Abstract:
A waste liquor treatment system comprising an evaporator in combination with a gas cooler, the evaporator providing fractional distillation of waste liquor, thereby separating the liquor into its several components of gaseous vapors, purified water and concentrated brine. Condensed liquor from the gas cooler or flushing liquor used to spray an industrial process gas in the collecting mains of the gas-producing plant provides thermal energy from its waste heat to run the evaporator. The evaporator consists of a boiler section, a condenser section, a vacuum pump, a liquor circulating pump, and nozzles for extracting the products. The gas cooler may be one or two stage. In the one stage cooler, the hot liquor which condenses in the gas cooling process or flushing liquor from the collecting mains of the gas-producing plant provides energy for the evaporator through means of a heat exchanger. In the two stage gas cooler, the hot liquor in the first stage is circulated directly to the boiler section of the evaporator. The hot liquor from the second stage is circulated through a separate heat exhanger.

Description:
RELATED APPLICATIONS 
     This application is a continuation-in-part of application Ser. No. 833,917, filed Sept. 16, 1977, which is a divisional of application Ser. No. 640,331, filed Dec. 12, 1975, U.S. Pat. No. 4,061,531 of Dec. 6, 1977. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to the treatment of waste liquor by a system which uses the heat that is normally wasted from the cooling of industrial process gas, such as coke oven gas, oil gas, or coal gas, to provide energy for the fractional evaporation of the liquor which condenses from the gas. 
     In the prior art the treatment of waste liquors that condense from the cooling of industrial process gas has been inadequate in that the product was not environmentally suitable for discharge to the waterways of the nation. Furthermore, the process of treating the liquors consumed valuable chemicals and gave rise to sludges which created a solid-waste disposal problem. 
     In an effort to overcome the inadequate treatment, to avoid the purchase of valuable chemicals, and to obviate the need for sludge disposal, a prior process was developed to fractionally distill the waste into components of gaseous vapors, purified liquor and concentrated brine. The process achieved its objectives; however, it consumed a large amount of energy and contained a substantial area of heat exchange surfaces that were subject to fouling and corrosion, thereby shutting down the process at frequent intervals. The prior art will be discussed below in specific relationship to coke oven gas, coal gas and oil gas technology. However, it is also applicable to other process gas technology. 
     Coke is made by the destructive distillation of coal in the absence of air. The heating process, which attains temperatures as high as 2000 F. drives off both the surface water and the water of combination from the coal. Cooling of the gas, which evolves from the heated coal, takes place by means of sprays in the gas collecting mains. The non-condensed gas and vapors leaving the mains, at a temperature of 165 to 180 F., require further cooling to approximately 95 F. Thus further cooling takes place in a gas cooler, known as a primary gas cooler. The purpose of the further cooling is to remove tar vapors and a major portion of the water vapor and to reduce both the volume and temperature of the gas before its admission to the exhauster, which draws the gas from the coke ovens. The vapors that condense are known as waste ammoniacal liquor. 
     Gas from coal is made by reacting heated coal air and steam. In the air reaction, the amount of air is regulated so that the combustion is essentially incomplete, thereby producing mainly carbon monoxide and nitrogen. In the steam reaction, the principal products are hydrogen and carbon monoxide. The first reaction produces heat which is absorbed in the second reaction. 
     Fuel gases made from coal vary in calorific value from approximately 150 to 550 BTU per cu. ft. The calorific value may be varied by using oxygen instead of air, or by enriching the gas with vapors from an oil cracking process, or by both in conjunction. The process may incorporate a waste-heat boiler for recovering energy. Oil gasification, such as the carbonization of oil at high temperatures, produces a gas having a calorific value essentially equal to that of natural gas, i.e., approximately 1000 BTU per cu. ft. 
     The various processes for making gas from coal and oil produce a gas containing components such as water and tar. The total gas requires cooling and cleaning prior to its ultimate use. Cooling takes place in a waste-heat boiler followed by a primary cooler, or solely in a primary cooler. As in the case of coke oven gas, during cooling, tar vapors and a major portion of the water vapor are condensed and the gas is reduced in volume. An exhauster removes the uncondensed gases. Uncondensed vapors remain as waste liquors. 
     There are two types of primary coolers. One is the direct primary cooler in which heat transfer takes place by direct contact between the gas and the previously condensed, separately cooled waste liquor. In the indirect primary cooler, heat exchange takes place through the medium of tubing. 
