METHOD AND APPARATUS FOR PREPARING HIGH-CONCENTRATION ALKALI

Abstract: Alkali is concentrated to high density by evaporation under high pressure at elevated temperature and expansion of the concentrated solution to low pressure, preferably below the atmospheric pressure, wherein the pressure difference between the high-pressure vessel (2) and the low-pressure vessel (25) is absorbed gradually by an absorbing means, preferably a liquid column (H) of a U-shaped siphon (26), so that wear and erosion are reduced considerably.

Description: Title of the Invention: METHOD AND APPARATUS FOR PREPARING HIGH-CONCENTRATION ALKALI. Background of the Invention: The present invention relates to a method and an appa¬ ratus for preparing high-density or concentration al- kali such as caustic soda (NaOH) and caustic potash (KOH) by evaporation at an elevated temperature. There¬ in the term "high-de sity" shall mean a concentration greater than about 98% NaOH or 94% KOHsresp. A typical prior art apparatus used to prepare high-den¬ sity caustic soda is shown in Fig. 1. In this figure, reference numerals 1 and 2 denote eva¬ porators, 3, 4 denote heat exchangers constituted by a multiplicity of tubes connected to the lower side of the evaporators, 5 denotes a heat medium heater, 6 de¬ notes a flaker, and 7 denotes a condenser. In this apparatus, a caustic soda solution of 50% den- sity and maintained at 80°C is supplied into the eva¬ porator 1 from a pipe 8 through the tube of the heat exchanger provided under the evaporator 1. The caustic soda solution is heated to 98 to 99°C within the heat exchanger 3, by a 100°C heat source which is formed by a vapor introduced through a pipe from the upper end of the evaporator 2 into the heat exchanger 3. Heating reduces the water content so that the caustic soda so¬ lution is concentrated to a density of about 60%. Reference numeral 10 denotes a discharge pipe through which the condensate is discharged after it has been used. The 60% caustic soda solution accumulated on the bot¬ tom of the evaporator 1 is transferred into the evapo¬ rator 2, through a pipe 11 leading from the bottom of the evaporator 1 and then through the tube of the heat exchanger 4 provided under the evaporator 2. During the transfer, the caustic soda solution is heated by molten salt which is supplied from the heat medium hea¬ ter 5 through a pipe 12 while it passes through the heat exchanger 4, in order to become a 98,5% caustic soda solution at 400 C. Numeral 13 denote a pipe through which the molten salt is discharged. The vapor derived from the upper end of the evaporator 1 is cooled by the condenser 7, and the condensate is taken out through the pipe 14. The inert gas which is not condensable is extracted through a pipe 15 and then through a pipe 17 by the action of a vapor ejec¬ tor 16. A numeral 18 denotes a pipe for supplying steam, while numerals 19 and 20 denote pipes for sup¬ plying and discharging water. The caustic soda solution of 98.5% density collected on the bottom of the evaporator 2 is introduced into the flaker 6 through a pipe 21 leading from a lower portion of the evaporator 2. The flaker 6 has a rotary drum 6a in which water is supplied to the inside so as to cool the solution to flakes 22 of high-density cau¬ stic soda. In this conventional arrangement, since the flaker 6 is at atmospheric pressure, it is difficult to main¬ tain pressure in the evaporator 2. Therefore, the in¬ ternal pressure in the evaporator 2 has to be maintai- ned at atmospheric pressure. However, if a high pres¬ sure would be tried to be maintained inside the evapo¬ rator 2, it would have been necessary to provide a suitable pressure-reducing means in the circuit of pipe 21 , to prevent the internal pressure from being relieved into the flaker 6. Such a pressure-reducing means might be constituted by a valve, orifice or a restriction. Unfortunately, however, no material was available which could long withstand the effect of re¬ stricting the flow of high density caustic soda at high temperature. The best material now available is pure nickel, but even this quickly corrodes and is eroded and soon becomes unusable when exposed to a suddenly expanding mixture of vapor and high density caustic soda at high temperature. Therefore, the inter- nal pressure of the evaporator 2 directly connected to the flaker 6 through the pipe 21 is usually maintained at atmospheric pressure, in prior art. To attain a 99% caustic soda solution in the evapora- tor 2, molten salt, as the heat source, is supplied to the heat exchanger 4 so as to heat the interior of the evaporator to 400 C. In consequence, the 400 C vapor is introduced into the pipe 9. Because of the high energy of this vapor; therefore, if all of this vapor is di- rectly supplied to the heat exchanger 3, this heat source would concentrate the 50% density caustic soda