Study on cost reducing

of solution and dosing plant

between

two chamber pendulum type

and

three chamber flow-through type

两箱摆式加药装置

和三箱直流加药装置

运营成本之研究

By: Alltech Dosieranlagen GmbH

研究方：阿尔泰克计量设备有限公司

November 28, 2000

Study by Alltech Dosieranlagen GmbH to exhaust the cost-reducing potentials when using two-chamber pendulum type plants in comparison with the three-chamber preparation plants. 阿尔泰克计量设备有限公司就两箱摆式加药装置和三箱加药装置在降低溶液制备成本可能性方面进行了研究。

High operating costs make the search for means and ways to reduce the prices inevitable. 高运行费用使寻找降低价格的方式和手段之研究不可避免。

Increased costs involved with waste disposal, higher costs involved with the supply of drinking water and that of flocculent are just a few examples, which mean increased operation costs for the user of dewatering and flocculent plants. The question is becoming more and more urgent: Where can we find ways and means to reduce those costs. 增加的成本费用包括废物的处理，饮用水以及絮凝剂的供应。这仅仅是若干方面。这些方面对于排水和絮凝剂装置的用户来说，就是运行成本的增加。我们在哪里才能找到降低这些成本的方法呢？这一问题变得越来越迫切。

The study carried out by Alltech Dosieranlagen GmbH answers this question. It shows potential to save on drinking water, auxiliary flocculent products and costs for maintenance, when two-chamber pendulum-type flocculent preparation plants are used.

由阿尔泰克公司进行的研究找到了以上问题的答案。研究发现，采用两箱摆式絮凝剂制备节省溶解自来水、降低絮凝剂用量和降低维修费用成为了可能。

Object of the study and structure of the survey

研究目标和调查结构

Object of the study were the different types of plants produced by a number of manufacturers. All those plants were tested at their individual sites under normal working conditions. For the operation of these plants were used liquid as well as powder flocculent found in different categories on the market.

研究目标是若干生产厂家的不同设备。所有这些被测试的设备都在各自的工作现场，处于正常工作状态。所有这些设备使用市面上所采购的不同规格的浓缩液和干粉絮凝剂。

The tests and the test results have been limited on fully automatic, continuously operating preparation plants and covered the following 2 types of plants:

试验和试验结果限于以下两种设备的全自动、连续运行模式：

1). Three-chamber preparation plants (flow-through system)

三箱制备装置（直流系统）

2). Two-chamber plants (preparation in batches)

两箱装置（批量制备）

Both types of plants are adequate for continuous operation.

两种装置都可满足连续运行模式

1. Preparation plants with a flow-through system

采用直流系统的制备装置

1.1. How does a flow-through plant works, and what kind of problems could occur?

直流系统制备装置的工作原理及缺陷

Flow-through plants are mostly designed as three-chamber plants. The method for constructing the tanks may be different but the principle remains the same:

大多数直流系统制备装置设计为三箱制备系统。制造箱体的方法可能不同，但原理相同：

1.1.1 In the make-up chamber auxiliary flocculent is poured in with water.

在制备箱中，絮凝剂和水一起注入。

An important factor here is the intensive dispersion of auxiliary flocculent through solution water before it comes in make-up chamber. Otherwise conglomerates cannot be dissolved by the agitator.

因此，非常重要的一点是絮凝剂在进入制备箱之前和溶解水必须充分混合，否则，结块的絮凝剂不能被搅拌机搅化。

1.1.2 In the next step, newly added solution presses the prepared solution in the ageing the next step, newly added solution presses the prepared solution in the ageing chamberscolved by the be different but the princhamber. 接下来，新加入的溶液会压在熟化箱里的溶液上。

Prior to this phase, the agitator mixes the solution contained in the make-up chamber. In this chamber, we could not detect a definite retention period. Un-matured products were quickly swirled by the agitator and compressed to overflow. 在这一阶段之前，搅拌器搅拌制备箱中的溶液。在制备箱中，我们检测不到确切的存留时间。没有熟化的溶液很快被搅拌机搅拌并压到溢流端。

1.1.3 Afterward, “matured”(!) solution contained in the ageing chamber is compressed in the same manner into the dosing chamber.

随后，熟化箱中熟化的溶液以同样的办法被压到计量箱输出箱中。

Due to the fact that an agitator to homogenize the solution is placed also in the ageing chamber, we will face the same kind of problems as for the make-up chamber. Here also, we could not detect a definite retention period although the agitator of the ageing chamber will be stopped when new solution is poured in.

因为在熟化箱中也有搅拌器，我们会遇到和制备箱中同样的问题，尽管熟化箱中的搅拌机在新的溶液注入时会停止搅拌，我们同样也检测不到溶液的存留时间。

1.1.4 Some manufacturers have a third agitator installed in the dosing chamber, from where the ready-to-use solution is metered.

有些制造商在第三箱（计量输出箱）中也装有搅拌器。

When an agitator should be mounted in the dosing chamber, please not that the quality of the solution becomes lower! It will have a longer ageing period avoid having the solution mixed in the dosing chamber.

