SYSTEMS USING ESP SOFTWARE DON GENIESSE SWENSON TECHNOLOGY - PowerPoint PPT Presentation

DEVELOPING INDUSTRIAL CRYSTALLIZATION SYSTEMS USING ESP SOFTWARE DON GENIESSE SWENSON TECHNOLOGY

SOLUBILITY DIAGRAMS INDICATE POTENTIAL CRYSTALLIZATION METHODS SODIUM CARBONATE SOLUBILITY IN WATER 35 Na2CO3.1H2O Na2CO3.7H2O Na2CO3 (anhyd) 30 FLAT SLOPE – EVAPORATIVE CRYSTALLIZATION 25 Na2CO3 SOLUBILITY (wt%) 20 REVERSE SLOPE – REACTIVE CRYSTALLIZATION Na2CO3.10H2O 15 STEEP SLOPE – VACUUM COOLING CRYSTALLIZATION 10 5 ICE 0 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 TEMPERATURE (C)

MECHANICAL VAPOR RECOMPRESSION (MVR) BLOCK FLOW DIAGRAM Duty: -1.57E+09 BTU/hr 4 CONDENSED CONDENSER 1,540,582 lb/hr 3 COMPRESSED 0.0% SOLIDS 1,540,582 lb/hr 3,245 gpm 316 F 237 F 24 psia Duty: 7.00E+07 BTU/hr 27,510 hp COMPRESSOR 2 STEAM 1,540,582 lb/hr 215 F 14.7 psia Duty: 1.68E+09 BTU/hr 1 FEED 5 SLURRY 7 K2SO4 EVAPORATIVE CRYSTALLIZER CENTRIFUGE 1,719,400 lb/hr 596,060 lb/hr 178,818 lb/hr 0.1% SOLIDS 6 RECYCLE 30.0% SOLIDS 100% SOLIDS 3,147 gpm 417,242 lb/hr 865 gpm 134 gpm 70 F 0.0% SOLIDS 215 F 215 F 731 gpm 215 F

SODA ASH EVAPORATIVE CRYSTALLIZERS

MVR CRYSTALLIZERS ARE USED FOR APPLICATIONS WITH LOW BOILING POINT RISE (BPR)

MULTIPLE EFFECT CRYSTALLIZERS FOR APPLICATIONS WITH HIGH BPR Duty: -3.60E+08 BTU/hr Duty: -3.80E+08 BTU/hr Duty: -3.80E+08 BTU/hr Duty: -3.90E+08 BTU/hr 5 CONDENSATE 8 CONDENSATE 11 CONDENSATE 14 CONDENSATE FIRST CONDENSER SECOND CONDENSER THIRD CONDENSER FOURTH CONDENSER 385,132 lb/hr 385,150 lb/hr 385,132 lb/hr 385,169 lb/hr 4 STEAM 0.0% SOLIDS 7 STEAM 0.0% SOLIDS 10 STEAM 0.0% SOLIDS 13 STEAM 0.0% SOLIDS 385,132 lb/hr 802 gpm 385,150 lb/hr 796 gpm 385,132 lb/hr 791 gpm 385,169 lb/hr 786 gpm 212 F 210 F 194 F 192 F 176 F 174 F 158 F 156 F 14.2 psia 9.7 psia 6.6 psia 4.3 psia Duty: 5.59E+08 BTU/hr Duty: 3.60E+08 BTU/hr Duty: 3.66E+08 BTU/hr Duty: 3.73E+08 BTU/hr 1 FEED FIRST EFFECT 6 SLURRY 9 SLURRY 12 SLURRY 15 SLURRY 17 K2SO4 SECOND EFFECT THIRD EFFECT FOURTH EFFECT CENTRIFUGE 1,719,400 lb/hr 1,334,268 lb/hr 949,118 lb/hr 563,987 lb/hr 596,061 lb/hr 178,818 lb/hr 0.1% SOLIDS 0.0% SOLIDS 0.6% SOLIDS 17.3% SOLIDS 16 RECYCLE 30.0% SOLIDS 100.0% SOLIDS 3,147 gpm 2,473 gpm 1,663 gpm 896 gpm 417,242 lb/hr 873 gpm 134 gpm 70 F 212 F 194 F 176 F 0.0% SOLIDS 158 F 158 F 739 gpm 2 STEAM 158 F 385,146 lb/hr 284 F 50 psia Duty: -3.60E+08 BTU/hr FIRST REBOILER 3 CONDENSATE 385,146 lb/hr 0.0% SOLIDS 829 gpm 281 F