solution" of 80°C supplied from the pipe 8 into the tube of the heat exchanger 3 up to 65%, provided ade¬ quate vapor pressure is achieved. In this conventional arrangement, however, the vapor can be used only as heat source at a relatively low saturation temperature of 100°C, so that the evaporator 1 can achieve a cau¬ stic soda solution of about 60% only. If all the vapor from the evaporator 2 is introduced into the heat ex¬ changer 3, the internal pressure in the evaporator 2 will rise and the pressure will be undesirably expand to the flaker 6. For these reasons, in the conventional apparatus shown in fig. 1 , the vapor introduced from the evaporator 2 into the tube 9 is not all introduced into the heat exchanger, but some of it is discharged into the atmos¬ phere from an intermediate region of the pipe 9, there¬ by wasting energy. Summary of the Invention: An object of the invention is to provide a method and an apparatus to prepare high-density alkali, which will obviate the above-described problems of the prior art. A special object of the invention is to provide a me¬ thod and an apparatus by which the alcali may be con¬ centrated more economically under high pressure with¬ out sudden expansion of the concentrated solution to atmospheric pressure by pressure reducing devices sub¬ ject to corrosion. To this end, according to the invention, the alkali solution is concentrated by evaporation under high pressure and elevated temperature and the concentra¬ ted solution is expanded to a low pressure by expan- sion through a pressure difference absorbing means absorbing gradually the pressure difference between the high pressure at the evaporation and the low pres¬ sure after expansion. With this arrangement, no surplus vapor is wasted; hence, energy is used very efficiently. Since the ex¬ pansion between high and low pressure regions takes place gradually over a considerable length avoiding any sudden expansion at limited points by valves etc. , the attack of the materials by corrosion is conside¬ rably reduced and materials may be used which are much less subject to corrosion. Especially, it is advantageous, in order to prevent pressure venting from the pressurized evaporator into the atmospheric pressure region, e.g. a flaker, to dispose as a pressure difference absorbing means a U-shaped seal siphon tube and a low-pressure vessel at less than atmospheric pressure between the evapo- rator and the flaker. With this arrangement, the pres¬ sure difference between the high-pressure vessel con¬ stituted by the pressurized evaporator and the low- pressure vessel, is maintained by the U-shaped seal siphon device, automatically. According to a further, very advantageous improvement of the invention an intermediate seal pot is disposed between the high-pressure evaporator and the low- pressure vessel connected with the low-pressure ves¬ sel by an additional recirculation pipe by which a part of the expanded cool solution is recirculated and mixed with the solution in the intermediate seal pot. Brief Description of the Drawings: The invention will become clear from the following description of the preferred embodiment in conjunction with the accompanying drawings. Fig. 1 is an illustration of a prior art apparatus, for preparing high-concentration alkali; Fig. 2 is an illustration of a first embodiment of the invention; and Fig. 3 is a vertical sectional view of a part of another embodiment of the invention. Description of Preferred Embodiments: Fig. 2 shows a first embodiment of the invention. In this figure, the same reference numerals denote the same parts or members as those appearing in Fig. 1. Especially, the evaporators 1 , 2 are substantially the same as those in Fig. 1. The embodiment of Fig. 2, how¬ ever, differs from the conventional apparatus shown in Fig. 1 in several ways. Firstly, a positive internal pressure of 1.61 to 2.22 atmospheres (bar) is maintained within the evaporator 2, and a saturation heat source of 110 to 123 C is produced " by adding water to the 372 to 377°C super¬ heated vapor generated in the evaporator 2, and the whole part of this heat source is supplied to the heat exchanger 3. Also, preheaters 23 and 24 are pro- vided in the pipes 8 and 11 , such that the caustic soda solution flowing in the pipes 8 and 11 is pre¬ heated by the heat source taken out from the heat ex¬ changers 3 and 4 through the pipes 10 and 13. Note also that the pressure in the evaporator 1 is reduced to a level of 0.114 bar (ATA) , so as to obtain a 64.6% caustic soda solution at 109°C. In this state, a 96.8% caustic soda solution is obtained in the eva¬ porator 2. With this arrangement, with a 123 C heat source used in the heat exchanger 3, and at pressure in the evapo¬ rator 1 of 0.114 bar, it is possible to remove the water up to a density of the caustic soda in the eva¬ porator 1 to 64.4% at a temperature