A multi-stage enhanced flocculation reactor for the treatment of simulated shale gas hydraulic fracturing flowback fluid: Effect of aspect ratios for the intense mixing section

Flocculation is a significant process in treating shale gas hydraulic fracturing flowback fluids. To achieve a high removal rate of pollutant, a range of multi-stage enhanced flocculation reactors that incorporated sequential intense, moderate, and weak mixing sections along the flow direction were devised, in which the aspect ratios (ARs) in the intense mixing section were varied. The results of the computer simulation indicated that the reactor with AR of 3.5 exhibited a gradual decrease in velocity and energy along the flow direction, and the flow field distribution is highly uniform and symmetrical. The generated flow field promoted the formation of small flocs in the intense mixing section and facilitated the collision of small flocs in the moderate mixing section, while preventing the fragmentation of flocs in the weak mixing section, therefore resulting in the generation of large and compact flocs. Moreover, the generated flocs demonstrated a good resistance to shear and oscillation, facilitating their separation from the simulated flowback fluids. The obtained reactor achieved remarkable removal efficiencies of 80.15 % for COD and 89.06 % for turbidity. Furthermore, when treating bentonite suspension, the multi-stage flocculation reactor achieved a turbidity removal rate of 99.34 % with a processing time of only 2.38 min and a settling time of just 20 min. This demonstrated the broad applicability of this reactor to various types of wastewater. This work provides valuable insights into the design of efficient flocculation reactors by integrating multiple mixing intensities within a reactor.