 flocculant. One series of tests was conducted with a flocculant dose rate of 4.5 ppm.
There was no increase in the mud density. Another series compared the resultant mud density
when flocculant was added at 2, 4 and 6 ppm. The results indicated that increasing the
flocculant dose rate from 2 to 4 ppm increased the final mud density marginally but there was
no further increase at 6 ppm.
Mud rake configuration
The design of the rake arrangement in the settling tube apparatus permitted a number
of combinations of rake elements both in terms of number of elements and spacing in the
holders, and three different element lengths of 300 mm, 600 mm and 1200 mm (Figure 7).
This flexibility, coupled with the variable speed drive, allowed the investigation of the effects
of a range of shear rates on the density of the settled mud.

T E S T A .2 T E S T A .3 T E S T A .4 T E S T A .5 T E S T A .6

Fig. 7—Illustration of different rake configurations used during the investigations.

501
Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

The results shown in Figures 8 and 9 were obtained at Marian Mill using different rake
configurations. The density of the underflow from the clarifier at the time of each test (and
nominally for the same juice) is also shown in Figure 9.
1.6

1.4
Test 8
Test 10
1.2 Test 11
Test 7
MUD DEPTH, m

0.8

0.6

0.4

0.2

0
0 10 20 30 40 50 60 70 80
TIME, minutes
Fig. 8—The effect of different rake configurations on the mud thickening
characteristics for juice samples collected at Marian Mill.
1100

1080
3
MUD DENSITY, kg/m

1060

1040
Test 8 Factory (8)
Test 10 Factory (10)
1020 Test 11 Factory (11)
Test 7 Factory (7)

1000
0 10 20 30 40 50 60 70 80
TIME, minutes

Fig. 9—Mud densities achieved in the settling tube and in the underflow from the
clarifier at Marian Mill for the corresponding tests shown in Figure 8.
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Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

The results obtained at Farleigh Mill for tests investigating different rake
configurations are given in Figures 10 and 11.
1.6

1.4

1.2
MUD DEPTH, m

1.0

0.8

0.6

Test A.2
0.4 Test A.3
Test A.4
0.2 Test A.5
Test A.6

0.0
0 10 20 30 40 50 60 70
TIME, minutes

Fig. 10—The effect of different rake configurations on the mud thickening for
samples collected at Farleigh Mill.
1100

1080
3
MUD DENSITY, kg/m

1060

1040

Test A.2 Factory (A.2)

Test A.3 Factory (A.3)
1020 Test A.4 Factory (A.4)
Test A.5 Factory (A.5)
Test A.6 Factory (A.6)

1000
0 10 20 30 40 50 60 70 80
TIME, minutes

Fig. 11—Mud densities achieved in the settling tube and in the underflow from
the clarifier at Farleigh Mill for the corresponding tests shown in Figure 10.
While the mud densities that could be achieved in the settling tube were higher than
the densities being achieved in the standard SRI clarifier design at Marian Mill, the densities
of the samples at Farleigh Mill were very similar to what was being achieved in the new
generation clarifier. Steindl (2001) identified the potential for much higher mud densities
from the new generation clarifier because of the reduced flow of recirculating juice at the
mud-juice interface.
Rotational speed of the rakes
Rake speeds in the test apparatus were set at 3, 4, 5, 8 and 9 r/h to investigate the
effects of different rake speeds on the final mud density. Although there were minor
variations in mud volumes and densities, overall there was no significant difference between
the test results.
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Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

