Fraction at Ion of Phosphate in Marine Aquaculture Sediments
Continuous Ion Exchange for Fertilizer & Phosphate ... · PDF fileContinuous Ion Exchange for...
Transcript of Continuous Ion Exchange for Fertilizer & Phosphate ... · PDF fileContinuous Ion Exchange for...
1
FiltrationProducts
AIChE – Central FloridaSand Key, FL Conference
June 10, 2006
Continuous Ion Exchangefor
Fertilizer & PhosphateApplications
Richard S. DennisSeparation Products Manager
Tampa, FL
FiltrationProducts
IntroductionFertilizer/Phosphate Applications
IntroductionIntroductionFertilizer/Phosphate ApplicationsFertilizer/Phosphate Applications
Continuous Ion Exchange – The “Higgins Loop”Specialized Applications for “Non Water” Processes Challenging Chemical Separations for Concentrated SolutionsPurification, Product Recovery & Chemical Metathesis
Fertilizer & Phosphate InstallationsNH3 & NO3 Recovery from Ammonium Nitrate Plant WastewaterPotassium Nitrate ProductionPhosphoric Acid PurificationPotassium Carbonate Production
Presentation OutlineIon Exchange BasicsHiggins Loop™ InstallationsPrinciples of OperationApplications: Potassium Nitrates & Phosphates
2
FiltrationProducts
Severn Trent ServicesThe Company
Severn Trent ServicesSevern Trent ServicesThe CompanyThe Company
Environmental Services CompanyOver $600 Million in Annual US Sales5,000 Employees WorldwideHeadquarters - Fort Washington, PA Part of Severn Trent Plc - Birmingham, U.K.
Separations: Filtration, Membranes & Biotreatment SystemsDisinfection Products & ProcessesEnvironmental Laboratory TestingOperations & Maintenance ServicesFiltration & Membrane SystemsChemical Separation & Water Purification Systems
FiltrationProducts
Ion ExchangeBasic Information
Ion ExchangeIon ExchangeBasic InformationBasic Information
Resin StructureSpherical Porous Beads – Organic Polymers16-50 Mesh Range (0.3-1.0 mm Ø)15-25% Pore Volume + 40-50% Void Space
Cation & Anion FunctionalityCation Resins: Sulfonated (R-SO3
-) to Hold CationsAnion Resins: Aminated (R-N-(CH3)x
-) to Hold Anions
Maximum Resin Loadings (Typical)Key: Valence, Molecular Weight & Resin Site CapacitiesK – 74 gpl; PO4 – 53-106 gpl, NH4 – 34 gpl
Resin Rinsing – Between Adsorption & Regeneration2-5 Bed Volumes to Recover Product or Minimize ContaminationProduct / Regenerant Dilution
3
FiltrationProducts
Continuous Ion ExchangeFeatures & Benefits
Continuous Ion ExchangeContinuous Ion ExchangeFeatures & BenefitsFeatures & Benefits
Separation Process PrinciplesContinuous & Countercurrent ProcessResin Flow Controlled with Process LiquidsBed Depth Limited only by Active Mass Transfer Zone (MTZL)Fresh Resin Moved Frequently into These “I-X” Zones
Ion Exchange BenefitsResin Working Capacity & Ion Selectivity OptimizedHigh Regeneration Product Strenghs & Low VolumesMore Efficient Regenerant UsageLow Liquid/Resin Treatment Ratios (<1) – Remove up to 150,000 ppm
Resin Rinsing BenefitsCountercurrent Contacting Minimizes Water - <1 Bed VolumeIncreased Product Recovery & Minimum Dilution
FiltrationProducts
Higgins Loop™Continuous Ion Exchange
Higgins Loop™Continuous Ion Exchange
BACKGROUNDBACKGROUND
Invented by Irwin Higgins in 1951 at ORNL (AEC)Focus on Radioactive Ion Separations with I-X Resins
Designed for Continuous, Selective Ion Separations
Applies Countercurrent Liquid/Resin Contacting to Ion Exchange
