Mechanical and hydraulic flocculation equipment engineered for controlled particle aggregation in drinking water, industrial process, and wastewater treatment. Paddle, turbine, and static-mixer types — VSD-controlled G-value from 10 to 100 s−¹.
Gentle slow-speed mixing for fragile flocs. G = 10–50 s−¹.
Axial and radial impeller designs for higher-intensity or multi-stage duty.
Inline coagulant flash-mixing without moving parts.
Camp & Stein G-value, GT product, and tapered staging calculations.
Flocculation is the third stage of the coagulation–flocculation–separation train. After coagulant addition and rapid flash-mixing (G > 300 s−¹), destabilised micro-particles must be grown into settleable or flotable macro-flocs through slow, controlled agitation. The governing parameter is the root-mean-square velocity gradient G (Camp & Stein, 1943):
G = √(P / μV)   where P = power input (W), μ = dynamic viscosity (Pa·s), V = tank volume (m³).
Typical flocculation target: G = 20–80 s−¹. The cumulative GT product (G × hydraulic retention time) should fall between 10,000 and 150,000 for most coagulation applications.
Too high a G-value shears growing floc aggregates back into primary particles. Too low a value gives insufficient collision frequency, leaving the water turbid after the separation stage. Our flocculators are sized and controlled to maintain the target G across the full diurnal flow range.
All mechanical flocculators are supplied with a VSD-linked paddle or impeller speed controller, allowing real-time G-value adjustment as flow rate or raw water quality changes.
Multi-chamber designs apply a descending G-value sequence — high G in the first chamber to promote particle collision, reducing to low G in the final chamber to consolidate and densify the floc prior to separation.
Baffled tanks and correct aspect ratios minimise short-circuiting, ensuring that all water receives the full design GT. CFD validation available for critical applications.
Gear-motor drives on all paddle and turbine units, with submerged or overhung bearing configurations. IP65 motor standard; ATEX options available for solvent-bearing streams.
Single units from 10 to 10,000 m³/day; parallel trains to 50,000 m³/day. Modular steel or GRP tank construction integrates with new build or retrofit civil basins.
Wetted parts in SS304, SS316L, or HDPE. Paddle blades profiled in UHMWPE for abrasion resistance in high-solids duties such as mining and aggregate process water.
| Type | G-Value Range (s−¹) | Best Application | Moving Parts | Footprint | Capital Cost |
|---|---|---|---|---|---|
| Paddle Wheel | 10–60 | Municipal WTP, sensitive flocs, DAF pre-treatment | Yes — paddle shaft | Moderate | Low–medium |
| Vertical Turbine | 20–100 | Industrial, compact installations, high-solids duties | Yes — impeller shaft | Small | Medium |
| Helical Impeller | 15–70 | Lamella pre-treatment, delicate flocs, low-shear duty | Yes — helical shaft | Small | Medium |
| Static / Inline Mixer | 50–300 (flash mix) | Coagulant dispersion, small flows, pipe-mounted duty | None | Minimal | Very low |
| Hydraulic Baffled | 20–60 | Developing-world WTPs, low-maintenance sites | None | Large | Low (civil) |
Surface water coagulation–flocculation–sedimentation for turbidity and NOM removal. G-value profiling to meet tight filter influent targets.
View Treatment ProcessPhysico-chemical pre-treatment for food, beverage, chemical, and mining effluents prior to DAF, lamella, or clarifier separation.
View Treatment ProcessOptimising floc structure for dissolved air flotation — target G = 20–40 s−¹ to produce neutrally buoyant aggregates that adhere readily to micro-bubbles.
View DAF SystemsConditioning particles to 50–200 μm settleable flocs ahead of inclined-plate settlers. Prevents carry-over and reduces polymer consumption.
View Lamella ClarifiersChemical precipitation with iron or aluminium salts followed by flocculation for effluent TP < 0.1Â mg/L to meet Environment Agency discharge consents.
View Coagulation ProcessControlled pH adjustment and flocculation for chromium, nickel, copper, and zinc removal from electroplating and surface treatment effluents.
View Chemical DosingSeawater coagulation–flocculation to remove colloidal particles and SDI prior to UF or direct-to-RO pre-treatment trains.
View DesalinationWhite-water recovery and effluent treatment using fibre-specific flocculant programmes with tapered G-value to preserve long-fibre flocs.
View IndustryFlocculators sit between the rapid-mix (coagulation) stage and the separation unit. Correct sequencing and G-value profiling across the train are critical to downstream performance.
Coagulant dispersed in < 30 seconds. Chemical dosing systems inject alum, PAC, or ferric at the flash-mix point immediately upstream of the rapid-mix tank or static mixer.
One to three chambers with tapered G-value grow particles to 50–500 μm. Flocculant polymer is dosed at the inlet of the first or second chamber to bridge and bind primary aggregates.
Flocculated water flows to DAF, lamella clarifier, or gravity sedimentation. Correct floc size and density is critical to separation efficiency and sludge volume index.
Integrated design: Reynolds & Bauhm designs the complete coagulation–flocculation–separation train as a single hydraulic system. G-value profiles, residence times, and chemical dosing points are optimised together — not as isolated equipment selections. Speak to our engineers for a process review.
Slow-speed horizontal or vertical paddle wheels for gentle, sustained floc growth.
View PageAxial and radial turbine impellers for higher-intensity or multi-stage flocculation.
View PageChemical coagulant flash-mixing without moving parts using pipe-mounted static elements.
View PageCamp & Stein G-value calculations, GT product, tapered flocculation staging, and chamber sizing.
View PageDiagnose pin floc, carry-over, excessive breakup, and drive mechanical faults.
View PageDiscuss your specific requirements with our technical team and receive a tailored proposal for your project.
Contact UsOur process engineers will review your raw water quality, coagulant regime, and downstream separation method to recommend the optimum flocculator type, G-value profile, and chamber configuration.