Application to clarifiers
The information gained from these investigations was used to redesign the scraper
arrangements in the new generation SRI clarifier (Steindl, 2006). Mud densities in excess of
1100 kg/m3 have been recorded from mills with the modified scraper design. The ability to
produce a higher density mud requires mills to review the mud handling arrangements to
ensure appropriate provisions are implemented to prevent blockages in the piping. The
benefit is that mills have an opportunity to further reduce the pol loss in filter cake.
Viscosity-density relationship
Viscosities and density-temperature relationships were measured on samples of
underflow mud from the Farleigh and Plane Creek clarifiers for background information.
Analyses of the samples are provided in Table 1.
Table 1—Composition of the mud samples collected from Farleigh and Plane
Creek mills.
Analysis Farleigh Plane Creek
Moisture, % 71.3 76.4
Mud solids, % 8.5 4.3
Fibre ratio 0.41 0.58
The viscosities of the mud samples were measured at 90°C using a pipeline
viscometer and the #7 tube (L/D ratio = 66.6). The average viscosities were:
Farleigh 0.046 Pa.s
Plane Creek 0.021 Pa.s
The results indicated that the samples were Newtonian. The claim by Nix (1972b)
that mud exhibited Bingham plastic characteristics was not tested. The values reflect the
higher quantities of fibre and mud solids in the Farleigh sample.
The densities were measured at a range of temperatures from 20° to 95°C. The results
shown in Figure 12 indicate the gradient in each case is similar to that of juice for the same
temperature range. This is similar to the conclusion reached by Nix (1972b) although the
correlation he developed to predict the density underestimates the mud densities measured for
the mud samples from both Plane Creek and Farleigh mills.

1120.0

1100.0

1080.0
3
DENSITY, kg/m

1060.0

1040.0

Plane Creek
1020.0 Farleigh
Juice

1000.0
20 30 40 50 60 70 80 90 100
o
TEMPERATURE, C

Fig. 12—Density-temperature relationship for mud from two factories.

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 Steindl, R.J. & Lavarack, B.P. Proc. Aust. Soc. Sugar Cane Technol., Vol. 28: 2006
__________________________________________________________________________

Summary of results on mud thickening trials

The results of the investigations into characterising the factors affecting mud
thickening are summarised as follows:
! Much of the mud thickening occurs before the mud reaches the mud cone
and no increase in density is achieved in the mud cone.
! There appears to be a limit to the density that can be achieved in the clarifier.
! The final mud density is not dependent on the depth of mud.
! The maximum density is achieved within about 30 minutes.
! The results obtained with the settling tube were similar to those obtained
directly from the clarifiers.
! There was no significant benefit of increased mud density for an increase in
flocculant.
! There are indications that final mud densities will be lower if the rakes
extend through the full depth of the mud layer and into the juice.
! The largest increase in mud density was achieved when the maximum
number of rakes was used, provided all rakes remained below the level of the
mud-juice interface.
! Mud densities measured in the new generation clarifier were higher than
those in the standard clarifier.
! The speed of the rakes did not affect the final mud density.
These results are applicable to typical juices with good mud flocculating and settling
characteristics.
Acknowledgements
The contributions made by the staff at the factories where the experimental work was
undertaken were greatly appreciated. SRI acknowledges funding for this project via the
SRDC, from the sugar industry and the Commonwealth Government.
REFERENCES
Farrow, J.B., Johnston, R.R.M., Simic, K. and Swift, J.D. (1999). Consolidation and
aggregate densification during gravity thickening. Engineering Foundation
Conference on Solid-Liquid Systems. Hawaii.
Hale, D.J. and Whayman, E. (1969). Pilot studies on the settling of cane muds. Proc. Qd
Soc. Sugar Cane Technol., 36: 233–243.
Nix, K.J. (1972a). Investigations of clarifier operation. Proc. Qd Soc. Sugar Cane Technol.,
39: 315–325.
Nix, K.J. (1972b). The density of primary mud. Proc. Qd Soc. Sugar Cane Technol.,
39: 281–287.
Steindl, R.J. (2001). Development of the new generation SRI clarifier design. Proc. Int. Soc.
Sugar Cane Technol., 24: 80–85.
Steindl, R.J. (2006). Mud transport in SRI clarifiers. Proc. Aust. Soc. Sugar Cane Technol.,
28: 526–535.
Urrutikoetxea, A. and Garcia-Heras, J.L. (1994). Thickening model for activated sludge
secondary settlers. Environmental Technology, 15: 1051–1060.

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