The objective of this project was to develop a suitable procedure for the design, control and optimisation of the Tubular Filter Press. To this end, the following objectives were defined for this study: • To extend or improve upon the constant pressure compressible cake filtration model, predictive solution procedure, and standard laboratory characterisation techniques requlred to obtain the empirical model parameters, presented in Rencken (1992). A new generalised area contact constant pressure compressible cake filtration model was developed for both the internal cylindrical and planar filtration geometries. The model utilises a heuristically developed area contact function which relates the interparticle contact area to the solids compressive pressure within the cake. If the area contact is zero, the model reduces to the conventional point contact model as presented in Rencken ( 1992). The sludge used in this investigation was found to exhibit a negligible degree of area contact. A new pseudo variable pressure solution procedure was developed, that is an extension of the constant pressure solution procedure, to account for the initial variable pressure stage of the Tubular Filter Press operation. The pseudo variable pressure solution procedure was found to account accurately for the initial filtration behaviour observed during the pressurisation period of the Tubular Filter Press. However for the normal operation of the Tubular Filter Press. the difference between the output of the pseudo variable pressure and constant pressure solution procedures, was found to be insignificant. Wall friction in compression-permeability (C-P) cell tests was identified as a main source of error. The significance of wall friction was investigated using a specially constructed C-P cell. that enabled the transmitted pressure through the cake sample to be measured. The accuracy of the characterisation which had been corrected for the effects of wall friction, was found to improve the prediction of the filtration behaviour of the sludge significantly. The direct shear test was identified and documented as a feasible experimental procedure to determine the coefficient of earth pressure at rest. The coefficient of earth pressure is unique to the non-planar filtration geometries. The coefficient of earth pressure at rest was determined for the sludge used in this investigation. • To incorporate the constant pressure compressible cake filtration model and the associated predictive solution procedures into a user-friendly computer programme that will facilitate the design and optimisation of full-scale plants. The predictive solution procedures were incorporated into the Windows 95 computer programme, COMPRESS, that can be used for any constant pressure compressible cake dead-end filtration application where the filtration geometry is planar or internal cylindrical. A control and optimisation strategy for the continuous operation of the Tubular Filter Press has been proposed. To develop a regressive solution procedure, and incorporate this procedure into a user-friendly computer progranune, that will enable the empirical model parameters. normally obtained from standard laboratory-scale tests, to be obtained from actual filtration data. A regressive solution procedure was developed that utilises a direct search optimisation technique that is an extension of the COMPLEX method. The regressive solution procedure was incorporated into the Windows 95 program, REGRESS. The program utilises filtration data from any dead-end constant pressure filtration application of either planar or internal cylindrical geometry. REGRESS provides an effective means for determining the true physical or plant specific filtration characteristics of the sludge. The regressive solution procedure also enables the parameters specific to the new area contact model to be determined. The sludge characterisation obtained from regressing on filtration data was found to be a significant improvement in predicting the filtration behaviour, than the characterisation obtained from the standard non-filtration laboratory-scale methods, even after the C-P cell data had been corrected for the effects of wall friction. The programs COMPRESS and REGRESS should greatly assist in the design. control and optimisation of the Tubular Filter Press process. / Thesis (M.Sc.Eng.)-University of Natal, Durban, 2000.

