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Simulation of Compressible
Cake Filtration
R. Holdich
Department of Chemical Engineering, Loughborough University of Technology,
Loughborough, Leicestershire LEll 3TU, UK
The equations derived from modern filtration theory for compressible cake filtration at apparently
constant pressure have been programmed into a conventional computer spreadsheet package.
Simulations were then performed, including investigations of the effect of increasing the slurry
concentration before filtering, and the distribution of pressure between the filter medium and the
cake with increasing filtration time. When the medium resistance is finite the pressure drop across
the cake is not constant and, consequently, the cake concentration and specific resistance are
functions of time, and must be iteratively deduced. The cell formulas for the computer spreadsheet
are provided, together with example outputs from demonstration simulations.
S optimisation
imulation of a process is a powerful means to investigate the resistance and the values for the constitutive equations linking
of operating conditions. In constant pressure filtration resistance (and cake concentration) to the cake forming
cake filtration there may be a variety of choices open to the pressure. The resistance and concentration data can come from
filtration engineer, such as the pressure at which to operate, the some simple laboratory tests, conducted over a period of a day or
feed slurry concentration to which it is economically viable to pre- two, or from plant operating data if cake samples and filtrate rates
thicken, the area needed etc. Simulation can be used to investigate have been obtained at different operating pressures.
For the sake of completeness the equations, or model, on which
the simulation is based are detailed in the Appendix. It is not
necessary to read or understand this in order to use or program the
spreadsheet simulation into the spreadsheet package of the
reader’s choice. However, some appreciation of Equations 2 and 3
would be useful, since these involve four of the inputs required
(and mentioned above). The average specific resistance to
filtration, and average cake concentration by volume fraction,
vary as a power law with applied filtration pressure. The power law
exponents (m and n) and constants (Cc and oo) are necessary
inputs in cell rows 9 to 12, in this respective order.
Simulation resutta
After convergence of the numerical model, the following are known
with respect to filtration time:
Cumulative filtrate volume.
Instantaneous filtrate rate.
i.e. the filtration is thus treated as
Cake height.
being the filtration of an incompressible material.
However, this is not the case with a medium resistance that is Dry mass of solids in the filter cake.
nontrivial. At the start of the filtration most of the pressure drop is Wet mass of solids in the filter cake
across the medium, and the fraction of pressure drop going to form
Average cake concentration.
the filter cake must therefore increase steadily as the filter cake
grows. With a compressible material the cake concentration and Pressure drop across the cake.
specific resistance will also increase. Hence, paradoxically, a Pressure drop across the medium.
constant total pressure filtration does not provide a constant
Concentration profile of the cake.
pressure forming the filter cake. To simulate this an iterative
computer solution is required. With a modest amount of effort this From a process scale-up (or design) point of view, the first eight of
can be achieved on a standard computer spreadsheet package the above list are the most important; the concentration profile is
following the procedures given in this paper. on a second spreadsheet, and provides a useful visible illustration
Two spreadsheets are described here for the simulation of a of the filter cake that is produced.
compressible filter cake during constant total pressure filtration. The process engineer can use the spreadsheet to investigate, or
The first one, ‘filter throughput with time,’ is the most relevant to simulate, the effect of changing process parameters on filter
engineers concerned with the specification and optimisation of operation, including the effects of total filtration pressure, slurry
equipment, and is therefore described in the most detail. The concentration, liquid viscosity, filtration area and medium
second spreadsheet, ‘concentration profile,’ is illustrative of the resistance. In this way it is possible to use the spreadsheet to
state of the filter cake, and is derived from the calculations simulate filter performance, systematically investigating cause and
described in the first spreadsheet. It is therefore only illustrated in effect in order to arrive at the optimum requirement for a
this paper, but with the necessary additions to the first spreadsheet particular duty; this could be the driest cake, fastest filtration
given in order to achieve it if the reader requires this additional rate, lowest effective pressure to use etc.
information.
Spreadsheet 1: Fdter throughput with time
Inputs An example printout from the top of the spreadsheet for filtration
A mathematical simulation requires certain physical property data simulation with respect to time is given in Figure 1, together with
before numerical solutions can be made. The minimum data the cell equations for column E, rows 15- 32. This column contains
required are the total filtration pressure, feed slurry concentration, first the required input data from rows 3 to 13, and then the initial
solid and liquid densities, liquid viscosity, filter area, filter medium calculations required to set the iterative solution off after row 16.
