industrial crystallization using esp software · mvr crystallizers are used for applications with...
TRANSCRIPT
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
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 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
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
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
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 CONDENS ER/2nd REBOILER
1st EFFECT EVAPORATOR 2nd EFFECT EVAPORATOR
1st REBOILER
2nd CONDENS ER/3rd REBOILER
3rd EFFECT EVAPORATOR
2nd CONDENS ER/3rd REBOILER
NaCl CENTRIFUGE
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
2nd CONDENS ER/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
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