The tubular filter press is a novel tubular configured filter press for the filtration or dewatering of sludges. The unique features of the filter press are: (i) during the cake deposition cycle, cake is deposited on the internal walls of a self-supporting array of horizontal collapsible porous fabric tubes; (ii) during the cake removal cycle, cake is dislodged from the tube walls by means of a roller cleaning device and the dislodged flakes of cake are hydraulically transported out of the tubes by the feed sludge which is simultaneously re-circulated at a high flow rate through the tubes. The two main problems experienced on a prototype tubular filter press, which was erected at a water treatment plant to dewater the sludge from the clarifier underflow, were: (i) tube blockage problems during the filtration cycle; (ii) low cake recoveries (high cake losses) during the cake removal cycle. The following objectives which were defined for this study, were regarded as fundamental prerequisites for any solution of the two main problems: (i) to develop a predictive dead-end internal cylindrical model for compressible cake filtration inside a porous tube; (ii) to investigate the cake losses during the cake removal cycle of the tubular filter press; (iii) to develop a predictive unsteady-state internal cylindrical cross-flow microfiltration model for a non-Newtonian sludge which, when filtered, produces a very compressible cake. (An alternative to dead-end filtration during the filtration cycle of a tubular filter press is low axial velocity cross-flow filtration). On the basis of the objectives the study was divided into three separate investigations. To date no one has developed a model which incorporates the cylindrical configuration of the filter medium for dead-end compressible cake filtration inside a porous tube. The most comprehensive model for dead-end external cylindrical compressible cake filtration is that of Tiller and Yeh (1985). This model was adapted for internal cylindrical compressible cake filtration. In essence the model by Tiller and Yeh (1985) requires the solution of a system of two ordinary differential equations in order to calculate the radial variation of solids compressive and liquid pressures in a compressible filter cake deposited externally on a cylindrical surface. The relevant equations were derived for internal cylindrical compressible cake filtration and it was found that one of the differential equations changes from: dPl/dr = H1/2nrK (external cylindrical) to dPl/dr = H12nrK (internal cylindrical). The other differential equation remains unaltered for internal cylindrical compressible cake filtration. A batch of waterworks clarifier sludge from the prototype tubular filter press was used for experiments to evaluate the performance of the internal cylindrical filtration model. The cake produced by the filtration of this sludge had to be characterized for the model. Compression-permeability data were obtained over a wide solids compressive pressure range. A Compression-Permeability (C-P) cell was used for high solids compressive pressures (10 kPa<_ ps<_400 kPa) and settling tests were used for low solids compressive pressures (0,0065 Pa <_ ps < 525,6 Pa). The cake was found to be very compressible (compressibility coefficient = 0,989). Empirical equations of the form, K' = Fps - b and (1 - E) = B pbs , were derived from the C-P cell and settling tests to relate permeability and porosity to solids compressive pressure. The equations were slightly different to those proposed by Tiller and Cooper (1962). The predictions by the internal cylindrical compressible cake filtration model were compared to the results of constant pressure internal cylindrical filtration experiments, at filtration pressures of 100 kPa, 200 kPa and 300 kPa, using the waterworks clarifier sludge. The internal diameter of the filter tube which was used for the experiments was 26,25 mm. The model accurately described the results of the filtration experiments in terms of volume of filtrate, average cake dry solids concentration, filtrate flux and internal cake diameter. The differences between external cylindrical, internal cylindrical and planar compressible cake filtration were highlighted. Since the tubular filter press is a novel process, the cake losses during the cake removal cycle have not been investigated before. An investigation was therefore conducted into the cake losses which occur during the cake removal cycle. The same batch of clarifier sludge was also used for the investigation of cake losses during the cake removal cycle at filtration pressures of 100 kPa and 300 kPa. It was found that significant cake losses occurred due to: (i) the shear of the cleaning fluid prior to the action of the rollers (losses varied between 10 % to 20 % of the deposited cake dry solids); (ii) the combined action of the rollers when dislodging the cake and the hydraulic conveyance of the dislodged flakes of cake (losses varied between 30 % to 40 % of deposited cake dry solids). A new shear model, which was developed, accurately predicted the cake losses and increase in internal cake diameter and average cake dry solids concentration, which occurred due to the shear of the cleaning fluid. For the shear model the sludge (cake) rheology was determined using a capillary-tube viscometer. It was found that the sludges exhibited Bingham plastic behaviour in the solids concentration range: 3,58 % m/m <_Cs <_16,71 % m/m. The cake losses due to the action of the rollers and hydraulic conveyance of the dislodged flakesof cake decreased markedly as filtration pressure and filtration time were increased, while a decrease in path length for hydraulic conveyance of dislodged cake flakes resulted in a mild decrease in these cake losses. A literature review revealed that to date only one mathematical model (Pearson and Sherwood, 1988) is available for the unsteady-state cross-flow microfiltration of a non-Newtonian sludge which, when filtered, produces a compressible cake. A new unsteady-state internal cylindrical axial convection shear model (for laminar flow of the feed sludge) was developed for cross-flow microfiltration of a Bingham plastic sludge which, when filtered, produces a very compressible cake. Similar to the approach by Pearson and Sherwood (1988) this model is a combination of the dead-end internal cylindrical compressible cake filtration model and the "cleaning fluid" shear model. The major difference between the new model and the model by Pearson and Sherwood (1988) is that unlike the convection-diffusion model of Pearson and Sherwood (1988), diffusive and shear induced diffusive back-mixing of particles were assumed to be negligible. The existence of a shear plane within the cake forms the basis of the model. Those cake layers with a yield stress less than the shear stress exerted by the flowing feed sludge at the inner cake wall are convected along the shear plane. It was assumed that the axial convection of the solids in the moving cake layer along the shear plane is the sole mechanism for removal of solids deposited at the cake surface. The model was compared to the results of cross-flow microfiltration experiments at one filtration pressure (300 kPa) and cross-flow flow rates of 0,84 l / min; 1,58 l / min; 2,43 l / min and 4,44 l /min. The model accurately described the variation of filtrate flux, internal cake diameter and average cake dry solids concentration during the unsteady-state time period. The model, however, had to be "extended" by incorporating empirical equations for changes in permeability and porosity (due to further cake compaction) to obtain a good fit between the model and experimental results during the pseudo steady-state time period. The results of all three investigations provide a greater understanding of the cake deposition process (during both dead-end and cross-flow filtration modes) and the cake removal process for the tubular filter press. This should assist in finding solutions to the two main problems which were experienced on the prototype tubular filter press. / Thesis (Ph.D.)-University of Natal, Durban, 1992.