Filtration & Separation December 1994 0015.1882/94/118$7 00 0 1994 Elsevler Science Ctd 825
PRESSIBLE
CAKESIMULATION
A A 1 B 1 C 1 D 1 E / F 0 ( II 1 I / J 1 K 1 L 1 M
1 FILTERWBl 0.36
2 INpuTs +*****I~****+**~*++*****~******~****~**
$ 0.3
2 Total pressuredrop: WOOOOPa
:0.25
~ 4 Shy concentration: 0.15 bymass
E 0.2
6 Solid density: 2650 kglmA3 2
g 0.15
6 Liquid density: 1000 kg/n+3 [cakehdaht 1
i 0.1
7 Liquid visc~.sity: 0.001 Pas
ii 0.05
6 Area offilter cell: 1 m*2
9 Pre&we exgonw in c4mcentration: 0.08
0 4ooo 6090 moo
10 Pressure.expownt in alphaequation: 0.5 Filtmtbr~time, s.
11 Constant in concentmtion equation: 0.15
12 constant in alpha equation: 4SE+O8
13 Medium resistance: 2E+12 l/m
14 C&CmAnD V&m& ++*+*******Ll**~*+t****,
16 Initial concentrationof slurry: 0.06243 v/v
16 Average cake concentration: 0.34664 v/v
17 Dry solidslfiltratevolmne: 201.8 l&&3
19 Averagealpha: 7.1E+lO mkj~
19 Exponent in height expmssion: 0.19048
20 Filtratevolume incmment: 0.009 ti3 0 4666 6666 12666
21 a: 71791.5 F6&atk~11
time, s.
22 b: 20000
s +++*++***+*#I*****+*****a **+****a +**+**w ******+:
k-----L
m
91 Filtrationtime (5): 0 180 371.277 573.851 moooo
26 FIRSTITERATION: h soooo
50
W Filtratevol (W3): 0 0.00873 0.01747 0.02622 L so000 ..^-..--- - ---_.. ---.
27
26
Fiie rate(mh3/s) 5E-05
Cake preaswe (Pa): 0
4.7EXS
5895.63
4.4E-05
11143.4
4.2E-05
15843.8
I
CL-
_-._. _._-”
_.,._..._..
40
._.________
2oooo _ _I..-...
.- ..--.-.-....._.
._.-,.._..
._ 20
29 cake cotlc (v/v): 0 0.27639 0.29083 0.29914
30 DrysolkWltrate: 0 213.734 210.681 209.094 0 0
These results provide an almost complete description of the concentration profile. This is a useful visual representation of the
filtration process, given the input conditions chosen. filter cake, which can be used to illustrate the effect of various
operating parameters on cake compressibility and the concentra-
Spreadsheet 2: Cake concentration profiles tion profile. This provides a fuller description of the filter cake than
The second spreadsheet is for the prediction of the cake the average concentration, by volume fraction, which was given as
concentration with distance from the filter medium, i.e. the an output in the earlier spreadsheet.
AI A 1 B 1 C 1 D 1 E 1 F 10 1 I+ 11 1 J 1 K 1 I. I M
f jPRO.WBl I
2 INpuTs **+****a +****+*r( +******a *lb****** ******a
l 200
3 Total pressuredrop: 1OOOOO Pa
4 Sluny concentration: 0.15 by mass E i I
6
6
Soliddensity:
Liquid density:
2650
1000
kg/@3
kg/&3
po
-----..--.
I------ .__.-_..,,_.-
-...------
.,
7
6
6
.lO
Liquidviscosity:
_AreaofBltercelk
Vesselheightorclearance:
presmmelxponentinconcentrat0~
0.001
1
0.19 m
0.08
Pas
I11”2
5
E 100 _._.___.
--__...,^..
_.___.-____._,
-... _.._
_______
_____
11 .Pltwure~inalphaequati~ 0.5
12 Constantin conoenaration
equation: 0.15
13 con&ant in alpha equation: 4.53+08
14 Medium- 2E+12 l/m
16 Cfi’JJLA-fED VALUES: **8+8++r(*t*l**+l WW+*I
16 hitialcoaamwionofshnry: 0.06243 v/v
17 Average cake wnwaation: 0.34664 v/v 0 0.1 0.2 0.3 0.4
16 Dry soli- volume: 201.8 k8k’3 Solid concentration, v/v.
18 Avexageaipha 7.1E+lO m/kg
50 &ponentinhe$htexpmssi~ 0.19048
21 Filtratevohune incremw: 0.02 &3 -0 -3600 -7200 -16606
22 8: 71791.5
33 b: 20000
--i 24 **+**+*~*****+*~****L***~*******~*******~*******~*********
Figure 3. Screen display for sproadshwt 2 - data input, inltlal calculations and iteration with output graph.
