CFD simulation and optimization of the settler of an industrial copper solvent extraction plant: A case study

A computational fluid dynamics simulation based on Eulerian–Eulerian two-phase method accompanied by experimental field measurements has been applied to study the behavior of aqueous–organic dispersion in the copper solvent extraction settler in the Sarcheshmeh copper complex, Iran. This simulation takes into account multiple-size group (MUSIG) model for droplet dispersion and droplet size distribution, which is based on a population balance equation and considers the break-up and coalescence models of the droplets. Fluid flow field has been calculated by solving the continuity and Navier Stokes equations along with the standard k-ε turbulence model. The turbulence model included buoyancy, drag, lift and turbulent dispersion forces.The simulation results have been compared with the experimental field measurements to validate the accuracy of the CFD work. Effects of the number of rows of picket fences and also their structure on the performance of the settler have been investigated. The results showed that the phase separation was achieved more effectively when two rows of picket fences with a distance of 1.3 m from each other are set into the inlet of the settler. The inspection of distribution of droplet size at different points in the settler showed that the presence of picket fences increases the size of droplets. Finally, the effect of closed to opened (C/O) area ratio of the picket fences on the performance of the settler was studied. The results showed that by increasing the C/O ratio, some circulation appears in the flow which causes a negative effect on phase separation.

Research Highlights
► A CFD simulation for an industrial settler in Sarcheshmeh copper complex, Iran.
► The effect of picket fences on phase separation in the settler was discussed.
► The simulation results were validated by the experimental data.
► Phase separation improves when two picket fences set into the inlet of the settler.
► Increasing closed to opened area ratio of fences has a negative effect on process.