Modelling Flocculation in a Thickener Feedwell Using a Coupled Computational Fluid Dynamics–Population Balance Model

The flocculation that takes place in the central feedwell of the thickener plays a crucial role in the coal-slurry thickening process, which is not only complex but also largely influenced by the flow characteristics. A coupled computational fluid dynamics–population balance model (CFD–PBM) was used to model the complex flocculation-thickening behaviour in an industrial-scale gravity thickener. The initialisation parameters of the inlet flow were obtained through self-designed image-recognition experiments, and then the effects of different types of conical deflectors on the floc distribution were simulated and analysed using them. The results showed that, under the condition that the angle of the conical deflector’s sides in the vertical plane was known, a reasonable increase in the height of the bottom surface could reduce the annular spanwise vortices at the underflow of the feedwell, thereby avoiding the erosion of the inlet flow and the annular spanwise vortex on the floc deposition layer. However, excessive height on the part of the conical deflector could affect the flocculation effect of solid particles. For the same central feedwell size of the thickener as in the simulation, the best flocculation effect was achieved at an angle of α = 24° in the vertical plane of the conical deflector. Turbulence regulation of the conical deflector promotes the aggregation of fine particles in the fluid of the feedwell, providing a new method for the intensification of the flocculation-concentration process.