FIVE EFFECT NaCl CRYSTALLIZERS

MULTIPLE EFFECT FALLING FILM NaOH CONCENTRATOR

VACUUM COOLING FLOWSHEET 13 STEAM 14 VENT EJECTOR 3 806 lb/hr 1,153 lb/hr 115.0 psia 11 STEAM 15.2 psia 350.0 F 347 lb/hr 272.6 F 3.4 psia 134.4 F 10 COOLING H2O 12 COOLING H2O CONDENSER 2 40,234 lb/hr 42,138 lb/hr 80.7 gpm 9 STEAM 85.5 gpm 85.0 F 2,252 lb/hr 134.4 F 3.4 psia 179.6 F 8 STEAM EJECTOR 2 805 lb/hr 115.0 psia 6 STEAM 350.0 F 1,447 lb/hr 97.9 psia 49.0 F 5 COOLING H2O 7 COOLING H2O CONDENSER 1 3,559,077 lb/hr 3,598,309 lb/hr 7,131.6 gpm 4 STEAM 7,233.8 gpm 85.0 F 40,678 lb/hr 97.9 F 0.9 psia 231.2 F 3 STEAM EJECTOR 1 27,558 lb/hr 115.0 psia 2 STEAM 350.0 F 13,120 lb/hr 0.15 psia 50.0 F Duty: 0.000E+00 BTU/hr 1 FEED 15 SLURRY 17 SOLIDS FLASH COOLING FILTER 451,038 lb/hr 437,918 lb/hr 83,154 lb/hr 0% SOLIDS 18% SOLIDS 16 PURGE 95% SOLIDS 749 gpm 721 gpm 354,764 lb/hr 115 gpm 69.0 F 50.0 F 0% SOLIDS 50.0 F 606 gpm 50.0 F