of the caustic soda in the evaporator 1 of 109°C. Consequently, a caustic soda solution of higher density and tempera¬ ture than the conventional arrangement can be intro¬ duced into the tube of the heat exchanger 4 associated with the evaporator 2. The amount of heat source to be supplied to the heat exchanger 4 can be reduced by an amount corresponding to the reduction of the amount of water to be removed in this heat exchanger, so that the respective energy is saved. In an evaporator with internal pressure raised to 1.61 to 2.22 bar, it is possible to obtain a 96.8% caustic soda solution. Since the interior of the evaporator 2 is pressurized, a means is to be provided to reduce the pressure be¬ tween the evaporator 2 and the cooled flaker 6. To this end, in this invention, a low-pressure vessel 25 at a pressure less than atmospheric pressure, about 0.52 bar, is connected to the evaporator 2, such that an expansion flash takes place between the high-pres- sure vessel, the evaporator 2, and the low-pressure vessel 25. At the same time, the lower end region of the evaporator 2, the high-pressure vessel, and the low-pressure vessel are connected through a hairpin shaped siphon tube 26, to maintain a seal head H large enough to compensate for the pressure difference be¬ tween the evaporator 2 and the low-pressure vessel 25. The height of this seal is about 10 m. It is possible to regulate automatically, by the virture of the U- shaped seal siphon tube 26, the pressure difference of expansion, i.e., between the high-pressure vessel 2 and the low-pressure vessel 25, even when the in¬ ternal pressure of the evaporator 2 changes. Since no abrupt relieve but only a smooth continuous relieve takes place in this seal siphon tube 26, corrosion and erosion which are inevitable in the conventional devices is considerably suppressed. One end of the seal siphon tube 26 projects slightly into the evaporator 2, to permit an overflow of the caustic soda solution accumulated on the bottom of the evaporator 2. The other end of the seal siphon tube 26 projects largely into the low-pressure vessel 25 ver¬ tically upward. A deflector 27 is supported by a plu¬ rality of supports 27a above the other end of the seal siphon tube 26, such that the caustic soda solution coming out of the seal siphon tube collides with the deflector 27 and is discharged into the low-pressure vessel 25. The caustic soda solution in the evaporator 2, at a pressure higher than atmospheric pressure and heated and concentrated to 96.8% or higher at 370°C, is sub¬ jected to an adiabatic flash into the low-pressure ves¬ sel 25 through the U-shaped seal siphon tube 26, so that the latent heat contained in the caustic soda so¬ lution itself is utilized as the heat source for the concentration by flash evaporation, thus achieving a concentration of the caustic soda solution up to 99%. The high density caustic soda solution, which has over¬ flown the end of tube 28 projecting slightly from the bottom wall of the low-pressure vessel 25 comes into a seal tank 29 and is sent to the flaker 6 through a pipe 30, thus becoming a flake-like product. With this arrangement, it is not necessary to pay spe¬ cific attention to the reduction of the pressure diffe¬ rence between the high-pressure vessel 2 and the low- pressure vessel 25, due to a reduction in the load, be¬ cause the difference between the levels of the liquid in both tubes of the Y-shaped seal siphon tube 26 is automatically reduced after the pressure difference has been reduced. The liquid in the U-shaped seal siphon tube 26, is agi¬ tated if the load fluctuation is too great. This pro¬ blem may be solved by a baffle in the seal siphon tube 26 to stabilize the liquid surface. Such a baffle, how- ever, will soon become unusable due to rapid corrosion and erosion. In this embodiment, therefore, the seal siphon tube 26 is constituted by a tall U-shaped pipe with a height of about 10 m. The pressure in the low-pressure chamber 25 should never be reduced below about 0.3 bar, thereby solidi¬ fying the caustic soda solution. To obviate this pro¬ blem, according to the invention,;, on the vapor dischar- ging pipes 35, 36 extending from the discharging pipe 31 connected to the upper end of the low-pressure vessel 25, regulating valves 33 and 34 are provided, which can regulate the flow of make-up steam or regu¬ late the discharge flow rate of vapor. If the internal pressure of the low-pressure vessel falls abruptly, the regulating valve 33 is opened to compensate for the pressure reduction, by steam injection from the pipe 35, and valve 34 reduces the discharges of vapor through pipe 36, thereby compensating the pressure re- duction in the low-pressure vessel 25, thus preventing the solidification of the caustic soda solution. Fig. 3 shows the U-shaped seal siphon tube 26 which constitutes an essential part