INDUSTRIAL CRYSTALLIZATION USING ESP SOFTWARE · mvr crystallizers are used for applications with low boiling point rise (bpr) ... types of evaporators & crystallizers na2co3 flowsheet

DEVELOPING INDUSTRIAL CRYSTALLIZATION SYSTEMS

USING ESP SOFTWARE

DON GENIESSE

SWENSON TECHNOLOGY

SOLUBILITY DIAGRAMS INDICATE POTENTIAL CRYSTALLIZATION METHODS

0

5

10

15

20

25

30

35

-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140

Na

2C

O3

SO

LU

BIL

ITY

(w

t%)

TEMPERATURE (C)

SODIUM CARBONATE SOLUBILITY IN WATER

Na2CO3.10H2O

Na2CO3.1H2ONa2CO3 (anhyd)Na2CO3.7H2O

ICE

STEEP SLOPE – VACUUM COOLING CRYSTALLIZATION

FLAT SLOPE – EVAPORATIVE CRYSTALLIZATION

REVERSE SLOPE – REACTIVE CRYSTALLIZATION

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


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 K2SO4EVAPORATIVE CRYSTALLIZER

COMPRESSOR

CONDENSER

CENTRIFUGE

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

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 CONDENSERTHIRD CONDENSERSECOND CONDENSERFIRST CONDENSER

FIRST REBOILER

CENTRIFUGE

FIVE EFFECT NaCl CRYSTALLIZERS

MULTIPLE EFFECT FALLING FILM NaOH CONCENTRATOR

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


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

VACUUM COOLING CRYSTALLIZER

DRAFT TUBE BAFFLE (DTB) REACTIVE CRYSTALLIZERS

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


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 CONDENS ER/2nd REBOILER

1st EFFECT EVAPORATOR 2nd EFFECT EVAPORATOR

1st REBOILER

2nd CONDENS ER/3rd REBOILER

3rd EFFECT EVAPORATOR


NaCl CENTRIFUGE

LIME REACTOR

LIME HEATER

1st CONDENS ER/2nd REBOILER

1st EFFECT EVAPORATOR 2nd EFFECT EVAPORATOR

1st REBOILER


3rd EFFECT EVAPORATOR


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


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


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

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

Documents

INDUSTRIAL CRYSTALLIZATION USING ESP SOFTWARE · mvr crystallizers are used for applications with low boiling point rise (bpr) ... types of evaporators & crystallizers na2co3 flowsheet