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

▶

Mar 16, 2023 353 likes •509 views

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)

SLIDE 1

DEVELOPING INDUSTRIAL CRYSTALLIZATION SYSTEMS USING ESP SOFTWARE

DON GENIESSE SWENSON TECHNOLOGY

SLIDE 2

SOLUBILITY DIAGRAMS INDICATE POTENTIAL CRYSTALLIZATION METHODS

5 10 15 20 25 30 35

10 20 30 40 50 60 70 80 90 100 110 120 130 140 Na2CO3 SOLUBILITY (wt%) TEMPERATURE (C)

SODIUM CARBONATE SOLUBILITY IN WATER

Na2CO3.10H2O Na2CO3.1H2O Na2CO3 (anhyd) Na2CO3.7H2O ICE

STEEP SLOPE – VACUUM COOLING CRYSTALLIZATION FLAT SLOPE – EVAPORATIVE CRYSTALLIZATION REVERSE SLOPE – REACTIVE CRYSTALLIZATION

SLIDE 3

MECHANICAL VAPOR RECOMPRESSION (MVR) BLOCK FLOW DIAGRAM

Duty:

1.57E+09 BTU/hr

1,540,582 lb/hr 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 1,540,582 lb/hr 215 F 14.7 psia Duty: 1.68E+09 BTU/hr 1,719,400 lb/hr 596,060 lb/hr 178,818 lb/hr 0.1% SOLIDS 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 6 RECYCLE 4 CONDENSED 3 COMPRESSED 2 STEAM 1 FEED 5 SLURRY 7 K2SO4 EVAPORATIVE CRYSTALLIZER COMPRESSOR CONDENSER CENTRIFUGE

SLIDE 4

SODA ASH EVAPORATIVE CRYSTALLIZERS

SLIDE 5

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

SLIDE 6

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

385,132 lb/hr 385,150 lb/hr 385,132 lb/hr 385,169 lb/hr 0.0% SOLIDS 0.0% SOLIDS 0.0% SOLIDS 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 1,719,400 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 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 158 F 385,146 lb/hr 284 F 50 psia Duty:

3.60E+08 BTU/hr

385,146 lb/hr 0.0% SOLIDS 829 gpm 281 F 16 RECYCLE 2 STEAM 3 CONDENSATE 1 FEED 6 SLURRY 9 SLURRY 12 SLURRY 15 SLURRY 17 K2SO4 5 CONDENSATE 8 CONDENSATE 11 CONDENSATE 14 CONDENSATE 4 STEAM 7 STEAM 10 STEAM 13 STEAM FIRST EFFECT SECOND EFFECT THIRD EFFECT FOURTH EFFECT FOURTH CONDENSER THIRD CONDENSER SECOND CONDENSER FIRST CONDENSER FIRST REBOILER CENTRIFUGE

SLIDE 7

FIVE EFFECT NaCl CRYSTALLIZERS

SLIDE 8

MULTIPLE EFFECT FALLING FILM NaOH CONCENTRATOR

SLIDE 9

VACUUM COOLING FLOWSHEET

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

SLIDE 10

VACUUM COOLING CRYSTALLIZER

SLIDE 11

DRAFT TUBE BAFFLE (DTB) REACTIVE CRYSTALLIZERS

SLIDE 12

Duty: XX cal/hr Duty: XX cal/hr Duty: XX cal/hr 21,438 kg/hr TOTAL 21,438 kg/hr TOTAL 21,438 kg/hr TOTAL 22 m3/min 22 m3/min 22 m3/min 21,438 kg/hr TOTAL XX C 21,438 kg/hr TOTAL XX C 21,438 kg/hr TOTAL XX C 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 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 0.0% SOLIDS 0.0% SOLIDS 10.7% SOLIDS 38.2% SOLIDS 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 2,814 kg/hr TOTAL 24,366 kg/hr TOTAL 125 C 125 C 10,319 kg/hr TOTAL 2.0 atm 2.0 atm 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 XX C XX atm 2,814 kg/hr TOTAL 24,366 kg/hr TOTAL 3 m3/min 26 m3/min XX C XX C 11,821 kg/hr TOTAL XX atm XX atm 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 4,238 kg/hr TOTAL 0.0% SOLIDS 4.3 m3/min 8,476 kg/hr TOTAL XX C 0.0% SOLIDS XX atm 6.6 m3/min XX C XX atm 39 CONDENSATE 42 CONDENSATE 45 CONDENSATE 38 STEAM 41 STEAM 44 STEAM 31 CaOH2 29 PURGE 45 SLURRY 46 NaCl 33 CaCO3 47 CENTRATE 32 FILTRATE 40 SLURRY 43 SLURRY 34 STEAM 50 H2O 49 EXCESS NaOH 48 50% NaOH 45A COOLED 35 CONDENSATE 37 CONDENSATE 36 STEAM 18 25% NaOH LIME REACTOR LIME HEATER