of another embodiment of the invention. Other parts are materially identical to those shown in Fig. 2. Referring to Fig. 3, a reference numeral 2 designates the evaporator constituting the high-pressure vessel upstream from the flash, 25 denotes the low-pressure vessel downstream from the flash, 26 denotes the U- shaped seal siphon tube, 27 denotes the deflector atta¬ ched to one end of the seal siphon tube 26 through supports 27a within the low-pressure vessel 25, and 28 denotes a pipe through which high density caustic soda is discharged from the low-pressure vessel 25. An intermediate seal pot 37 is disposed in the lower region of the vertical extension of the seal siphon tube 26 adjacent to the low-pressure vessel 25. The upper end of this intermediate seal pot 37 is connec¬ ted to the lower end of the low-pressure vessel 25 through a rise-pipe 39, and the deflector 27 is atta- ched to the rise-pipe 39. The lower end of the rise- pipe 39 is opened in the top of the intermediate seal pot 37. At the same time, the end of a pipe 42, lea¬ ding from the evaporator 2 constituting the high- pressure vessel of the seal siphon tube 26, is posi- tioned to face the opening 41 of the rise-pipe 39 at a distance from the opening 41 , thus having the effect of a nozzle. The lower end of the intermediate seal pot 37 and the region of the low-pressure vessel 25 different from the region where the rise-pipe 39 is secured are con¬ nected to each other through a fall-pipe 38. The fall- pipe 38 and the rise-pipe 39 in combination constitute a hairpin shaped seal 40. In this seal siphon structure, the space 44 between the fall-pipe 38 and the rise-pipe 39 is always filled with caustic soda solution, so that the pressure head cor¬ responding to the pressure difference between the evaporator 2 and the low-pressure vessel 25, is applied to the intermediate seal pot through the fall-pipe 38, whereby the pressure in the intermediate seal pot 37 is maintained at the level equal to that before the expansion, e.g., 2.22 bar. The rise-pipe 39 is de- signed to cause a pressure drop equal to the pressure drop of expansion. In the event that the pressure drop varies because of a varying load, the internal injec¬ tor constituted by the opening 41 and the end of the pipe 42 within the intermediate seal pot 3 functions to allow the rise-pipe 39 to suck a corresponding amount of caustic soda supplied by natural circulation through the fall-pipe 38, so that the pressure diffe- rence is automatically controlled. Consequently, the venting of the vapor from the evaporator 2 serving as a high-pressure vessel is prevented, thereby ensuring stable evaporation. It will be understood that any change in the pressure within the evaporator 2 as the high-pressure vessel cau¬ ses a change in the liquid surface of the caustic soda solution 44 in the pipe 42. If the hairpin seal structure 40 in the U-shaped seal siphon pipe 26 and the intermediate seal pot equipped with the internal injector are omitted, the pressure drop may or may not be balanced by the region of the seal siphon tube 26 in the low-pressure vessel 25, when the pressure difference is changed. Assume that boiling occurs at 1/3 of the height of the seal si¬ phon tube in the low-pressure vessel 15 or near the lower end of the pipe, thus allowing the caustic soda solution to jump. However, by providing the hairpin sealing structure 40 and the intermediate seal pot 37 having the internal injector as in Fig. 3, boiling can be confined to the rise-pipe 39, because the internal injector in the intermediate seal pot 37 is maintained at a pressure of 2.22 bar, due to the head. To recapitulate, with this invention, an alkaline solu¬ tion which has been concentrated by pressure and heat is further concentrated by being subjected to flash evaporation which is conducted under a reduced pres¬ sure. It is thus possible to easily prepare a high- density alkaline solution by using the heat source efficiently. Also, since the pressure difference between the high- pressure vessel and the low-pressure vessel is ba¬ lanced because of the U-shaped seal siphon tube, high pressure to low pressure flash evaporation can be ef- fected reliably and safely. It is noted that reliable operation can be achieved despite a pressure variation at the high or at the low pressure end of the system or a change in the pres- sure difference by self-balancing the pressure dif¬ ference by providing the U-shaped seal siphon tube with an intermediate seal pot having a hairpin sealing structure and an internal injector. Additionally, steam may be injected into the low-pressure zone. Although the invention has been described in specific terms, the invention is not limited to the described embodiments. The invention may be modified without de¬ parting from the scope of the invention which is limi- ted solely by the appended claims.