Commercialized in 1955; Acquired by Severn Trent (Tetra) in 1991
Alternative to Solvent Extraction, Fixed Bed I-X & Precipitation
Over 5 Decades of Experience
CCIXTM - Continuous Countercurrent Ion ExchangeReferenced as the “Higgins Contactor” in Handbooks
Chemical, Mining, Nuclear & Municipal Industries
4
FiltrationProducts
LOOP CONFIGURATIONLOOP CONFIGURATION
Higgins Loop™Higgins LoopHiggins Loop™™
C
D A
B
Pulse - Controls Resin Flow through Loop
Backwash
Adsorption - Ion Loaded onto ResinAdsorption
Regeneration - Ion Desorbed from ResinBackwash - Fines & Solids Removal
Cylindrical Resin Loop4 Vessels Separated by Loop Valves
Countercurrent FlowsResin Moves Clockwise Intermittently
Res
inLi
quid
s
Feed & Regen Flows-Counterclockwise
Pulse
ButterflyLoop
Valves
Regeneration
FiltrationProducts
Nalco Chemical Company – 1996Colloidal Silica Products Producer
Process – Silicic Acid ProductionReplaces Fixed Bed I-X SystemProduces 9% H2SiO3 from 12% Na2SiO3Cation Exchange Between H+ & Na+
Remove 19,000 ppm Na from SolutionLiquid/Resin Treatment Ratio – 2.5
System Capacity & Size42”-Ø Loop – 550 ft3 Resin Inventory50,000 lbs/Day SiO2 Product – 60 gpm
PerformanceImproved SiO2 Recoveries from 85% to 96%$1.1 Million Annual Savings
Process ApplicationsChemical MetathesisProcess ApplicationsProcess Applications
Chemical MetathesisChemical Metathesis
5
FiltrationProducts
MEADWestvaco Chemical – 1998Granular Activated Carbon Producer
Process – Phos Acid PurificationRemoves Cations from Activation AcidCation Exchange Between H+ & Ca2+/ K+
Removes over 400 ppm from SolutionSystem Capacity & Size
24”-Ø Loop w/ 36”-Ø Acid Treatment Zone 480 ft3 Resin Inventory60 gpm 40% H3PO4 Capacity
Performance2 “Folded” Loops in Operation for 8-20 Yrs
Process ApplicationsAcid Purification
Process ApplicationsProcess ApplicationsAcid PurificationAcid Purification
FiltrationProducts
Vicksburg Chemical Co – 1994Potassium Chemicals Producer
Process: Potassium Carbonate Product’nPotash & Ammonium Carbonate FeedsCation Exchange Between K+ & NH4
+
70 gpl K Resin Loading (1.8 equ/l)System Capacity & Size
Two 54”-Ø Loops – 2,500 ft3 Resin Inventory25,000 Tons/Yr “K-Carb” Production70 gpm Capacity
PerformanceProduces 18+% K2CO3 Solution <50 ppm Cl in Final Product93% K Recovery from KCl
Process ApplicationsChemical MetathesisProcess ApplicationsProcess Applications
Chemical MetathesisChemical Metathesis
6
FiltrationProducts
EMIT Water Discharge TechnologyNatural Gas Produced Water Treatment
Process – Na Removal from Produced H2OCoal Bed Methane Extraction ApplicationRemoves Na from High NaHCO3 WaterCation Exchange Between H+ & Na+
HCO3 forms CO2 for Aeration/TDS ReductionSystem Capacity & Size
12-24”-Ø Loop – 80-350 ft3 Resin Inventory6-25K Barrels/Day of Water TreatedOver 4.0 MGD Treatment Capacity - 2005
PerformanceMakes Water Suitable for DischargeReduces SAR, CO3 & TDS
Process ApplicationsWater Purification
Process ApplicationsProcess ApplicationsWater PurificationWater Purification
FiltrationProducts
Modular DesignModular Design
Higgins Loop™ I-X Systems24”-Ø EMIT Loop
Higgins LoopHiggins Loop™™ II--X SystemsX Systems2424””--ØØ EMIT LoopEMIT Loop
7
FiltrationProducts
Higgins Loop™CBM Water Na Removal
Higgins LoopHiggins Loop™™CBM Water Na RemovalCBM Water Na Removal
30% HCl
Spent Regen
PulsePump
ResinTrap Tank
Clean Water
Dilution H2O
Raw Water
D A
B
C
