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Two Technical Advances in Wet Chemical Scrubbing Technology

Two Technical Advances in Wet Chemical Scrubbing Technology. Richard Hanson MA MEng CEng MIChemE ERG (Air Pollution Control) Ltd. Introduction | Two Technical Advances. V-tex TM technology Development Process Description Applications and Case studies Zero-effluent scrubbers

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Two Technical Advances in Wet Chemical Scrubbing Technology

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  1. Two Technical Advances in Wet Chemical Scrubbing Technology Richard Hanson MA MEng CEng MIChemE ERG (Air Pollution Control) Ltd

  2. Introduction | Two Technical Advances • V-texTM technology • Development • Process Description • Applications and Case studies • Zero-effluent scrubbers • Process Description • Applications and Case Study • Summary

  3. V-texTM| Development • Developed in UK by AEA Technology • Used in difficult applications • reliability and performance • Eg. nuclear industry • V-texTM technology used in • Scrubbing • Stripping • Distillation • Mixing

  4. V-texTM| Development • V-texTM Scrubbing • Since early 1990s in UK and Ireland • Mid-late 1990s in USA • More than 400 systems installed • Technology is now owned by ERG • What is it…?

  5. V-texTM | Process Description • Key features • V-texTM chamber • Tangential gas inlet • Opposed jet spray nozzle • Intense mixing • Central gas outlet

  6. V-texTM | Process Description • Opposed jet self-cleaning spray nozzle • Fine droplet spray pattern • Induced swirl from tangential gas flow • Typical droplet size 100-200 μm • Large surface area for mass transfer

  7. V-texTM | Process Description • Mass transfer models • Traditional packed towers • Tower diameter = f (gas rate) • Efficiency = f (packed height) = f (HTU) • HTU = f (packing type, liquor rate, gas rate) • V-texTM • Chamber diameter = f (gas rate) • Efficiency = f (liquor rate, liquor pressure)

  8. V-texTM | Implications of transfer model (1) Non-clogging • No packing to foul • Applications for dirty gas/liquor • Scrubbing with slurries • Reliable performance, lower maintenance, guaranteed efficiency

  9. V-texTM | Implications of transfer model (2) Significantly reduced vessel height • High pseudo-Kga values • Intense mixing, high turbulence • Gas residence time reduced approx x10 for same scrubbing efficiency

  10. 7.4 m 2.2 m V-texTM | Implications of transfer model • Example: • 1000 m3/hr air • HCl removal efficiency 99.5% ERG Packed Tower Scrubber V-texTM Scrubber

  11. V-texTM | Case studies • Cl2 scrubbing • Chemical industry • Chlorine scrubbing from process air stream • NaOCl by-product for sale

  12. V-texTM | Case studies • HCl scrubbing • Pharmaceutical industry • Hastelloy C276 and ECTFE/PTFE • Pressure and explosion rating certified • >99.5% HCl removal efficiency, batch scrubbing

  13. V-texTM | Case studies • Reactive gas scrubbing + particulate removal • Optical Fibre Manufacturer • Removal of HCl and SiO2 • Scrub liquor contained up to 5% weight SiO2 with no blockage • Constant back pressure improved optical fibre quality

  14. V-texTM | Case studies • Multi-component contaminants • Tobacco Manufacturer • Steam quench/sub-cooling with NH3, VOC and dust scrubbing • Scrub liquor contained entrained dust – unsuitable for packed tower • SO2 scrubbing ex-incinerator • 12,000Am3/hr with 5,000mg/m3 SO2 • Lime slurry scrubbing • >99.8% removal SO2

  15. Zero-Effluent | Process Description • Vacuum evaporation: application to scrubbing • Established technology • Process application innovation • System integration – optimisation of capital and operating costs • Minimises water usage and effluent disposal • Simplified flowsheet • Evaporator/condenser circuit, heat pump circuit, effluent circuit

  16. Schematic courtesy of H2O GmbH Zero-Effluent | Process Description

  17. Zero-Effluent | Process Description • Typical Scrubber blowdown 500 litre/hr  < 40 litre/hr concentrated sludge waste + recovery of > 460 litre/hr process water to system • Operation at 5kPa and 40oC • Typically 0.15kW per litre water evaporated

  18. Zero-Effluent | Case study • Aerospace industry • Chromic acid scrubber • 200 litre/hr treatment rate • 200 g/litre CrO3 commodity recovery • Return on investment = 9 months

  19. Zero-Effluent | Applications • High water/effluent costs and low energy costs • Feedstock, product and by-product recovery • Minimised loading for RO and ion-exchange treatment plants

  20. Summary • Innovations in Scrubbing technology • V-texTM • Solid-laden gas/liquor applications • Space limitations • Zero-effluent • Feedstock/product recovery • Utility optimisation

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