CFD modelling of thickeners at Worsley Alumina Pty Ltd

Computational fluid dynamics (CFD) modelling of process unit operations is a tool that is being used increasingly by mineral processing industries to reduce operating and capital costs and increase throughputs.Worsley Alumina first became involved with CFD modelling through support of the AMIRA Thickener Technology Project 266A in 1994, and subsequent extension projects in which CSIRO has been developing validated CFD models of thickener operation. The CSIRO Division of Minerals has been involved with CFD modelling since 1984 mainly on high temperature furnace applications and has been developing multi-phase thickener models since 1992. The benefits of obtaining a better understanding of flow patterns in thickeners using this modelling method became obvious and projects commenced in the third quarter of 1995 to utilise the CSIRO expertise. Projects have been ongoing almost continuously since that time. The CFD modelling was verified using tracers to measure actual flow patterns in a settler. Once verification had been achieved the CFD model was used to test innovative changes in design aimed at achieving higher throughputs and improved operation. These innovative changes when implemented on the full plant gave results similar to the CFD model predictions and resulted in improved process stabilisation, reduced chemical costs and very large savings in capital requirements for our major expansion that has just been completed. There are a number of assumptions made in the CFD model and these are discussed in detail in the paper together with details of individual CFD modelling projects and cost benefits achieved from completed projects.