II--X SYSTEM X SYSTEM CONFIGURATIONCONFIGURATION
System ComponentsLoop & Cation Resin4 Loop Valves8 Process ValvesFlow & Conductivity MetersPulse Pump & Resin TankBrine Dilution & Feed UnitPLC Controller
B
Backwash
Pulse
Adsorption
Rinse
Regeneration
HClDilution& Feed
FiltrationProducts
NORMAL SERVICENORMAL SERVICE
Higgins Loop™Principles of Operation
Higgins LoopHiggins Loop™™Principles of OperationPrinciples of Operation
Na ADSORPTION
R-H + Na+ R-Na + H+
HCl Regeneration
R- Na + HCl R-H + NaCl
Clean Water Contains <20 mg/L Na
15% HCl Used for Regeneration[NaCl] in Spent Regen - 20%
HCl Acid
Spent Regen
Clean Water
Raw Water
D A
B
C
Adsorption
Regeneration
8
FiltrationProducts
Higgins LoopHiggins Loop™™ OperationOperation
RESIN PULSING RESIN PULSING -- AA
Initial PositionResin Volume in Pulse Vessel
ActionProcess Flows are Stopped
Regen Interfaces are Normal
Loop Valves B, C & D Open
Pulse Water Flow is StartedNaCl Salt
Spent Regen
Clean Water
Dilution H2O
Raw Water
C
B
AD
C
B
D
Pulse Water
ResinPulse
Water/RegenInterfaces
FiltrationProducts
Overflow
RESIN PULSING RESIN PULSING -- BB
Final PositionResin Pulsed Below B Valve
ActionPulse Water Flow is Stopped
ResinPulse
Interfaces Move with Resin
Loop Valves B, C & D Close
Pulsing Time - 20 Seconds
Pulse Water
DC
B
A
C
B
D
Water/RegenInterfaces
Higgins LoopHiggins Loop™™ OperationOperation
9
FiltrationProducts
SERVICE CYCLESERVICE CYCLE
ActionProcess Flows Restarted
Pulse Vessel Recharged withResin - A Valve Opens
Resin is Backwashed
B’wash H2O
Overflow
A
Clean Water Rinses InterfacesBack to Normal
Pulse Water Displaced fromRegen Vessel
Spent Regen Effluent Flows
C
Dilution H2O
Clean Water
Raw Water
HCl Acid
A
B
Water/RegenInterfaces
Dilution H2O
AD
Spent Regen
Higgins LoopHiggins Loop™™ OperationOperation
FiltrationProducts
Fertilizer ProductionKNO3 Production from KCl & HNO3
Fertilizer ProductionKNO3 Production from KCl & HNO3
Process Objectives
Premium Cl-free Fertilizer Directly from PotashConcentrated KNO3 Solution Requiring Minimum EvaporationConcentrated Cl Solution for HCl/CaCl2 Byproduct Recovery
KCl + R-H ➨ R-K + HCl (Byproduct)Resin Regeneration:
Salt Production:
where “R-” is a cation resin site
Ion Exchange Chemistry
HNO3 + R-K ➨ R-H + KNO3 (Product)
10
FiltrationProducts
Higgins Loop™KNO3 ProductionHiggins Loop™
KNO3 Production
430 ft3 of Cation ResinAvg Resin Rate – 3.1 ft3/MinResin Loading – 70 gpl K36”-Ø Higgins Loop25 TPD KNO3 Capacity32% KNO3 with <50 ppm Cl
31.8% KNO3
Displ’d H2O
26%KCl
Water
24% HNO3
Pulse Pump
11.1 GPM25 TPD 100% KNO3
12.3% K; 4.4% N<20 PPM Cl
Potassium Nitrate
11.0 GPM20.3 TPD KCl13.6% K
HCl
To CaCl2 Conv’n12.2 GPM12.0% Cl
10.6 GPM17.4 TPD HNO3
K-loaded ResinOrange Beads
H-loaded ResinGreen Beads
A
C
D
B
Regeneration
Production
Backwash
Wash
Res
in
Pulse
Rinse
ResinTrapTank
FiltrationProducts
Higgins Loop™KH2PO4
Ion ExchangerH3PO4
KCl
Phos Acid Feed7.5 GPM; 28% P2O516.8 TPD P2O5
Potash Feed6.3 GPM; 26% KCl11.6 TPD KCl
MKP I-X Product7.9 GPM
27% P2O5; 9% K
HDS™ RegenPrecipitation
SystemCaCl2
Byproduct CaCl2to Evaporation & Sale8.6 TPD CaCl2
Spent KCl Regen8 GPMAl, Ca, Cd, H, Fe, K & Mg
CaO
Lime for Spent Regen3.5 TPD CaO
HDS™ MKPPrecipitation
System
MKPEvaporation &
DryingPurified MKP
7.1 GPM14,000 PPH
MKP Product17.6 TPD KH2PO4
KOH
1.0 TPD KOH
38.1 TPD
MKP
CaO
Water Vapor
HDS™ SludgeDewatering& Washing
Solids
