The ShockWave Power™ Technologybw-f57a2f557b098c43f11ab969efe1504b-bwcore.s3.amazonaws.com/... ·...
Transcript of The ShockWave Power™ Technologybw-f57a2f557b098c43f11ab969efe1504b-bwcore.s3.amazonaws.com/... ·...
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The ShockWave Power™ Technologygy
“Controlled cavitation technology for scale-free heating and increased mass transfer applications
in pulping and recovery applications”
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HDI Outline
• Introduction to Cavitation Technology
• Advantages to Conventional Technology
• Applications to Pulp and Paper
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HDI Company Highlights
H d D i I27
19
441
441
75
20
85
59
Athens
Atlanta
Rome
Cornella
Hydro Dynamics Inc.• Located in Rome, Georgia
P t t d C it ti T h l
441
19
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27
82
27
82
82
341
341
1 301
301
84
8484 319
82
1129
1
75
75
16
16
20
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185
95
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Bainbridge
Macon
Albany
Augusta
Columbus
Savannah
Moul-trie
Tifton
Blakely
Cuthbert
CordeleMcRae
Douglas
La Grange
Ameri-cus
Milledgeville
DublinOakPark
Lyons
Dorchester
Waycross Bruns-wickPearson
StatesboroSwainsboro
Griffin
Madison
• Patented Cavitation Technology - Scale-Free Heating- The Next Generation Mixing Technology
- Process Intensification
441ValdostaThomasville
- Process Acceleration- Increase mass transfer- Convert Batch to Continuous
P d t C tl I t ll d i M M k t• Products Currently Installed in Many Markets- Many Industries- International installs- Fortune 500 companies- Testing at major universities
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HDI A New Tool
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HDI Cavitation – A Powerful Force…
• Cavitation is the sudden formation ShockWave Exampleand collapse of low-pressure bubbles in liquids by means of mechanical forces.
ShockWave Example
• The bubbles release an energy wave into the surrounding liquid.
Thi i l• This energy wave is commonly known as a shockwave.
As a cavitation bubble implodes, a shockwave is released
• Uncontrolled, cavitation can be very destructive to process equipment such asprocess equipment such as pump impellers.
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HDICavitation Induced
ShockwaveShockwave
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HDI The Shockwave Power™ Reactor
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HDI ShockWave Power™
Wh t i it?• What is it?– A Patented Breakthrough Technology
Based on “Controlled Cavitation”Based on Controlled Cavitation
• How is it Produced?– The Dynamic Action within the
ShockWave Power™ Reactor
• What can it be used for?– Scale-Free Heatingg– Microscopic Mixing
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HDI The SPRHow We Control CavitationHow We Control Cavitation
CavitationCavity Cavitation
Rotor
Cavity
• The heart of the technology is a specialized rotor with cavities
• The spinning action generates h d d i it ti ithi thhydrodynamic cavitation within the cavities away from the metal surfaces.
• The Cavitation is controlled thereforeHousing
Liquid• The Cavitation is controlled, therefore
there is no damage.• Video www.hydrodynamics.com/technology
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HDIShockWave Power™ Reactor
Controlled Cavitation Demonstration
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HDIIntrinsic Value:
Scale-Free HeatingScale Free Heating
Cool
Even Heating
N H t C ldCool • No Hot or Cold Spots
• No Heat TransferNo Heat Transfer Surfaces
• No Scorching
Hot
• Pinpoint Temperature Control
ConventionalControlledCavitationConventional
HeatingCavitation
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HDIIntrinsic Value:
Microscopic Mixingp g
Conventional Mixing Cavitation Increases Surface Contact Area
Two materials are chopped into microscopic sizes and intimately blended in the SPR.
The powerful forces of cavitation produce results that far exceed th f ti l t h lCavitation allows for
more Intimate Mixingthose of conventional technology using blades or other means.
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HDI Mixing Comparison
C t t (k ) 1/Contactor (kLa), 1/s
Mechanically Agitated Tank 0.02 – 0.2
Jet Loop 0.01 – 2.2Jet Loop 0.01 2.2
Tubular/Venturi Ejector 0.1 - 3
Quantum™ Mixer 0.05 – 1.1
SPR 0.9 – 5.2
KLa is a mixing constant and a good measure of mixing ability
The SPR has a proven ability to mix liquids and The SPR has a proven ability to mix liquids and gases that surpasses conventional technology
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HDI SPR Comparison to Static Mixer and HomogenizerStatic Mixer and Homogenizer
Mixing color with viscous liquidsMixing color with viscous liquids
StaticMixer ShockWave Power Reactor Homogenizer
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HDI Advantages of Cavitation
• Scale-Free Heating to reduce foulingScale Free Heating to reduce fouling• Microscopic Mixing• Process Intensification• Reduction of Reaction Times
H thi l t l d ?How can this apply to pulp and paper?