当计量输出箱中安了搅拌器后，溶液的质量将会大大降低。为了避免输出箱中溶液的混合，必须要有更长的熟化时间。

Test with different types of diffusers built in the chambers were negative and no distinct improvement in the characteristics of the plant were achieved.

实验表明在溶液箱中安装不同形式的混合器效果并不明显，装置的性能并不能得到明显改善。

1.2 Result of the survey with regard to the flow-through plants

直流装置研究结果

On all flow-through plants and after adding dye to auxiliary flocculent, we have obtained following results in respect of the maturing period:

在所有的直流装置中，在给絮凝剂着色后，就熟化时间我们获得了以下结果：

The maturing period in flow-through plants has nominal capacity of 8-10 minutes at the maximum.

直流系统装置在其额定输出量下，最大熟化时间在8－10分钟。

After this period, the already dyed solution flows into the dosing conduit. We could detect non-diluted powdery residues in the micro-filters.

经过熟化时间段后，着色的溶液流入了计量管道。我们在微滤器上发现没有被稀释的干粉残留。

1.3 The effect this has on “paper Industry” as example

这一缺陷对造纸工业的影响

For Paper-making machines as well as for staining cloth from filter-presses, the above mentioned mis-performance can have negative results. You will have paper of low quality (wrong batch) and the filtering cake will stick onto the clothes of the filter press. No doubt the filter-tissue will have a shorter life-time. Another negative aspect is that non-matured solution which has no flocculating effect and is thrown away together with the dewater sludge.

对于造纸机以及压滤机滤布，以上装置存在明显缺陷。纸张质量会不稳定，不同批次会出现不同的颜色。滤饼会粘在压滤机的滤布上，毫无疑问会缩短滤布的使用寿命。另一个不利的影响就是没有熟化的溶液没有絮凝作用，会和脱水污泥一起白白浪费掉。

1.4 Result

结论

Considering the size/capacity ratio, a flow-through plant becomes advantageous only then, when the solution does not flow directly in the process but has enough time to mature (in dosing conduit or in a storage tank).

结合装置的尺寸和出液量，只有溶液不直接流入工艺过程（流入计量管道或流入一贮存罐中），而且有足够的熟化时间时，直流装置的优势才能显现出来。

If the solution should flow directly into the process, we advise against using a flow-through plant. This negative result is even higher, when the make-up concentration is high. The reason is that, when the make-up concentration is high, so is the viscosity of the solution. The agitators can no longer homogenize the solution contained in the chamber. At the same time, the newly poured solution with low viscosity will look for the easiest way to get into the next chamber. In this way, a flow-through channel is formed from the input point up to the discharge point.

如果溶液必须直接流入工艺，我们建议不要采用直流式计量装置。制备浓度越高，直流式计量装置的缺点越明显。因为制备浓度越高，溶液的粘度也就越高，搅拌机就不能将溶液箱中的溶液搅拌均匀。同时，新注入的粘度较低的溶液会很容易流入下一个箱体。从而从溶液的注入端到泄液点形成一个直流通道。

This short-circuit-flow will not use the full volume of the chamber. With the result, the ageing period will be further reduced. You can disregard this result only when the output is low (in relation to the 1/2 of the chamber volume) and by low make-up concentration (0.05%~0.1%).

短路溶液流不会用完溶液箱所有容积，结果使熟化时间进一步缩短。这一缺陷只有在溶液输出仅为装置容积1/2且浓度较低（0.05％-0.1％）时可以忽略不计。

2. Two-chamber plants (Operation by batches)

两箱制备装置（分批制备）

2.1 How does a two-chamber plant function?

两箱制备装置的原理

With the two-chamber plant, make-up is done in batches and allows a continuous discharge. The two-chamber plants can be divided into two groups.

两箱制备装置的溶液制备分批进行，允许连续的泄液。这类装置分为两类：

In type 1, each chamber has a definite function. One chamber is used for preparation and the other chamber for metering the product. In the first chamber the solution is prepared and matured which then flow into the dosing chamber or can be pumped by means of a transfer pump.

第一类：每一个溶液箱都有明确的功能。一个箱体用于溶液制备，另一个箱体用于溶液计量。制备箱体中制备好的溶液流入计量箱中，或通过输送泵抽到计量箱中。

Type 2 is a two-chamber pendulum plant, such as the CONTINUFLOC system of Alltech Dosieranlagen GmbH (see flowsheet on page 8). In one of the chamber the make-up process will start and left to mature, whereas the matured solution in the other chamber can be discharged at the same time. The discharging of one of the chambers is finished, the discharge can be switched over to the chamber in which the solution is matured. Thus the plant had a continuous discharge. When the discharge of one chamber is finished, the pendulum filling distribution channel can switch from the full chamber to the empty one automatically and start the filling of powder and solution water. Thus the plant can have a continuous preparation.

