DEVELOPING INDUSTRIAL CRYSTALLIZATION SYSTEMS USING ESP SOFTWARE DON GENIESSE SWENSON TECHNOLOGY

DEVELOPING INDUSTRIAL CRYSTALLIZATION SYSTEMS USING ESP SOFTWARE DON GENIESSE SWENSON TECHNOLOGY

Na2CO3 SOLUBILITY (wt%) SOLUBILITY DIAGRAMS INDICATE POTENTIAL CRYSTALLIZATION METHODS SODIUM CARBONATE SOLUBILITY IN WATER 35 Na2CO3.7H2O Na2CO3.1H2O Na2CO3 (anhyd) 30 25 FLAT SLOPE EVAPORATIVE CRYSTALLIZATION 20 Na2CO3.10H2O REVERSE SLOPE REACTIVE CRYSTALLIZATION 15 10 STEEP SLOPE VACUUM COOLING CRYSTALLIZATION 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 CONDENSER 4 CONDENSED 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: COMPRESSOR 2 STEAM 1,540,582 lb/hr 215 F 14.7 psia 7.00E+07 BTU/hr 27,510 hp Duty: 1.68E+09 BTU/hr 1 FEED EVAPORATIVE CRYSTALLIZER 5 SLURRY CENTRIFUGE 7 K2SO4 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 FIRST CONDENSER 5 CONDENSATE SECOND CONDENSER 8 CONDENSATE THIRD CONDENSER 11 CONDENSATE FOURTH CONDENSER 14 CONDENSATE 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 SECOND EFFECT 9 SLURRY THIRD EFFECT 12 SLURRY FOURTH EFFECT 15 SLURRY CENTRIFUGE 17 K2SO4 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 2 STEAM 739 gpm 158 F 385,146 lb/hr 284 F 50 psia Duty: FIRST REBOILER -3.60E+08 BTU/hr 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 EJECTOR 3 14 VENT 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 CONDENSER 2 12 COOLING H2O 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 CONDENSER 1 7 COOLING H2O 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 FLASH COOLING 15 SLURRY FILTER 17 SOLIDS 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

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

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