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HDI Pulp and Paper Applications
Black Liquor Recovery Area• Heating Prior to the Evaporatorg p• Heating Prior to the Boiler• Concentration • Oxidation
• Heat Value Reduction• Polishing• Scale Reduction
• Viscosity Reduction• Atomization at the Boiler
Recovery After the Boiler• White Liquor
• OxidationFiber Area
Environmental • Dissolved Air Flotation Fiber Area
• Bleaching• Oxygen delignification• Ozone• Chlorine Dioxide
• Dissolved Air Flotation• Oxidation
Paper Machine• Emulsification of Sizing• Hydration of Dry Additives Chlorine Dioxide
• Peroxide• Refining• De-inking• Dissolved Air Flotation
• Hydration of Dry Additives
Biofuels• Biodiesel From Tall Oil• Cellulosic Ethanol
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Bl k LiBlack Liquor TechnologyTechnology
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HDI Black Liquor Preheating by Oxidation to Reduce ScalingReduce Scaling
What is it:B idi i N S d By oxidizing Na2S and Organic Compounds in black liquor, the temperature of the temperature of the liquor is increased past the point where the calcium carbonate the calcium carbonate scaling occurs.
Benefits:• Reduced Scaling• If the evaporators are
a bottleneck, a mill can Dr. Verrill’s paper to be presented at the TAPPI Fall 2003 Conference Heating Black Liq or b Partial
18
increase production 1% to 4%.
2003 Conference – Heating Black Liquor by Partial Oxidation with Controlled Cavitation as a Means to
Reduce Evaporator Fouling
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HDI Black Liquor Heat Value Reduction
What is it:6200
6300
Oxidize Na2S & Organics in black liquor to increased throughput
b il 5900
6000
6100
6200
u/lb
BLS
recovery boiler.
Benefits:• Increased Black 5600
5700
5800
5900
ing
valu
e, B
tu• Increased Black
Liquor Solids Burned• Decreased Scaling• If the boiler is a
5400
5500
5600H
eat
If the boiler is a bottleneck, a mill can increase production by 1.5% - 5% or Dr Frederick’s paper presented to the International
5300
Residence Time
ymore.
Dr. Frederick s paper presented to the International Chemical Recovery Conference – Economic Benefits of Utilizing Controlled Cavitation Technology for Black Liquor Oxidation and Heating
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HDI Black Liquor Polishing
What is it: Typical Sulfide Concentration Profile Oxidize Na2S in the Black Liquor after the oxidation towers.
25
30
g/l
Reactor volume: 1.92 galLiquor Flow Rate: 19 gal/minRotor Speed: 1750 rpm
Benefits:•Overcome inefficiencies
f id ti t t
15
20
Na2
Con
c, g
of oxidation towers to fully oxidize the Black Liquor efficiently•Reduce TRS in air 0
5
10Ex
it N
Reduce TRS in air emissions from boiler 0
Time, Sec.
51 2 3 4
HDI Internal Test
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HDI Polishing Plant Trial Comparison
• Reaction is exothermic so temperature rise can
Oxidation Comparison
8 0
9.0
10.0O2 Flow = 1400 SCFH
temperature rise can be used to show extent of reaction.
4 0
5.0
6.0
7.0
8.0
xida
tion
(o F)
ShockWave Power Generator
• All cavitation heat has been subtracted
• Much less oxygen 0 0
1.0
2.0
3.0
4.0
T
Ox
Serpentine Reactor
Much less oxygen required
0.0900 1100 1300 1500 1700
RPM
HDI Plant Trial
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Whit LiWhite Liquor TechnologyTechnology
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HDI White Liquor Oxidation
What is it:O idi ed hite liq or• Oxidized white liquor oxidation is often used as a caustic source in a mill.
Benefits:• A readily available andA readily available and
cheap source of caustic for the plant.
• Can be used for oxygen ygdelignification
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HDI White Liquor Results (Partial)
Partial Oxidation (250 F/100 PSI)
35000
40000
45000
SulfideThiosulfateSulfate
25000
30000
35000
g/kg
10000
15000
20000
mg
0
5000
Partial 0 min Partial 5 min Partial 10 min Partial 15 min Partial 30 min
Time
HDI Internal Test
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HDI White Liquor Results (Full)
Full Oxidation (300 F/300 PSI)
50000
60000SulfideThiosulfateSulfate
30000
40000
g/kk
20000
30000
mg
0
10000
Full 0 min Full 5 min Full 10 min Full 15 mn Full 30 min
Time
HDI Internal Test
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O2 DeligO2 DeligTechnologygy
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HDI Oxygen Delignification
What is it: Oxygen Delignification is the
removal of lignin from pulp fibers through the reaction
Oxidation of Pulp
35
40
45
with environmentally friendly oxygen.