Claims: Claims : 1. A method for preparing a high-concentration alka¬ li by concentrating an alkali solution by evapo- 5 ration at an elevated temperature, characterized in that the alkali solution is concentrated by evaporation at a high pressure above the atmos¬ pheric pressure, and the concentrated solution is expanded to a low pressure by a gradual expan- Ifj. sion through a pressure difference absorbing means absorbing the pressure difference between the high pressure at the concentration stage, and the low pressure after expansion. 15 2. A method according to claim 1, characterized in, that the pressure difference is absorbed by a liquid column disposed between the high-pressure concentration stage and the low-pressure stage, the height of said column is chosen so that its 2Q liquid pressure is corresponding to said pressure difference. 3. A method according to claim 1 or 2, characterized in, that the low pressure to which the concentra- 25 ted solution is expanded is chosen below the at¬ mospheric pressure. 4. A method according to one of claims 1 - 3, cha¬ racterized in, that a part of the expanded and 30 cooled solution is recirculated and mixed with the concentrated solution after having left the evaporation stage. IS 5. An apparatus for using the method for preparing a high-density alkali according to one of claims 1 - 4, characterized by a high-pressure evapora¬ tion vessel (2J operated at elevated temperature and under a pressure above atmospheric pressure, and a 1 ow.-pressure expansion vessel (25) operated under a pressure not exceeding atmospheric pres¬ sure, wherein said high-pressure vessel (2) and said low-pressure vessel (25) are connected to each other by a pressure difference absorbing means (26) absorbing the pressure difference be¬ tween the high-pressure vessel and the low-pres¬ sure vessel gradually over its length. 6. An apparatus according to claim 5, characterized in, that said pressure difference absorbing means (26) is a liquid column the vertical exten¬ sion of which is such, that the hydrostatic pres¬ sure in said column corresponds to said pressure difference between the high-pressure vessel (2) and the low-pressure vessel (25). 7. An apparatus according to claim 6, characterized in, that the liquid column (26) is a part of a U-shaped seal siphon tube connected between the high-pressure vessel (2) and the low-pressure vessel (25). 8. An apparatus according to claim 7, characterized in, that an intermediate seal pot (37) is dispo¬ sed in the lower region of said liquid column (26), the upper end of this intermediate seal pot being connected to the lower end of the low-pressure vessel (25) through a rise-pipe (39) and the lo- wer end of said intermediate seal-pot (37) being connected to said low-pressure vessel (25) by a recirculation pipe (38). 9. An apparatus according to claim 8, characterized in, that the intermediate seal-pot (37) comprises an internal injector constituted by the opening (41) of the lower and of the rise-pipe (39) into the seal-pot and by the end of a pipe (42) connecting the intermediate seal-pot (37) with the high-pres¬ sure vessel (2) which is disposed opposite to the opening of the rise-pipe. 10. An apparatus according to one of claims 5 - 9, characterized in, that the low-pressure vessel (25) has an internal pressure below the atmospheric pressure. 11. An apparatus according to claim 10, characterized in, that a seal tank (29) is disposed between the low-pressure vessel (25) having a pressure below the atmospheric pressure and a cooled flaker (6) for for producing a flake-like high-concentration alkali. 12. An apparatus according to one of claims 5 - 11, characterized in that pipes (35, 36) are connected to the upper end of the low-pressure vessel (25) comprising regulating valves (33, 34) for regula¬ ting the flow-rate of make-up steam or the dis- charge flow-rate of vapor, respectively.

Inventors: KOBAYASHI TAKAYUKI, SALA SIRO, WINKLER ROBERT, YOKOTA SHINJIRO, KOBAYASHI, TAKAYUKI, SALA, SIRO, WINKLER, ROBERT, YOKOTA, SHINJIRO
Applicants: ESCHER WYSS AG, UBE INDUSTRIES, SULZER-ESCHER WYSS AG, UBE INDUSTRIES, LTD.
Application year: 1985
Main classification: C01D1
IPC codes: C01D1