HDS™ SludgeFe & Al PO4SO4, SiF6 & F
HDS™ Sludge
4.1 TPD Solids
Mono Potassium Phosphatefrom KCl & Wet Process H3PO4
Mono Potassium Phosphatefrom KCl & Wet Process H3PO4
Ion ExchangeProduction
Purification& Refining
ByproductTreatment
Waste MetalsHandling
11
FiltrationProducts
Mono Potassium PhosphateProcess Economics Mono Potassium PhosphateProcess Economics
Operating Factor of 300 Days/Yr or 82.2% TPY 100% Unit $ Total $________ _____ ______ Product Streams
Mono Potassium Phosphate 100.0% 5,277 $450 $2,374,824 Calcium Chloride 38.0% 2,481 $200 $496,260
Total Revenues $2,870,000 Chemical Usages
Phosphoric Acid (as P2O5) 28.0% 5,036 $120 $604,351 Potassium Chloride 100.0% 3,470 $120 $416,352 Potassium Hydroxide 45.0% 290 $500 $145,103 Lime (Calcium Oxide) 100.0% 778 $70 $54,475
Subtotal $1,220,281 Utilities
Evaporation Steam (Tons) 100.0% 15,454 $10 $154,541 Cation Resin Addition (Ft3) N/A 37.50 15.0% $120 $4,500 Electrical Power (MWH) N/A 0.90 $80 $21,600
Subtotal $180,641 Fixed Costs
Operating Labor N/A 24.0 Hrs/Day $30 $216,000 Maintenance 2.5% of Capital Equip't $37,125 Depreciation on Total Capital of $2,673,000 10.0% of Capital $267,300
Subtotal $520,425
Total Costs $1,920,000 Investment Summary
Return on Investment 36% Annual Gross Profit: $950,000
Operating Factor of 300 Days/Yr or 82.2% TPY 100% Unit $ Total $________ _____ ______ Product Streams
Mono Potassium Phosphate 100.0% 5,277 $450 $2,374,824 Calcium Chloride 38.0% 2,481 $200 $496,260
Total Revenues $2,870,000 Chemical Usages
Phosphoric Acid (as P2O5) 28.0% 5,036 $120 $604,351 Potassium Chloride 100.0% 3,470 $120 $416,352 Potassium Hydroxide 45.0% 290 $500 $145,103 Lime (Calcium Oxide) 100.0% 778 $70 $54,475
Subtotal $1,220,281 Utilities
Evaporation Steam (Tons) 100.0% 15,454 $10 $154,541 Cation Resin Addition (Ft3) N/A 37.50 15.0% $120 $4,500 Electrical Power (MWH) N/A 0.90 $80 $21,600
Subtotal $180,641 Fixed Costs
Operating Labor N/A 24.0 Hrs/Day $30 $216,000 Maintenance 2.5% of Capital Equip't $37,125 Depreciation on Total Capital of $2,673,000 10.0% of Capital $267,300
Subtotal $520,425
Total Costs $1,920,000 Investment Summary
Return on Investment 36% Annual Gross Profit: $950,000
FiltrationProducts
Process Development & DesignApproach
Process Development & DesignApproach
Project QualificationProduct Market, Pricing, Quality, etc.Preliminary System Sizing, Estimate & EconomicsApplications Testing (Bench & Pilot)Commercial Plant Location
Testing & Design Higgins Loop™ & Other Pilot Testing @ STS TampaDesign by STS (Loop) & Engineering Firm
Severn Trent ParticipationDirection of Process Development & System Design
Testing by Client, USF Students or SubcontractTechnical Support for Commercial SystemHLS Technology License & Production Fees
12
FiltrationProducts
Continuous I-X for Fertilizer ProductsSummary
Continuous I-X for Fertilizer ProductsSummary
HLS - Proven I-X Technology That Works5+ Decades of Experience in Specialized ProcessingReliable, Low Maintenance SystemFlexible Operation with PLC Controls & Qualify Monitoring
Produces Premium Fertilizers EconomicallyConvert Low Value Feedstocks into Value Added ProductsLow Capital Investment & Small System FootprintLiquid Fertilizer SolutionsDiversify FL Phosphate Plant Product Line
Favored Market Position Exclusive Rights to Proprietary ProcessAbility to Produce Customized Blends