VACUUM COOLING CRYSTALLIZER

DRAFT TUBE BAFFLE (DTB) REACTIVE CRYSTALLIZERS

FULL-SCALE PROCESS PLANTS MAY USE A COMINATION OF SEVERAL TYPES OF EVAPORATORS & CRYSTALLIZERS 15 NONCONDENSED 18,081 kg/hr TOTAL XX C XX atm Process Duty: XX cal/hr Utility Duty: XX cal/hr Mean dT XX C 1 FEED XX 14 CONDENSATE PREHEATER 1 PREHEATER 1 530,000 kg/hr TOTAL 34,302 kg/hr TOTAL 1.2% SOLIDS 2 PREHEATED XX C Comp Ratio: XX 422.2 m3/min 529,991 kg/hr TOTAL XX atm Process Duty: XX cal/hr XX C 0.0% SOLIDS XX kW XX atm 382 m3/min XX hp XX C 12 COMP STEAM COMPRESSOR COMPRESSOR XX Duty: XX cal/hr XX atm 176,626 kg/hr TOTAL Overall dT XX C 5 OVERHEAD XX C 11 OVERHEAD 25 CONDENSATE CONDENSER/REBOILE CONDENSER/REBOILE 220,644 kg/hr TOTAL XX atm 176,626 kg/hr TOTAL 174,885 kg/hr TOTAL Process Duty: XX cal/hr XX C XX C 24 COMPRESSED 183 m3/min Utility Duty: XX cal/hr XX atm XX atm 174,885 kg/hr TOTAL XX C Mean dT XX C 13 NONCONDENSED XX C XX atm 16 STEAM PREHEATER 2 PREHEATER 2 17 CONDENSATE 52,383 kg/hr TOTAL XX atm 21,190 kg/hr TOTAL 21,190 kg/hr TOTAL XX C XX C 3 PREHEATED XX C XX atm Comp Ratio: XX XX atm 529,991 kg/hr TOTAL XX atm Duty: XX cal/hr 0.0% SOLIDS Duty: XX cal/hr XX kW 371.6 m3/min XX kW XX hp XX C Process Duty: XX cal/hr Process Duty: XX cal/hr Process Duty: XX cal/hr 20 CONDENSATE 23 M/U STEAM CONDENSER CONDENSER MVR COMPRESSOR MVR COMPRESSOR XX atm Utility Duty: XX cal/hr Utility Duty: XX cal/hr Utility Duty: XX cal/hr 1,550 kg/hr TOTAL 100 kg/hr TOTAL Overall dT XX C 19 STEAM XX C 22 STEAM XX C STRIPPER STRIPPER 7 BOTTOMS 10 STEAM EVAPORATOR EVAPORATOR 6 CONDENSATE 1,550 kg/hr TOTAL XX atm 174,785 kg/hr TOTAL XX atm VAPOR BODY VAPOR BODY 515,982 kg/hr TOTAL 164,823 kg/hr TOTAL 168,261 kg/hr TOTAL XX C XX C 4 MAKEUP STEAM 0% SOLIDS 8 BOTTOMS XX C 177.4 m3/min XX atm XX atm 30,000 kg/hr TOTAL 440.9 m3/min 504,178 kg/hr TOTAL XX atm XX C XX C XX C 0.0% SOLIDS XX atm XX atm XX atm 426.5 m3/min Duty: XX cal/hr XX C Duty: XX cal/hr XX atm 9 CONCENTRATE 21 MONO FEED 26 SLURRY 27 MONO SOLIDS CENTRATE TANK CENTRATE TANK MONO CRYSTALLIZER MONO CRYSTALLIZER MONO CENTRIFUGE MONO CENTRIFUGE 339,355 kg/hr TOTAL 415,652 kg/hr TOTAL 240,867 kg/hr TOTAL 96,355 kg/hr TOTAL 0.0% SOLIDS 30 RECYCLE 0.0% SOLIDS 40.0% SOLIDS 28 CENTRATE 100% SOLIDS 257.9 m3/min 69,365 kg/hr TOTAL 332.9 m3/min 160.5 m3/min 144,511 kg/hr TOTAL 42.8 m3/min XX C 0% SOLIDS XX C XX C 0% SOLIDS XX C XX atm 56.5 m3/min XX atm XX atm 117.7 m3/min XX atm XX C XX C XX atm XX atm 18 25% NaOH 29 PURGE PURGE SPLIT PURGE SPLIT 8,476 kg/hr TOTAL 75,146 kg/hr TOTAL 0.0% SOLIDS 0% SOLIDS 6.61 