Master of Science

This study was undertaken to evaluate the dewatering characteristics of a bench-scale belt filter press and a full-scale screw press, and to develop a suitable bench-scale test to simulate dewatering in a full-scale screw press. Tests were conducted to determine the effect of pressure and shear on dewatering of anaerobically digested, alum, waste activated, and pulp and paper sludges. The first part of the study involved tests conducted on a bench-scale belt filter press. Pressure was varied to develop performance characteristics with respect to cake and filtrate solids, and polymer demand. The second part of the study consisted of mixing intensity tests conducted to evaluate the effect of shear on dewatering in sludges. The third part of the study involved field evaluation of dewatering performance using a full-scale screw press. Tests were conducted to determine the shear produced in the dewatering process and to assess its effect on polymer conditioning requirements. The tests indicated that the polymer demand produced by the belt filter press simulator and the screw device was minimal. Rather, a substantial polymer demand was observed as a result of shear in the pipes and pumps during full-scale screw press dewatering operations. A combination of a high speed mixing device and a free drainage tester was capable of predicting polymer conditioning requirements for a full-scale screw press. Individual sludge performance characteristics varied with pressure producing changes in cake solids and filtrate quality. / M.S.

Experiments were performed on alum, anaerobically digested and aerobically digested sludges to determine the optimum polymer conditioning for a belt filter press The optimum polymer dosages for all three zones of a belt filter press were compared with each other to determine the best overall conditioning. The requirements of all three zones of a belt filter press were the same. However, the gravity rate of drainage seems to under predict the dosages for optimum belt filter press performance. In addition the total mixing energy, G (the shear) and t (the mixing time), that represents the laboratory belt filter press was found to be approximately 45,000. Using a mixing energy input of 45,000 and a standard Buchner funnel apparatus the correct polymer dose for the belt filter press can be predicted. / Master of Science

Thesis (MTech (Chemical Engineering))--Cape Peninsula University of Technology, 2016. / Polymers used as flocculants in the secondary sludge dewatering process are one of the most expensive inputs in these plants. The disadvantage is that these polymers cannot be recycled. Currently, controlling of polymer dosing rate is done by trial and error method. It has been shown that huge savings can be made by optimising the polymer dosing using rheological properties. It is not an easy task to optimise this process because of changing sludge characteristics on a daily, seasonal and annual basis. To try and optimise polymer dosing and polymer concentration, the variation in rheological properties needs to be understood first. The correlation between the process parameters and the rheological properties needs to be determined. There is currently no database of rheological properties of secondary wastewater sludge feeding belt filter presses available. To address these issues, a 12 week assessment of the rheological properties of the sludge feed to the belt filter press before and after conditioning in four wastewater treatment plants in Cape Town was conducted. The rheological properties were determined using an MCR-51 rheometer with parallel plate geometry under controlled temperature. After concluding the assessment, a 3-level Box-Behnken factorial trial was conducted at Plant K wastewater treatment plant to statistically analyse the correlation and/or interactions between the process parameters (sludge feed flow rate, polymer dosing concentration, polymer dosing rate and belt press speed) and the rheological properties of the sludge to optimise the plant performance.