Output taken from this spreadsheet is provided in Figure 3, in concentration are illustrated in Figure 4. The cake concentration
which only three filtration times in addition to the start are increases from 29% to 34% by volume, and the fraction of pressure
illustrated. The times chosen for this example are 1, 2 and 3 hours. drop attributable to the filter cake rises from 10% to 80X, on
The only significant difference between this and the earlier increasing the feed solids content from 5% to 35% by weight. Both
spreadsheet is the inclusion of the vessel height, or clearance of these effects are attributable to the increasing cake depth with
between the filter surface and some other internal structure, which feed concentration leading to a higher cake resistance to filtrate
is contained in cell E9. This is used to fix the first concentration flow at the fixed filtration time.
profile illustrated on the graph inserted on the spreadsheet.
Iteration, in order to establish cake height and pressure drop Closing comments
across the cake, is carried out in an identical way to that already This paper is intended to be of assistance to anyone who needs to
described. After these are fixed, Eqn. 8 (see the Appendix) is simulate apparently constant pressure compresssible cake filtra-
solved for various values of dimensionless cake height y/L, which tion. The simulations described also provide some insights into the
are then converted to real heights from a knowledge of L. The filtration process, especially when the filter cycle is very short. Many
modification needed to the earlier spreadsheet in order to program further conclusions can be made after the simulator has had the
in Eqn. 8 for concentration should not pose any significant opportunity to try out the spreadsheets with his/her own data.
problems, and the cell equations are not therefore reproduced here. The spreadsheet cell equations and accompanying illustrations
One distinct advantage of showing the full concentration profile of the spreadsheet text, and graphics, are the minimum required to
over reporting the average value is that the cake concentration at convey the necessary information to program the simulation into a
the filter medium is given. This could be important if poor cake spreadsheet. In order to achieve the simulation, the first iteration
discharge or handling problems occur when this is below some and the calculations at the given filtration time must be copied
threshold. Also, the maximum cake concentration can be seen to over as many cells as are required. This is a standard spreadsheet
become progressively greater with time, as more of the available operation, and should not present much of a problem. More
pressure drop goes into forming the filter cake. advanced spreadsheet operations - such as programming in
macros, which could be used to check for convergence of the
Further observations from simulations solution - have been deliberately avoided, in order to keep the
There are several interesting results illustrated in Figures 1- 3. The spreadsheet simple to use and readily understandable.
average cake concentration reaches an almost uniform value when If the reader does not want to become involved in entering the
the pressure drop over the cake is still only 40% of the total. From spreadsheet formulas, then a copy of both the spreadsheets
this time onwards the filter cake will have nearly uniform described above, and a simulation of a rotary vacuum filter, are
properties of concentration and resistance. This effect is seen available on a 3.5 inch MS-DOS disk, at a nominal cost of 25 (UK
with most filter cakes, even ones with high values of the pressure only, including postage and packaging). The spreadsheet file
exponent in the concentration equation (spreadsheet 1, cell E9). format is Novell’s Quattro Pro for Windows v5, which is compatible
This helps to explain why the well known (time/filtrate volume) with most other modern spreadsheet programs.
against volume graph (the t/V versus V plot) becomes linear after The simulation work is continuing with more solid/liquid
an initial period when am&sing laboratory data. However, for short separation operations being produced in computer spreadsheet
filtrations - such as those provided by continuous machines - form in the future, and ideas for new simulations would be
the fraction of the total pressure drop over the cake may never welcomed.
reach an acceptable value, and low cake concentration - with
consequent material handling problems - may occur. Bibliography
Using the spreadsheet simulation it is possible to assess the Tiller, F.M. (Ed.): ‘Theory and practice of solid-liquid separation,
benefits of increasing the feed slurry concentration prior to 2nd edn.’ (Department of Chemical Engineering, University of
filtering. The feed slurry concentration has been altered from Houston, Texas, USA, 1975).
between 5% and 35% by weight, and all the other inputs illustrated
in Figure 1 have been kept constant. The filtration time under Appendix
consideration was 1 hour. The resulting increase in the fraction of Filtration models
pressure drop going to form the filter cake and the cake Our knowledge and understanding of compressible cake filtration
828 December 1994 Filtration & Separatlon
owes a lot to the work of professor Tiller and professor Shirato, and is given by
their many research papers published in the 1960s and 1970s. The
modelling process employed in the spreadsheets in the present
paper applies their basic concepts of compressible cake filtration.