m3/min 61.2 m3/min XX C XX C XX atm XX atm Duty: XX cal/hr Duty: XX cal/hr Duty: XX cal/hr 1st CONDENSER/2nd REBOILER 1st CONDENSER/2nd REBOILER 39 CONDENSATE 2nd CONDENSER/3rd REBOILER 2nd CONDENSER/3rd REBOILER 42 CONDENSATE 2nd CONDENSER/3rd REBOILER 2nd CONDENSER/3rd REBOILER 45 CONDENSATE 21,438 kg/hr TOTAL 21,438 kg/hr TOTAL 21,438 kg/hr TOTAL 38 STEAM 22 m3/min 41 STEAM 22 m3/min 44 STEAM 22 m3/min 21,438 kg/hr TOTAL XX C 21,438 kg/hr TOTAL XX C 21,438 kg/hr TOTAL XX C 31 CaOH2 XX C XX atm XX C XX atm XX C XX atm 27,572 kg/hr TOTAL XX atm XX atm XX atm 33.2% SOLIDS 22.2 m3/min XX C XX atm Duty: XX cal/hr Duty: XX cal/hr Duty: XX cal/hr Duty: XX cal/hr 29 PURGE 32 FILTRATE 1st EFFECT EVAPORATOR 1st EFFECT EVAPORATOR 40 SLURRY 2nd EFFECT EVAPORATOR 2nd EFFECT EVAPORATOR 43 SLURRY 3rd EFFECT EVAPORATOR 3rd EFFECT EVAPORATOR 45 SLURRY COOLING TANKS LIME REACTOR LIME REACTOR 75,146 kg/hr TOTAL 90,693 kg/hr TOTAL 69,255 kg/hr TOTAL 47,816 kg/hr TOTAL 26,378 kg/hr TOTAL 0% SOLIDS 33 CaCO3 0.0% SOLIDS 0.0% SOLIDS 10.7% SOLIDS 38.2% SOLIDS 45A COOLED 61.2 m3/min 12,025 kg/hr TOTAL 9.8% NaOH 12.8% NaOH 18.6% NaOH 54.5% NaOH 26,378 kg/hr TOTAL XX C 100.0% SOLIDS 78.3 m3/min 56.9 m3/min 34.9 m3/min 15.1 m3/min 39.1% SOLIDS XX atm 4.4 m3/min XX C XX C XX C XX C 55% NaOH XX C XX atm XX atm XX atm XX atm 15.0 m3/min XX atm XX C XX atm 34 STEAM 36 STEAM 2,814 kg/hr TOTAL 24,366 kg/hr TOTAL NaCl CENTRIFUGE NaCl CENTRIFUGE 46 NaCl 125 C 125 C 10,319 kg/hr TOTAL 2.0 atm 2.0 atm 47 CENTRATE 100.0% SOLIDS 16,059 kg/hr TOTAL 10.4 m3/min Duty: XX cal/hr Duty: XX cal/hr 0.0% SOLIDS XX C 2.8 m3/min XX atm LIME HEATER LIME HEATER 1st REBOILER 1st REBOILER XX C 35 CONDENSATE 37 CONDENSATE XX atm 2,814 kg/hr TOTAL 24,366 kg/hr TOTAL 3 m3/min 26 m3/min 49 EXCESS NaOH PURGE SPLIT XX C XX C 11,821 kg/hr TOTAL XX atm XX atm 48 50% NaOH 0.0% SOLIDS 4,238 kg/hr TOTAL 7.7 m3/min 0.0% SOLIDS XX C 2.8 m3/min XX atm XX C XX atm Na2CO3 FLOWSHEET CONTAINS FALLING FILM EVAPORATION, 50 H2O NaOH DILUTION 4,238 kg/hr TOTAL MVR CRYSTALLIZATION, FLASH COOLING, REACTIVE 0.0% SOLIDS 18 25% NaOH 4.3 m3/min 8,476 kg/hr TOTAL XX C 0.0% SOLIDS CRYSTALLIZATION & MULTIPLE EFFECT EVAPORATION XX atm 6.6 m3/min XX C XX atm

SUMMARY  ESP SOFTWARE IS A VALUABLE TOOL FOR DEVELOPING INDUSTRIAL CRYSTALLIZATION PROCESSES, PREDICTING CHEMICAL SCALING, THEORETICAL YIELDS AND ENERGY REQUIREMENTS.  SWENSON TECHNOLOGY VALIDATES ESP PROCESS MODELS USING PUBLISHED DATA, LABORATORY TESTS, AND PILOT PLANT RUNS TO CONFIRM PHYSICAL PROPERTIES AND DETERMINE CRYSTAL GROWTH RATES FOR EQUIPMENT DESIGN