     Waste liquor is usually discharged to a receiving body of water such as a river or a lake. Its usual flow is 15 to 35 gallons per ton of coal which is charged into the coke ovens, 40 to 60 gallons per ton of coal used to produce coal gas, and about one quart per gallon of oil converted to gas. It is highly toxic and must be treated before it is environmentally acceptable for discharge. 
     The composition of waste liquor from coke oven gas production varies, depending on the nature of the coal from which it is derived, the type of coke oven that is used, and the coking temperature. A typical range of composition expressed in milligrams per liter is listed below: 
     
         ______________________________________Phenolics              300 to 4000Free ammonia (separable bysteaming)             1300 to 2000Fixed ammonia (requireschemicals for itsseparation)           2600 to 4000Carbonate             2300 to 2600Cyanide                10 to  100Thiocyanate            50 to  500Total dissolved solids                 4000 to 13000______________________________________ 
    
     The composition of waste liquor from coal gas and oil gas production varies according to the gasification process and the type of coal or oil which is employed. A typical composition for waste liquor produced during coal gasification is: 
     
         ______________________________________Specific Gravity   1.01Sulfate            2.2 Grams per literChloride           0.9 Grams per literSulfide            0.5 Grams per literPhenol             1.9 Grams per literCarbon dioxide     3.6 Grams per literFree Ammonia       0.03 Grams per literFixed Ammonia      0.02 Grams per liter______________________________________ 
    
     Waste liquor from oil gas production contains about 0.05% hydrocarbons corresponding to the composition of light tars. Other components will be in very small amounts. 
     The most common method of treating waste liquor from coke oven gas production for discharge is to pass it through a free still, a fixed still, and an activated sludge plant. The free still causes the evolution of free ammonia and certain acidic gases due to direct contact with live steam. The fixed still causes the evolution of fixed ammonia due to the addition of a basic chemical compound such as lime or sodium hydroxide and further direct contact with live steam. The activated sludge plant removes nearly all the phenolics and 25 to 60 percent of the cyanide and thiocyanate. 
     A well-operated plant, such as the one just described, will produce an effluent containing less than 1 milligram per liter of phenolics and acceptable levels of ammonia. However, the content of cyanide and thiocyanate will be above the toxic limits and the level of total dissolved solids will be essentially undiminished. The color of the liquid will be dark brown and will taste bed. It will also be necessary to provide an environmentally acceptable land area for receiving the lime sludge from the fixed still as well as the biological sludge from the activated sludge plant. 
     Waste water from coal and oil gasification is commonly passed through a sand filter and an activated carbon filter to remove the organic components. Any inorganic components from coal gasification are not removed from the waste water. For complete treatment, a biological oxidation step can be included. 
     A newer process has been recently developed to provide a better quality effluent and to avoid, in part, the problem of disposing of the sludge. The central unit in this process is a free ammonia still combined with a multiple effect evaporator. Three effluents are produced. The first is gaseous vapors consisting of ammonia, certain acidic gases, and water vapor. These are incinerated and pass to the atmosphere in an environmentally acceptable manner. The second is purified water which contains most of the phenolics, the reason for the lack of separation being that the boiling points of water and the phenolics are close to one another. The phenolics are further treated by an activated sludge plant, or extracted as a usable by-product. The third is concentrated brine which contains the fixed ammonia, cyanide, thiocyanate, and other dissolved solids. This is incinerated and, in a scrubber unit which is incorporated with the incinerator, recovered as a useful acid. The composition of the acid is principally hydrochloric acid and contains a small percentage of sulphuric acid. Incineration of the raw, dilute waste liquor was also tried, but it required an excessive amount of energy. 
     The newer process has produced an environmentally acceptable effluent as well as a usable acid. It has two disadvantages. The first is that of fouling and corrosion on the heat exchange surfaces. This occurred despite the fact that the waste liquor was decanted and then filtered before admitting it for treatment and despite the refractory material that was used for the heat exchange tubing, titanium having been the material of choice. Plant shut-downs to correct the results of the fouling and corrosion have been frequent. The second is that of high consumption of energy that is required for distillation, despite the employment of multiple effects to achieve maximum conservation of energy. 
     A purpose of the invention is to separate the components of gaseous vapors, purified water, and concentrated brine from waste liquors which condense from the cooling of industrial process gas, so that the components may be utilized or treated in an efficient manner. 