第二类：如阿尔泰克(Alltech)公司的Continufloc系统。该系统是一种摆式加药装置。溶液制备从开始到熟化以及排放在一个箱体中一气呵成。一个箱体在制备溶液过程中，另一个制备箱中已经熟化的溶液则排放。一个箱体中的泄液结束，装置会自动从排空的箱体中切换到溶液已经制备好的箱体，继续排放溶液，从而实现连续泄液。当一个箱体内的溶液排空后，摆式投加系统会自动从制备好溶液的箱体切换到排空的箱体，进行溶解水和干粉的投加，从而实现不间断制备。

In the case of two-chamber pendulum type plants, it is essential to have an intensive dispersion prior to pouring in the solution!

在这种两箱制备装置中，大功率的混药器显得尤为重要。干粉进入溶解箱前必须和溶解水充分混合。

In two-chamber make-up plant, a high make-up concentration should cause no problem, because there is no risk of a short-circuit-flow.

因为没有短流溶液流的危险，所以两箱制备装置高制备浓度没有问题。

2.2 Result of the survey on two-chamber plants

两箱装置的试验结果：

When a two-chamber plant is functioning as detailed in the layout plan, then the quality of the solution is perfect because the maturing time has been reached.

当两箱制备装置严格按照流程工作后，可以制备出质量非常均匀的溶液，因为溶液可以有足够的, 熟化时间。

Necessary condition for respecting the maturing time is: Tank should be large enough to corresponding to the discharge capacity; for plants where transfusing should be done, the period of transfusing should be added to the maturing time. When all these conditions are met, then the maturing time can be adhered to.

熟化时间的条件：根据泄液量，箱体必须足够大。对于采用输送方式的两箱装置，熟化时间必须将溶液输送时间考虑进去。当满足所有的条件后，熟化时间就可以达到。

Please not: when the make-up concentration is high, the transfusing time will increase. 请注意：如果制备浓度提高，溶液的输送时间会相应延长。

Advantages of the two-chamber pendulum type plant compared to plants necessitating transfusing are:

两箱摆式制备装置和两箱输送制备装置相比较，其优势在于：

The Plant has small dimension and yet give the same output

(thus to save the space)

同样输出量，摆式装置体积更小，节省空间

Transfuse pumps will become redundant and are not high in size

无需输送泵，高度更低

2.3 Conditions when the maturing time is adhered to?

满足熟化时间的条件：

Quantity of flocculent calculated during the planning time or in the laboratory study will corresponding with the quantity actually required if the maturing time is adhere to. 在试验策划期间以及在实验室研究阶段计算出的絮凝剂量和熟化时间所需的量完全相同。

We could not detect negative effects on the other remaining equipment.

我们没有对其他类型制备装置的缺点进行对比研究。

3. Resume

结论：

The results of the tests mentioned above highlight the advantages of the two-chamber plants against the flow-through plants when following conditions are met. Among all the two-chamber plants the best alternatives are offered by the two-chamber pendulum type plants with the best solution quality.

以上试验结果发现，如果满足以下条件，和直流三箱装置相比较，两箱装置具有明显的优势。而在两箱制备装置中，摆式制备装置是最理想的选择，制成的溶液质量最佳。

With regard to the costs involved with operating the plant, here are some results: With identical processes you will have upto 20% saving on flocculent when you use a two-chamber pendulum type Continufloc plant instead of a three-chamber flow-through plant. With the three-chamber flow-through plant, you will throw away 20% of the auxiliary flocculent.

在设备运行成本方面，我们研究得出的结论是：对于同样的工艺，Alltech公司两箱摆式制备装置Continufloc比三箱直流制备装置要节省20％的絮凝剂。而三箱直流制备装置要白白浪费掉20％的絮凝剂。

A further advantages of the two-chamber pendulum type CONTINUFLOC plant is the saving on quantity of drinking water. For the preparation process, you will still use drinking water, but for the post-dilution, you can use cleaned swage water. For the two-chamber plants, you will use less drinking water, because the make-up concentration can be higher. For example, if you select a 0.5% make-up concentration instead of 0.1%, you will reduce the consumption of drinking water by 80%.

Alltech公司两箱摆式制备装置Continufloc的另一个优势在于节省自来水的用量。在制备过程中，Continfloc仍然使用自来水，但二段稀释可以使用处理过的污水。相对于三箱直流制备装置，Contibufloc制备浓度更高，所以能够节省自来水。比如：选用0.5％而不是0.1％的制备浓度，Continufloc可以节省80％的自来水。

The high percentage in make-up concentration will further mean a smaller tank and thereby saving in space.

此外，更高浓度意味着可以用较小的溶解箱达到同样的制备量，从而缩小了制备箱体积，节省了空间。

Minimum wear and low maintenance costs speak also for the advantages of a two-chamber plant.

两箱制备装置的优点还在于将损耗和维修成本降到了最低。

PS：Enclosed the folowsheet of Alltech two-chamber pendulum-type solution and dosing plant Continufloc

附：Alltech两箱摆式加药装置流程图

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