FlocClay Laboratory Bench Test Procedure

1. Safety & Handling Precautions

Due to the fine, powdered nature of FlocClay and its active components, the following personal protective equipment (PPE) and safety standards must be adhered to during testing:

• Personal Protective Equipment (PPE): Always wear proper safety glasses/goggles, a standard dust mask (e.g., N95) to prevent dust inhalation, and nitrile laboratory gloves.
• Handling & Spills: Keep the dry product bag sealed when not in use to avoid moisture absorption. In case of a dry spill, vacuum or sweep up cleanly. Avoid using water on large dry spills, as bentonite clay and polymers become extremely slippery when wet.
• First Aid: In case of eye contact, flush thoroughly with water for 15 minutes. For skin contact, wash with soap and water.

2. Equipment & Materials Needed

• FlocClay dry powdered mix sample.
• 1-Liter (1,000 mL) sample of the target wastewater.
• Laboratory scale (accurate to 0.1g or 0.01g).
• Graduated glass beakers (preferably 1,000 mL).
• Variable-speed overhead mixer or multi-position jar tester. (Note: Magnetic stirrers can be used but are not recommended as they can shear and break up delicate flocs during the slow mix phase).
• Stopwatch or digital timer.

3. Step-by-Step Testing Protocol

Step A: Prepare Your Test Sample

Measure exactly 1,000 mL (1 Liter) of the raw wastewater into a beaker. Record the initial baseline appearance (color, turbidity, presence of an oil sheen, and pH if known).

Step B: Establish a Starting Dosage

Depending on the heavy nature of the emulsion, a standard testing range is 0.5 to 5.0 grams per liter (g/L). Weigh out a starting increment—typically 1.0 gram—on your laboratory scale for the first test.

Step C: The Rapid Mix Phase (Coagulation)

Turn the overhead mixer on to a high speed (~100 to 150 RPM) to create a strong vortex. Add the pre-weighed FlocClay directly into the center of the vortex. Mix rapidly for 1 to 2 minutes. This step activates the coagulant to break the emulsified oil bonds and neutralize charged particles.

Step D: The Slow Mix Phase (Flocculation)

Immediately reduce the mixer speed to a low setting (~30 to 40 RPM). Mix gently for 2 to 3 minutes. This allows the polymer and bentonite clay to bind the particles into large, heavy macro-flocs without shearing them apart.

Step E: Settling and Visual Evaluation

Turn off the mixer entirely. Let the sample sit undisturbed for 5 to 10 minutes. Check the beaker for heavy sludge settlement at the bottom and clear water in the middle.

Step F: pH Check and Adjustment

If coagulation and flocculation have not occurred, it may be due to high or low pH. Check the pH of the sample and adjust if needed to between 6.5 – 9. Once adjusted, check to see if coagulation and flocculation occur, or if an incomplete chemical reaction has occurred. Repeat Steps B – E again by adjusting the amount of chemical added and evaluate to see if results have changed.

Step G: Threshold Adjustment Rule

If the water between the flocs is still cloudy, milky, or shows a lingering surface sheen, the emulsion is not fully broken. Discard the sample and repeat the test on a fresh 1L sample using a higher dosage or different blend of FlocClay (e.g., 4.0 g, 6.0 g, etc.) until the water clears perfectly.

4. Upscaling Math & Calculations

To upscale your optimized bench results to your large processing tanks, use the standard rule that 1.0 gram per Liter (g/L) is equal to 8.34 pounds of product per 1,000 Gallons of wastewater.

Formula 1: Total Lbs. of FlocClay = (Tank Volume in Gallons / 1,000) * (Optimum Bench Dose in g/L) * 8.34

Formula 2: Number of 50 lb. Bags = Total Lbs. of FlocClay Needed / 50

Practical Operational Example:

Your optimum bench test required 4.0 grams in the 1-Liter beaker, and your large treatment tank holds 5,000 Gallons.

Total Mass Calculation: (5,000 / 1,000) * 4.0 * 8.34 = 166.8 lbs. of FlocClay total.

Bag Allocation: 166.8 lbs / 50 lbs = 3.34 Bags (Round up to 3.5 bags for the physical batch).

Settling Demo: This video shows the successful flocculation of oils and solids with FlocClay.

Watch the FlocClay settling demo on YouTube.

5. Bench Test Data Logging Table

Use this table to record variations during bench trials to pinpoint the exact optimal dose.