     A further purpose is to separate the components of gaseous vapors, purified water and concentrated brine from waste liquors which condense from the cooling of industrial process gas and to utilize the heat from the cooling of said gas to provide the energy for separating the components from the liquor. 
     A further purpose of the invention is to separate the components of gaseous vapors, purified water and concentrated brine from the waste ammoniacal liquor which condenses in the primary gas coolers of a coke oven gas, oil gas, or coal gas by-product plant so that the components may be used or treated in an efficient manner and to do so utilizing the thermal energy which is normally wasted from the primary gas coolers. 
     A further purpose of the invention is to provide a system for separating the components of gaseous vapors, purified water and concentrated brine from waste liquors in which the principal mechanism of heat transfer to or from the foul gas or foul liquor is by direct contact, thereby avoiding corrosion and fouling of heat exchange surfaces. 
     A further purpose of the invention is to provide a system for separating the components of gaseous vapors, purified water and brine from waste liquors in which the salt in the brine is crystallized and withdrawn from the brine in the crystal form. 
     SUMMARY OF THE INVENTION 
     I have discovered that the heat which is removed from industrial process gas in the primary cooler is somewhat greater than the thermal energy which is required in the single stage evaporation of the waste liquor, and that is possible to operate the gas cooler and evaporator together in a common, efficient and reliable system. 
     In accordance with the invention, the industrial process gas is cooled in the primary cooler by direct contact between spray droplets of waste liquor and the hot gas. The heated liquor is then circulated through a single stage evaporator which is operated at a partial vacuum. The liquor boils in the vacuum, thereby cooling it for return to the primary cooler. Cooling coils in the evaporator condense the purified water. A vacuum pump draws off the uncondensed vapors. 
     The evaporation of water from the waste liquor causes the latter to increase its content of dissolved solids. When the concentration of dissolved solids reaches approximately 25 percent, brine is extracted. The extraction flow rate of the brine is set at such an amount as to maintain the concentration of the dissolved solids as high as is practicable. 
     While it is evident that the invention will normally be applied to the treatment of waste liquor from a by-product coke plant, or from a coal or oil gasification process, it will also be evident that the invention can be applied to liquor which condenses from the cooling of any industrial process gas. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the invention and, together with the description, serve to explain the principles of the invention. 
     FIG. 1 is a diagrammatic general arrangement and process flow sheet of the invention in which a two-stage gas cooler is used. 
     FIG. 2 is a diagrammatic general arrangement and process flow sheet in which a one-stage gas cooler is used. 
     FIG. 3 is a partial diagrammatic general arrangement and process flow sheet in which the bottom of the evaporator is fitted for the production of salt crystals. 
     FIG. 4 is a diagrammatic general arrangement and process flow sheet in which flushing liquor supplies the heat for the process. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. 
     First considering FIG. 1, industrial process gas from the collecting mains enters the inlet nozzle 10 of the two-stage primary gas cooler 11. In the first stage 12 of the primary gas cooler 11, the gas is cooled by sprays 13 of brine 14. In the second stage 15, the gas is further cooled by sprays 16 of condensed liquor 17. The cooled industrial process gas leaves the primary gas cooler 11 through the outlet nozzle 18. 
     The brine 14 flows through pipe 19 to the evaporator 20, which is maintained at a partial vacuum by means of vacuum pump 21. Flow through the pipe is created by the differential in pressure between the gas cooler, which is at nearly atmospheric pressure, and the evaporator, which is under a strong partial vacuum. The brine 14 boils inside the evaporator and, in so doing, becomes cooled to a temperature equivalent to the vapor pressure, which approaches the absolute pressure of the evaporator. The brine pump 22 recirculates the brine to the sprays 13 by means of pipe 23. 
     The partially cooled gas from the first stage 12 of the primary gas cooler passes upward around a separating hat 24 into the second stage 15. The separating hat prevents the free flow of condensed liquor 17 from the second stage to the first stage. The condensed liquor flows through a pipe 25 to a liquor pump 26 which recirculates it to sprays 16 through pipes 27 and 28, and heat exchanger 29. In the heat exchanger, the liquor is cooled by water which flows from pipe 30 and discharges to drain 32 via pipe 31. 