15
20
25
30
35
% O
xida
tion
ShockWave Power Reactor
Benefits: O2 delig is normally very
costly and capital intensive0
5
10
15
0 10 20 30 40 50 60
% Conventional Technology
Reaction Goal (35%)
costly and capital intensive. Cavitations offers potential
for faster reaction in smaller footprint resulting in capital
Time (minutes)
Comparison of Lab SPR to Parr Bomb Reactor
footprint resulting in capital savings.
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HDI Placement in Process
The SPR can be used Balance of
New Installation – Small Tower
The SPR can be used as a new O2 system, with or without towers,
Digester
WasherO2
SmallWasher
Balance ofbleaching
or as a retrofit to an existing system
SPR
S aTower
Digester Tower
Balance ofbleaching
Retrofit-Mixer Replacement
Digester
Balance ofbleaching
New Installation – No Tower
WasherO2 Washer Washer
O2 Washer
Mixer SPR
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HDI Lab Parr Bomb Results
40
30
35
40
20
25
30
atio
n (%
)
10
15
20
Del
igni
fica
SPR10 minutes4% Consit3.5% NaOH
Conventional60 minutes10% Cosist3.5% NaOH
Conventional22 minutes4% Consist3.5% NaOH
0
5
90 PSI90 C
90 psi90 C
90 psi90 C
Tests
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HDI Plant Trial MCOD Conditions
• 24 TPD Pilot Trial24 TPD Pilot Trial• HWD after DD washers• Impact on Fiber Propertiesp p
• 8-10% Consistency1 8% Caustic on Pulp• 1.8% Caustic on Pulp
• 2.0% Oxygen on Pulp• At least 190 FAt least 190 F• In Line Pressure of 90 psi• 5 Minute Retention Time
Medium Consistency Batch
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HDI Delignification
40
30
35
ifica
tion
20
25
ent D
elig
n
10
15
Perc
e
11 13 15 17
Starting Kappa Number
Dr. Hart’s paper to be presented at the TAPPI 2005 Bleaching Conference – Medium Consistency Oxygen Delignification
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HDI Residence Time - HWD
40
35
25
30
Del
ig %
20
150 5 10 15 20 25
Time
Dr. Hart’s paper to be presented at the TAPPI 2005 Bleaching Conference – Medium Consistency Oxygen Delignification
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HDI Delta K 30 sec
5
4
2
3
a K
30
sec
y = 0.538x - 5.5899R2 = 0.3281
0
1
Del
ta
-1
010 11 12 13 14 15 16 17 18
Starting K
Dr. Hart’s paper to be presented at the TAPPI 2005 Bleaching Conference – Medium Consistency Oxygen Delignification
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HDI Brightness
55
50
55
s (%
)
45
Brig
htne
ss
35
40GE
B
350 5 10 15 20
Reaction Time (min)
Dr. Hart’s paper to be presented at the TAPPI 2005 Bleaching Conference – Medium Consistency Oxygen Delignification
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HDI Other Results
• No negative strength impact compared to conventionalNo negative strength impact compared to conventional.• Achieve up to 25% delignification without retention tanks.• 10 to 15 minutes residence time achieves 40% to 50%
delignification.• Use for both MC and LC pulps.• Potential to use existing caustic/washing (Wingems).• Results are pulp specific, but can save several $/ton.
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HDI How Does it Work?
The SPR is a world class mixer for liquids and gases Delivers small bubble size for increased mass transfer Ultrasonic effect to open fiber pores to allow chemical
t ttransport
Additional BenefitsAdditional Benefits Low energy cost (0.07 HP/gal) Small footprintp
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Extracting More Lignin
Lignin
g g
Oxygen
We start with fiber containing entrapped lignin
The SPR exposes the mixture of fibers and oxygen to shockwaves, which help to push the oxygen much deeper into the fiber
When the pressure wave contracts, the fragmented lignin is pulled from the fiber
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System Robustness
System RobustnessSystem Robustness
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HDI Conclusions
• Cavitation has many potential areas of use in y pthe pulp and paper industry.
• The scale-free heating and gas-liquid mixingThe scale free heating and gas liquid mixing capabilities make it an excellent candidate for use on black liquor.q
• Cavitation is also very well suited for enhancing oxygen delignification throughenhancing oxygen delignification through process intensification and increased mass transfer.
• Cavitation is a powerful tool for fluid processing
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HDI Acknowledgements
• MeadWestvaco Corporation• MeadWestvaco Corporation• Dan Armstead• Peter Hart• BOC• IPST• IPST
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The ShockWave Power™ Technologygy
Contact: Douglas G. MancoskyHydro Dynamics IncHydro Dynamics Inc.8 Redmond Court NWRome, Georgia 30165 USAwww.hydrodynamics.comTel: (706) 234-4111Toll Free: (877) 493-7639