ON-LINE MEASUREMENT OF

RHEOLOGICAL PARAMETERS FOR

FEEDBACK CONTROL
Alex van der Spek, Zdoor BV, The Netherlands
Bob Maron, CiDRA Minerals Processing, USA

Objective

Client motivation: Water and land reclamation from existing tailings

impoundment
CiDRA motivation: develop on-line rheology measurement with existing
technology
Technical Goal:
Mature Fine Tailings,
non-Newtonian slurry

Newtonian slurry, large

solids + water carrier fluid

Recovered
water
solids

flocculant
Short pipe reactor

Constraints:
velocity high enough for throughput, adequate mixing of flocculant, and...
velocity low enough to NOT break down flocks after they form, and...
Correct flocculant dosage to achieve agglomeration
2

On-line rheology measurement

methods investigated
1. Monitor velocity profile change
2. Measure wall shear rate from velocity profile, assume
rheological model, cross plot vs wall shear stress from
pressure drop
3. Monitor degree of turbulence from energy spectrum of
vorticity

Key concept
length scales and flow

Solid particles

Vortical structures

If...

Vortical Structure size

>>

solid particle size

...Then
NO INTERACTION
4

Key concept
length scales and flow

Vortical structures

Solid particles

If...

Vortical Structure size solid particle size

...Then
INTERACTION !!
5

Length scales and energy propagation

Kolmogorov Theory of homogeneous isotropic turbulence

Constant bulk velocity, energy propagation
mechanical
energy

heat

Turbulent vortices transport energy from larger to shorter length scales (vortices)
Max vortical
length scale,
pipe diameter

1000

100

vortical
length scale
range

10

Min vortical
length scale,
Kolmogorov
length scale,
~200 um

Length scale (mm)

0.1

>>

Particle size,
fines
~ 40 um max

0.01
6

Vortical Structures - use in SONARtrac

Volumetric Flow Measurement
L

Sensor Array

Velocity
Measurement via
Tracking of
Vortical
Structures

Amplifiers and
Digitizers

Rev 10

T T T T T T T

L = Velocity
T

Sonar Array Processing for Volumetric Flow

Each spatial wavelength has a discrete

temporal frequency ( Frequency= Velocity/ Length -> f=U/ )

Velocity/Length1
Frequency

Frequency

Velocity/Length2

Size2
Size1

U/3

Velocity/Length3

Size3

Temporal / Spatial Decomposition

Wavenumber-frequency (K-) plot

Slope of Ridge
Determines Flow
Velocity

U/2
U/1

1/1

1/2
Wave Number

1/3
8

Kolmogorov Theory predicts Vortical power spectra...

is measured by Sonar array
2
3

5
3

Frequency (Hz)

Where,

Wavenumber k (1/ft)

1
=
( )

Sonar array infers (by direct measurement) Power Spectra vs wavenumber, therefore...
Can evaluate energy dissipation (i.e. rheology information) rate without differential pressure
9

Wavenumber k (rad/ft)

Power (dB) re 20 uPa

Frequency (Hz)

Kolmogorov Theory
Vortical power spectra

Power vs wavenumber spectra follow Kolmogorov Theory

2 5
3 3

Wavenumber k (rad/ft)

10

Sonar array measures Vortical Power Quality

High Vortical
Power Quality =
low loss
propagation of
coherent power

Same velocities, but different Power Quality Spectra vs Wavenumber

Low Vortical
Power Quality =
high loss
propagation of
coherent power
Rev 10

11

Sonar flow profile meter

Vortical Power Quality (and flow) at 5 heights

V 0

V 45

Coherent Str

V 90

V 135
V 180
ALTURA (NORMALIZADA)

V 0

0.9

profile

V 45

0.8
0.7

Reference flow rate

profile side sensor

0.6

V 90

0.5
0.4
0.3

V 135

0.2

V 180

0.1
0
0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

CAUDAL (m/seg)

12

1.60

1.80

2.00

2.20

2.40

Test setup
Sonar
flow
profile

Sonar
flow
profile

flow
mixer

Velocity profile,
non-Newtonian
Bingham flow,
Flocculant
injection

agglomeration

Sonar

Short pipe reactorflow

profile

Large flocks in waterbased carrier fluid

water

solids

Velocity profile,
Newtonian
Turbulent flow,
with agglomerated
solids

Mature Fine Tailings

Non-settling fines

13

Sonar array & Velocity Profile

Stop
With flocculant, Newtonian flow
NO velocity profile change top-bottom flocculent

NO flocculant, non-Newtonian flow

Non-Newtonian Bingham flow
No velocity profile change

----- upstream
----- midstream
----- downstream

Velocity Profile (m/s)

Pipe top

Pipe bottom
time Rev 10

14

Sonar array & Velocity Profile

Stop
With flocculant, Newtonian flow
NO velocity profile change top-bottom flocculent

----- upstream
----- midstream
----- downstream

Velocity Profile (m/s)

Pipe top

Upstream

NO flocculant, non-Newtonian flow

Non-Newtonian Bingham flow
No velocity profile change

Midstream

Downstream

Pipe bottom
time Rev 10

15

Sonar array & Velocity Profile

Stop
With flocculant, Newtonian flow
NO velocity profile change top-bottom flocculent

----- upstream
----- midstream
----- downstream

Velocity Profile (m/s)

Pipe top

Upstream

NO flocculant, non-Newtonian flow

Non-Newtonian Bingham flow
No velocity profile change

Midstream

Downstream

Pipe bottom
time Rev 10

16

Sonar array & Vortical Power Quality

With flocculant
Newtonian flow
High-loss energy propagation

Stop
flocculent

NO flocculant
Non-Newtonian Bingham flow
Low-loss energy propagation

----- upstream
----- midstream
----- downstream

Vortical Power Quality

Pipe top

Pipe bottom
time

Rev 10

17

Vortical Power Quality (VPQ) changes with rheology

MFT

Sonar
VPQ

flocculant

count

Vortical Power Quality

mixer

Sonar
VPQ

Sonar
VPQ

Large flocks in waterbased carrier fluid

agglomeration

water

solids

time
up-stream

mid-stream

down-stream

Histograms, Vortical Power Quality

18

Possible Implementation

Measuring real-time rheology change with Sonar Array Flow Meter

Sonar
flow
meter

count

VPQ
up-stream

Sonar
flow
meter

Sonar
flow
meter

VPQ

VPQ
mid-stream

down-stream

Histograms, Vortical Power Quality (VPQ)

19

Summary

Measuring rheology change with Sonar Array Flow Meter

Agglomeration Rheology change Length scale change (particle size change)
Length scale Vortical Energy Transport (Kolmogorov Theory)
Sonar array measures Vortical Energy Transport (power vs. wavenumber)
Power vs. wavenumber integrated into Vortical Power Quality (standard measurement)
rheology change Change in Sonar Vortical Power Quality real-time measurement
Future work: move from integrated Vortical Power Quality figure of merit...to (better?)
spectrum measurement

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