     During the cooling of the industrial process gas in the primary gas cooler 11, a major portion of tar vapors, water vapors, and other condensibles is removed from the gas. Most of the removal takes place in the first stage 12 where the condensibles pass directly into the brine 14 through the drain cone 33. The condensibles in the second stage mix with the recirculated liquor, thereby adding to its volume. Excess liquor overflows from the basin 34 through the overflow pipe 35 to the first stage where it becomes added to the brine 14. 
     In the evaporator 20, the vapors from the brine pass around the separating hat 36 to the condenser 37 where the majority of the vapors condense, fall into basin 38, and are extracted through pipe 39. The uncondensed vapors leave the top of the evaporator and go to vacuum pump 21 via pipe 40 and from the vacuum pump via pipe 41. Water flows to the condenser 37 from pipe 42 and from the condenser to the drain 44 via pipe 43. 
     Brine is extracted from the bottom of the evaporator by means of pipe 45. The rate of extraction is set to maintain the desired level of concentration of dissolved solids in the recirculated brine. The partial vacuum in the evaporator 20 as well as the flow of cooling water to the condenser 37 are set to maintain a desired rate of evaporation which, in turn, affects the level of liquid in the basin of the evaporator. If the level of brine in the basin rises above the desired setting, the partial vacuum is increased, (the absolute pressure is decreased), and the water flow to the condenser is increased, thereby increasing the rate of evaporation. Reverse actions are required to correct a brine level that is too low. 
     There are two heat transfer units, the heat exchanger 29 and the condenser 37. In the heat exchanger 29, the heat transfer surfaces contact water on one side and the dilute liquor on the other side. In the condenser 37, the heat transfer surfaces contact water on one side and a dilute solution of phenolics in water on the other side. Experience has shown that fouling of these surfaces is not a serious problem and that a wide variety of materials, the 316 grade of stainless steel being one such, will provide corrosion-free service. 
     In FIG. 2, the primary gas cooler 11a is one stage and a brine heater 46 is placed in series with the heat exchanger. The gas enters the gas cooler through inlet nozzle 10a and leaves through outlet nozzle 18a. Condensed liquor 17a is circulated to the liquor sprays 16a by the liquor pump 26a through the brine heater 46 where it is cooled by the brine 14a and the heat exchanger 29a where it is further cooled by water. In the brine heater 46, the brine 14a is heated for recirculation to the evaporator. 
     The vapors which condense in the primary gas cooler 11a mix with and add to the quantity of the recirculated liquor 17a. Pipe 47 extracts liquor from the recirculated liquor system and introduces it to the basin of the evaporator 20a. The rate of extraction is set to maintain the desired level of liquid in the basin of the primary gas cooler. 
     In the embodiment of FIG. 2, the brine heater 46 is supplied with heat from the condensed liquor 17a. FIG. 4 illustrates an alternative embodiment in which the brine heater 46b is supplied with heat from flushing liquor 55. This liquor has been previously heated by spraying it into the mains which lead the gas from the gas-making process. Flushing liquor from the gas mains discharges via pipe 56 into the storage and tar-decanting tank 57 from which spray pump 58 supplies the brine heater. The liquor discharging from the brine heater is delivered to the sprays of the gas main via pipe 59. 
     Apart from the use of flushing liquor 55 instead of condensed liquor 17a to supply heat to the brine heater 46b, the embodiment of FIG. 4 is identical to that of FIG. 2. The condensed liquor in the embodiment of FIG. 4 simply bypasses the brine heater and flows directly to heat exchanger 29a for cooling before being recycled to the primary cooler. 
     All remaining functions, constructions, and operations of other equipment such as the evaporator, condenser 37a, separating hat 36a, the pumps, lines 39a, 40a, 43a, 45a, and so forth are the same as described above and in FIG. 1 and their description will not be repeated. 
     The arrangements of FIGS. 2 and 4 are advantageous compared to the arrangement of FIG. 1 in respect to the primary gas cooler. The one-stage primary gas cooler 11a is smaller, of simpler construction and, because it is not exposed to the brine 14a, may be of carbon steel as compared to the larger, more complex two-stage primary gas cooler 11, which must have a higher grade of material such as grade 316 stainless steel where there is contact by the brine 14. For these reasons, the former primary gas cooler is less expensive than the latter for a given capacity. There is an additional advantage in that the one-stage, direct-contact, primary gas cooler presently exists in many industrial process gas plants, thereby permitting the creation of the treatment facility by the addition of the evaporator 20a, the brine heater 46, the vacuum pump 21a, and so forth. 
