Flocculation kinetics and aggregate structure of kaolinite mixtures in laminar tube flow

Evolution of aggregate size in two-staged flocculation process. [Display omitted] ► Kinetics of two-stage flocculation of kaolin. ► Laminar tube flow tube allows for realistic estimation of the shear rate. ► Direct sampling minimizes the effect of sampling on the aggregate structure. ► Aggregate structure and aggregate density evolution are monitored. ► Aggregates with statistically reproducible and well defined structure are produced. Flocculation is commonly used in various solid–liquid separation processes in chemical and mineral industries to separate desired products or to treat waste streams. This paper presents an experimental technique to study flocculation processes in laminar tube flow. This approach allows for more realistic estimation of the shear rate to which an aggregate is exposed, as compared to more complicated shear fields (e.g. stirred tanks). A direct sampling method is used to minimize the effect of sampling on the aggregate structure. A combination of aggregate settling velocity and image analysis was used to quantify the structure of the aggregate. Aggregate size, density, and fractal dimension were found to be the most important aggregate structural parameters. The two methods used to determine aggregate fractal dimension were in good agreement. The effects of advective flow through an aggregate’s porous structure and transition-regime drag coefficient on the evaluation of aggregate density were considered. The technique was applied to investigate the flocculation kinetics and the evolution of the aggregate structure of kaolin particles with an anionic flocculant under conditions similar to those of oil sands fine tailings. Aggregates were formed using a well controlled two-stage aggregation process. Detailed statistical analysis was performed to investigate the establishment of dynamic equilibrium condition in terms of aggregate size and density evolution. An equilibrium steady state condition was obtained within 90 s of the start of flocculation; after which no further change in aggregate structure was observed. Although longer flocculation times inside the shear field could conceivably cause aggregate structure conformation, statistical analysis indicated that this did not occur for the studied conditions. The results show that the technique and experimental conditions employed here produce aggregates having a well-defined, reproducible structure.