C, = CoAp,“,, (;) m’(l-WI- n, (8)
The mathematical development begins with the conventional
constant pressure filtration equation rearranged into the form of Combination of Eqns. 7 and 8 permits the cake concentration at
a quadratic equation: any height within the cake to be calculated.
Solution scheme
J!!++%V-t = 9 (1) The first assumption needed to start the iterative solution process,
2A2AP
is that all the total pressure drop acts over the filter cake, i.e. the
where p is the liquid viscosity, V is the cumulative filtrate volume, medium resistance is temporarily neglected. The solution then
A is the filter area, R, is the resistance of the filter medium, t is follows the following scheme:
the filtration time, AP is the total pressure drop over both cake (1) Values of average specific resistance and dry mass solids per
and medium, Z is the average mass of dry cake deposited per unit unit volume filtrate are calculated according to Eqns. 2 and 4,
filtrate volume, and (Y is the average specific resistance of the filter at whatever time is required.
cake. The average specific resistance can be described by a power-
(2) The volume of filtrate produced is obtained by solving Eqn. 1,
law function of the cake forming pressure:
taking the positive root of the quadratic equation only. The
5 = a& - n)APctke (2) medium resistance is included in this calculation.
(3) The instantaneous filtrate rate comes from Eqn. 5.
Similarly, the average cake concentration by volume traction is
(4) The pressure drop over the filter cake is then calculated
c = Cs(1 - m)AP& (3) according to Eqn. 6, which is a new value including the effect of
the filter medium.
where (~0, n, CO and m are empirical constants.
(5) The new cake pressure drop is then used to recalculate values
The average mass of dry cake per unit volume filtrate is
of average resistance and dry cake mass per unit volume of
obtained from the average cake concentration and the mass
filtrate.
fraction of solids in the feed slurry (s) by
The process is repeated from stages 1 to 5, until the difference in
1 calculated values of filtrate rate falls below some set value between
z= (4)
h__G the iterations. On a computer spreadsheet, without using macros,
( “P CP*> the easiest way to achieve this is to fix the number of iterations at a
high value, so that convergence is guaranteed. The spreadsheet
where p and ps are the liquid and solid densities, respectively.
described here uses six iterations, and the difference in flow rate
The instantaneous filtrate rate Q can be obtained from Eqn. 1 in
between iterations is usually less than 0.5% after the fourth
its differential form:
iteration. To simpliij the cell equations in the spreadsheet the
following terms have been grouped:
Q+ [-$=V+!& WC
1
a=2A2aP
The pressure drop over the filter cake can be calculated at any time
by deducting the pressure drop over the medium from the total
applied pressure: b=* (10)
AAP
AP,, = AP-CLR”Q (6) The b term remains constant throughout the filtration, and the
A
solution scheme references the cell location containing this value
professor Tiller and professor Shirato showed that the cake depth (spreadsheet 1, cell E22) for all iterations. However, a changes as
at any instant in time can be calculated from the average specific resistance and dry solids per unit filtrate
change, and a new value of a is calculated for each iteration. The
AP(‘-mmn) A
coke following iteration uses the new value of a in the solution of Eqn. 1.
L= (7)
woCo~dl-m-~) 0
When the filtrate rate has been obtained by the above
procedure, Eqns. 7 and 8 may be solved to provide the cake
and the volume concentration inside the filter cake C, at a height y concentration profile.