     The arrangements of FIGS. 2 and 4 are disadvantageous compared to the arrangement of FIG. 1 in respect to the brine heater 46 or 46b. The brine heater is exposed to the foul, highly concentrated brine 14a or 14b and careful attention must be given to various facets of design to prevent fouling and corrosion. To minimize fouling, the velocity of brine in the tubes must be high; nevertheless, provisions must be included for mechanical and steam cleaning, as well as the provision of standby heaters, to insure continuity of service. To avoid corrosion, the tubes must be made of titanium or a similarly refractory material. Titanium will be satisfactory because the temperatures are well below 200 F. 
     In an existing gas-producing plant which has one or more direct-contact, primary gas coolers, the arrangement of FIG. 2 or FIG. 4 will doubtless be preferred. In an existing gasproducing plant where the hot gas is sprayed with flushing liquor, it may be desirable to utilize the arrangement of FIG. 4. In other instances, the arrangement of FIG. 1 would be the more advantageous. 
     The gaseous vapors 41 and 41a contain about 10 percent ammonia and about 90 percent water vapor with the minor addition of certain acidic gases. The vapors may be incinerated in an environmentally acceptable manner or the ammonia may be recovered as a useful by-product. Both are feasible and have been demonstrated commercially. 
     The dilute solution of phenolics in purified water 39 and 39a may be introduced into an activated sludge plant for the purpose of destroying the phenolics, into a bed of activated carbon for the purpose of adsorbing the phenolics, or into a phenol recovery unit for the purpose of obtaining a useful byproduct of phenolics. All three are feasible and have been demonstrated commercially. 
     The brine 14, 14a, and 14b contains the dissolved solids in a solution of approximately 25 percent concentration together with condensed tar. The brine may be delivered to a liquid incinerator which consumes the tar and converts the salts to acidic gases. A scrubber and absorber are associated with the incinerator. They cool the gas and produce a useful acid byproduct in which the major constituent is hydrochloric acid and the minor constituent is sulphuric acid. One use of the acid is in the pickling of steel for the purpose of providing a clean, oxide-free surface. The liquid incinerator has been demonstrated commercially. 
     Another use for the brine is to produce it in the crystalline form, free of tar. Because the dissolved solids contain ammonium chloride in a high ratio, approximately 85 percent by weight, the crystals are useful, one such use being as fertilizer. FIG. 3 shows a partial arrangement and process flow sheet for separating the tar and producing the crystals. 
     In FIG. 3, the liquor comes from the primary gas cooler through pipe 47b. The liquor first enters the decanter 48 where the tar is separated from the liquor, the tar being extracted through pipe 54, and the liquor being delivered to the evaporator 20b through pipe 49. The concentration of dissolved solids of the brine 14b in the evaporator 20b is maintained at a high level, approximately 50 percent, such that the cooling of the brine solution causes the the formation of salt crystals. The agitator 50 is driven by motor 51 to keep the crystals in suspension. The slurry pump 53 draws the mixture of brine and crystals from the bottom of the evaporator through pipe 52 and delivers the mixture through pipe 45b to commercially available equipment for dewatering, drying and storing the crystals. The brine which is removed from the crystals during dewatering is returned to the evaporator 20b. It is evident that the production of salt crystals is equally applicable to the arrangement which employs a one-stage primary cooler as to that which employs a two-stage primary cooler. 
     In FIG. 1, pipe 55 is used to extract a quantity of condensed liquor 17 from the liquor circulating system. The extracted liquor is used for two purposes. One is to provide make-up flow to the flushing liquor system of the industrial process gas collecting mains. The other is to provide nutrients for the biological mass in the activated sludge plant. The flow of condensed liquor 17 to the brine 14 is reduced by the amount of liquor that is extracted through pipe 55. In FIG. 2, pipe 55a serves the same purpose of extracting the condensed liquor. 
     Various types of equipment may be substituted for the equipment which is shown in the drawings and described above. For example, an ejector may be employed in place of the vacuum pump 21, and recirculation from the slurry pump 53 to the evaporator 20 may be employed to obviate the need for the agitator 50. Heat for the process may be supplied by both condensed liquor 17 and flushing liquor 55. Thus, it will be apparent to those skilled in the art that various modifications and variations could be made in the process and apparatus of the invention without departing from the scope or spirit of the invention.