1st CONDENSER/2nd REBOILER 1st EFFECT EVAPORATOR 2nd EFFECT EVAPORATOR

1st REBOILER

2nd CONDENSER/3rd REBOILER 3rd EFFECT EVAPORATOR 2nd CONDENSER/3rd REBOILER NaCl CENTRIFUGE

LIME REACTOR LIME HEATER

1st CONDENSER/2nd REBOILER 1st EFFECT EVAPORATOR 2nd EFFECT EVAPORATOR

1st REBOILER

2nd CONDENSER/3rd REBOILER 3rd EFFECT EVAPORATOR 2nd CONDENSER/3rd REBOILER NaCl CENTRIFUGE PURGE SPLIT NaOH DILUTION COOLING TANKS

FULL-SCALE PROCESS PLANTS MAY USE A COMINATION OF SEVERAL TYPES OF EVAPORATORS & CRYSTALLIZERS

Na2CO3 FLOWSHEET CONTAINS FALLING FILM EVAPORATION, MVR CRYSTALLIZATION, FLASH COOLING, REACTIVE CRYSTALLIZATION & MULTIPLE EFFECT EVAPORATION

18,081 kg/hr TOTAL XX C XX atm Process Duty: XX cal/hr Utility Duty: XX cal/hr Mean dT XX C XX 530,000 kg/hr TOTAL 34,302 kg/hr TOTAL 1.2% SOLIDS 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 XX Duty: XX cal/hr XX atm 176,626 kg/hr TOTAL Overall dT XX C XX C 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 183 m3/min Utility Duty: XX cal/hr XX atm XX atm 174,885 kg/hr TOTAL XX C Mean dT XX C XX C XX atm 52,383 kg/hr TOTAL XX atm 21,190 kg/hr TOTAL 21,190 kg/hr TOTAL XX C XX C 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 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 XX C XX C 1,550 kg/hr TOTAL XX atm 174,785 kg/hr TOTAL XX atm 515,982 kg/hr TOTAL 164,823 kg/hr TOTAL 168,261 kg/hr TOTAL XX C XX C 0% SOLIDS 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 339,355 kg/hr TOTAL 415,652 kg/hr TOTAL 240,867 kg/hr TOTAL 96,355 kg/hr TOTAL 0.0% SOLIDS 0.0% SOLIDS 40.0% SOLIDS 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 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 1 FEED 14 CONDENSATE 15 NONCONDENSED 16 STEAM 17 CONDENSATE 2 PREHEATED 12 COMP STEAM 5 OVERHEAD 11 OVERHEAD 25 CONDENSATE 3 PREHEATED 20 CONDENSATE 23 M/U STEAM 24 COMPRESSED 13 NONCONDENSED 4 MAKEUP STEAM 8 BOTTOMS 9 CONCENTRATE 21 MONO FEED 26 SLURRY 27 MONO SOLIDS 19 STEAM 22 STEAM 7 BOTTOMS 10 STEAM 6 CONDENSATE 30 RECYCLE 28 CENTRATE 18 25% NaOH 29 PURGE PREHEATER 1 STRIPPER VAPOR BODY COMPRESSOR EVAPORATOR PREHEATER 2 CENTRATE TANK MONO CRYSTALLIZER MVR COMPRESSOR CONDENSER/REBOILE MONO CENTRIFUGE PURGE SPLIT CONDENSER PREHEATER 1 STRIPPER VAPOR BODY COMPRESSOR EVAPORATOR PREHEATER 2 CENTRATE TANK MONO CRYSTALLIZER MVR COMPRESSOR CONDENSER/REBOILE MONO CENTRIFUGE PURGE SPLIT CONDENSER

SLIDE 13

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

SLIDE 14