PI '807
Modellberechnung des Kompressionsverhaltens
volz W. H@linger, Ch. St&klmayer
Es 1.9em C0mpurersimurer~onsm0d~~r fur die Ansammlung ernes Sraubhlterkuchens enrwckelf
von Staubfilterkuchen
und A. Hack1
Slmulalronsergebnrsse verm~rrern eme rheorebsche Darslellung der lnneren Srrukrur emes
worden O,e Oynamrk des Kompressionsverhaltens im Kucheo la81 sich m!r Hllle dleses F,lrerkuchens und bmren e,ne Erklarung iur dre schrchrarrrge Srruktur des F!lterkuchens, die bei
Programms wnulreren Be, der Smwlabon rsr e!ne Korrelahon der zwischen den Twlchen fruheren exper,menre,,en “nrersuchungen beobachrer wurde (5 sn 7 abb 3
ref)
wrkenden Krafte und dem sich daraus ergebenden Oruckabfall !m Kuchen zu beobachren De
Some aspects of the design of filter fabrics for use in solid/liquid separation processes
PI
*"813
Elnige Aspekte der Konstruktion von Filtergeweben xum Einsak bei Fe&-IFliissigstoffabscheldungsprozessen
VOTLE. Hardman
Texrrlgewebehlter brlden emen wesenrlrchen Bestandre,/ zahNoser indusrrreller Prozesse, mdem sre werden Es wrrd kurz auf Texblrohsroffe sowe - unrer besonderer Bezugnahme auf Aspekre der
.?ur Produkrrernhert, Senkung van EnergrelProdukrionskoslen und zu emer rerneren Umwelr F!lriabon und Ftltrationseus~uslung - auf die Konsrwklionselemenre verschredener Tuchhlrer
berrragen. Des Referaf enthM eme allgememe Beschrelbung der Fakforen, d!e be! der und deren Endbearbertung erngegenge” (6 s”, 4 abb, 2 lab, 4 ref)
K0”srwkbon emes Gewebes flir elne” Fest-lFluss,gstoff-Abscherdungsprozess berucks!chbgr
Ouelques aspects des tlssus flltrants utilis6s dens les proc&ldis de siparation solidelliquide
par E. Hardman
Les bswes frftrants rexrrfes sonr une part essenberre d’une quanrrt6 rnnombrable de pro&d& compre quand on chowr “n rlss” pour “n pro&de de s~parabon sokdeiliqu,de On y drscufe
mdustrrers, contr!buenr B ra pure@ des prodwfs, 8conomisanr /es coirrs d’8nergre et deproductron bnevemenf les maberes de base ems! que /es ei&nenrs d’&borabon et de fmrssage des t!ssus en
er am~,,oranr I’enwronnement L’arbcle d&rrf, en termes g&%+raux, /es facteurs qvr sonr pns en ref&ence parbculr8re B ia hkration et aux equrpements de hftrafion. (6 pags.. 4 hgs.. 2 tabs., 4 MS)
Unos aspectos de disefio de telas de flltro para uso en procesos de separaci6n s6lidolliquido
par E. Hardman
Tefas de f&o son una parte eserwal de proces0s mdusrnales sm ntimero, conrubuyendo a ia rela pare “n proceso de separacdn sdlrdolliqurdo. Se flare de matena prune rexbl y. con
pureze de productas, a econom~a de energra y de c0sres de produccibn y un ambrenre mas rImpI referenoa parricular a consrderacrones de fllrracr6n y equpo de frltrao6n. los elementos de
El articulo describe, en r&mmos generales, 10s facrores que se benen en cuenta en el djseiro de consfrucc~~n de tele y merodos de ecabar (6 pigs.. 4 f!gs.. 2 tabs., 4 refs.)
lzl
819
Be! F&ralrons- und Enrwasserungsprozessen
Kuchenelnheltllchkeit bei der Druckfiltration von Kohlenschlamm
van D. J. Sung,
smd die Kuchensrrukfur und das AusmaB der
J. G. Groppo und B. K. Parekh
nredriger Feuchfrgkerfsgehak ,m Fllrerkuchen auf dre e,nhe,fkche “errerlung “on Pertrkeln be,
Homogenertar ~0” Festsroffen ,rn Fllferkuchen wrchbge Parameter. In dem Referal 1st eme emem Vermrschungsrndex van mehr als 0,750 zuruckzufuhren Es wrd au8erdem dargeregr, dafl
neuarbge. abgewandeke Labormerhode z”, Erzeugung e,nes F,Herkuchens emherrkcher Strukrur d!e Fllrerkuchenfeuchrigke,f und der Vermrschungsmdex umgekehrr proporrronal smd. d.h em
be, Oruckfrlrratron beschrreben. D,e Emhertrichke,r des F,lferkuchens, dre anhand des hoherer Vermrschungsrndex hangr srers m,f emem Fllterkuchen gerrngen Feuchrrgkerrsgehalts
Vermmchungsmdexes ausgedruckt wrd. wurde mrf Hllfe des Kramersschen Modells fur zusammen (6 sn, 9 abb, 4 tab, 28 ref.)
verschredene Arren “on Kuchenbrldungsbedrngungen erm,tte,r. Der Unrersuchung nach 1st ei”