WIRE INDUSTRY ACID PURIFICATION INTERWIRE 2015 DR. ROGER FRANCOIS – BEKAERT TOM PHILIPP, P.E. –...
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Transcript of WIRE INDUSTRY ACID PURIFICATION INTERWIRE 2015 DR. ROGER FRANCOIS – BEKAERT TOM PHILIPP, P.E. –...
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WIRE INDUSTRYACID PURIFICATION
INTERWIRE 2015
DR. ROGER FRANCOIS – BEKAERT
TOM PHILIPP, P.E. – PRO-pHx, Inc.
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THE CHEMISTRY
The catalyst changes the solubility of ferrous chloride and ferrous sulfate into insoluble iron precipitates. Organics are co-precipitated. Acids are purified and not regenerated.
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Pickling Tanks
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Drag-out Recovery
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FILTRATION• In the past filtration was done with filter cartridges and filter
bags.
• Previous arrangement was not satisfactory due to its labour intensive nature.
• Recently, a Two Chamber Global Automatic Back Wash Filtration System was installed.
• Back washing of the chambers take place when back pressure reaches 1.38 bar (20 psi) or every 1.5 hours.
• The chambers are air purged before and after back washing to reduce acid loss and dilution.
• Filter medium is rated at 20 micron.
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•FILTERS EVALUATED
2008 Global 1X PVC 2009 Westech gravity bag filter 2011 Siebec bag & cartridge filter 2012 Global 2X CPVC
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Global 2X CPVC
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Automatic Filter CyclesCycle Function
Service Filtered acid to pickle tank
Blowdown Unfiltered acid to pickle tank
Fill Cylinder fills with water
Backpulse Air & water discharge solids
Blowdown Cylinder emptied of fluid
Fill Cylinder fills with acid
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Filter Connections
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CHEMISTRY CONSUMPTION
•ACID USEAGE 6 LITERS/TON•CHEMISTRY USEAGE 0.06 LITERS/TON
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Project Performance Before After
Bath Concentration g/l HCl 160 80
Bath Decants Yes No
Iron Concentration g/l 100 Max 40 -80
Virgin HCl Reduction None 30%
Lime Neutralization Reduction None 70%
Filter Cake Reduction None 65%
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USA PROJECT ECONOMICSINSTALLED
• Previous Annual Costs• (Virgin acid + Wastewater treatment) $128,000.00• Filtration Equipment – Installed 49,000.00• Annual chemistry, utilities, labor 32,000.00• First Year Savings 47,000.00• Future Yearly Savings 96,000.00• Period to recover investment 6.8 months
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SOUTH AFRICAN PROJECT
25,000 – 35,000 MT/YEARTWO LINES
USED 16% Regenerated Acid – off-site
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Off-Site Regeneration
• Excessive recycle costs – ($ 0.65 /gal)• In and out hauling of dilute acids• Storage requirements for hazardous waste acid
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Drawing of System Layout
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Fouled Membrane Reason for having tanks
cleaned prior to use of chemistry
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African Project Economics Historic annual cost for regenerated acid $ 116,800 Initial cost: equipment installed $ 43,950 Annual operating cost: chemistry/utilities $ 35,830 First year savings $ 37,030 Future yearly savings $ 80,970 Average monthly savings, first 5 years $ 6,015 Period to recover investment 6.5 months
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Summary
Three wire plants have installed the precipitation chemistry and filtration for continuous acid purification. The technology accomplishes:• Lower acid pickling concentrations• Elimination of bath decants or dumps• Reduced virgin acid purchases• Reduced neutralizing chemical purchases• Reduced filter cake production• Improved process control