Process for the generation of chlorine dioxide

Abstract: A process for the rapid generation of chlorine dioxide under reduced pressure. A reaction column (15) having a venturi tube (14) therein and a reaction chamber (17) in fluid communication with the outlet of the venturi tube is provided. An aqueous chlorate solution (22) and a gaseous stream of acid (27) are introduced into the reaction chamber (15) to react and form chlorine dioxide. A driving medium (13) is introduced into the venturi tube, and the chlorine dioxide from the reaction chamber is mixed with the driving medium at the outlet of the venturi tube. The chlorine dioxide/driving medium mixture is passed through a reaction column. In an alternate embodiment, a chlorite solution is introduced into the reaction chamber together with the chlorate solution and the gaseous stream of acid. In a further embodiment, a chlorite solution is introduced into the reaction column after mixing of the driving medium with the chlorine dioxide.

Description: This invention relates to the production of chlorine dioxide and more particularly to an inexpensive, simple method of rapidly producing high yields of chlorine dioxide. Chlorine dioxide has been used in a variety of applications subsequent to its discovery in 1811 by Sir Humphry Davey. Applications that are commercially used today include the bleaching of wood pulp for paper making; bleaching of textile, flour, flower, cherry, tallow, and recycled paper; disinfection of industrial process water, drinking water, waste water, and food contact surfaces; use as a disinfectant and odor control agent in a variety of industries and applications; use for the destruction of pollutants such as cyanide and phenols; and use of its oxidation powers for industrial process purposes. Chlorine dioxide use has become popular in many of these applications because of its strong oxidation power, quick and broad biocidal capability, and its ability to oxidize without the formation of unwanted chlorination by-products. The one drawback to chlorine dioxide is that, because of its tendency to explode when compressed or stored in concentrations of over 10 percent, it must be produced on-site prior to use rather than produced at a central location and shipped to the point of use. This has lead to a variety of generation processes for its production. The two basic types of processes are differentiated by use of either sodium chlorite or sodium chlorate as the precursor chemical. Sodium chlorite based processes are, in general, small, safe and very easy to operate. There are several patents disclosing these types processes. United States Patent No. 4,250,144, issued to Ratigan, describes a process for the reaction of dissolved chlorine (hypochlorous acid) in water with sodium chlorite. United States Patent No. 4,590,057, issued to Hicks, discloses a process where molecular chlorine is reacted directly with sodium chlorite prior to dilution in water to form chlorine dioxide. Though these are by far the two most common chlorite based methods, there are a profusion of other chlorite based methods that react sodium chlorite with various acids or oxidizers to form chlorine dioxide. Though they all are relatively simple to operate when compared to the chlorate based processes, the chlorine dioxide produced from chlorite is inherently from 4 to 5 times as expensive as that produced from a chlorate based process. Sodium chlorite is much more expensive to produce than sodium chlorate. Industries where chlorite based process are used are the water disinfecting, food, and industrial water treatment sectors where typical use capacities are under 907 kg (2,000 lbs.) per day. Sodium chlorate based process are, in general, much larger and more complex to operate than a chlorite based process. United States Patent No. 3,920,801 issued to Grotheer describes an electrolytic cell process where sodium chlorate is reacted through a cascade system with hydrochloric acid and heat to produce chlorine dioxide and chlorine. United States Patent No. 4,081,520 issued to Swindells et al, describe a process where sodium chlorate is reacted with a mixture of liquid sulfuric acid and methanol to form chlorine dioxide. United States Patent No. 3,755,068 and 3,789,108 issued to Rapson, and 4,534,952 issued to Rapson, et al., describe a process where sodium chlorate is reacted with a mixture of sodium chloride and acid to form chlorine dioxide and chlorine. United States Patent No. 2,373,870, issued to Holst, discloses a process where sulfuric acid is reacted with sodium chlorate and sulfur dioxide to form chlorine dioxide. Sodium chlorate reactors are extremely capital intensive, with generator costs ranging from $2,500,000.00 to $10,000,000.00 compared with $3,500.00 to $100,000.00 for chlorite based processes. Chlorate units also require constant operator supervision where chlorite based process operate for months on end without operator supervision. The chlorite generator because of its small reaction column, vacuum chemical feed, and simplicity is safer, and produces a more pure chlorine dioxide stream than the chlorate based unit. Because of the cost and operational differences of the chlorite and chlorate based processes, there has been a tremendous drive to "downscale" chlorate processes to chlorite generation systems. Though there have been several patents granted on these systems, none has been commercially successful. An example of these would be United States Patent No. 4,451,444, issued to Santillie et al. This is because of the inherent nature of the reactants used require longer reaction times than the chlorite based processes. Retention time in a chlorite based process varies from minimal (< 0.5 seconds) in the Hicks et al process to a maximum of 15 minutes as described in the acid chlorite type processes. These reactions are carried out at room temperature. In contrast the chlorate based processes allow for 2 to 4 hours of retention time, or use multiple pass reactors such as described by Day et al, United States Patent No. 2,484,402, and operate at temperatures commonly exceeding 90°C. French patent 1,018,948 discloses a sodium chlorate based process for the production of chlorine dioxide involving aqueous hydrochloric acid reaction within an aqueous solution of chlorate at atmospheric pressure. The chlorate and aqueous acid are introduced concurrently in the reaction vessel. The reaction products are removed by causing a stream of air or inert gases saturated with water vapour to flow through the reactor. The reaction is however still slow and heat producing. The instant invention provides a process for the efficient and comparatively inexpensive production of high yields of chlorine dioxide. The process is useable on-site and reacts an aqueous solution of chlorate with a gaseous stream of an acid in a reaction column. The reaction product is primarily chlorine dioxide and is formed almost instantaneously. It is therefore an object of this invention to provide for a process where a chlorate solution and an anhydrous acid in gaseous form are mixed together under a vacuum prior to dilution in a water stream to form a mixture of chlorine dioxide and chlorine. It is another object of this invention to provide for a process where a sodium chlorate solution and anhydrous hydrogen chloride gas are mixed together under a vacuum prior to dilution in a water stream with a subsequent addition of sodium chlorite to form a product stream that is predominantly chlorine dioxide. It is a further object of this reaction to provide for a process where sodium chlorate is reacted with an anhydrous acid mixture where a substantial amount of the mixture is made up of anhydrous hydrogen chloride. Another object of this invention is to provide for a process where chlorine dioxide and mixtures of chlorine dioxide and other compounds are formed by the substantially instantaneous reaction of sodium chlorate with one or more compounds where the reaction takes place under vacuum prior to the addition of a substantial amount of dilution water. Yet another object of this invention is to provide for a process where one or more chemicals is reacted with chlorate in a reaction column with less than 5 minutes retention time to form chlorine dioxide or a mixture of chlorine dioxide and other oxidants. In accordance with the teachings of the present invention, there is disclosed a process for the rapid preparation of chlorine dioxide under reduced pressure, wherein an aqueous chlorate solution is mixed with a gaseous stream of an acid. A reaction column having a venturi tube therein is provided. The venturi tube has an inlet and an outlet. A reaction chamber is connected to the reaction column adjacent to the venturi tube. The reaction chamber is in fluid communication with the outlet of the venturi tube. Aqueous chlorate solution is introduced into the reaction chamber. The gaseous stream of acid is introduced into the reaction chamber concurrently with introduction of the chlorate solution. When these reagents are mixed, chlorine dioxide is rapidly produced within the reaction chamber. The chlorine dioxide is transferred to the reaction column at the outlet of the venturi tube and a driving medium is introduced into the inlet of the venturi tube such that mixing of the driving medium and the chlorine dioxide takes place in the reaction column at the outlet of the venturi tube. In a preferred embodiment, the chlorate is sodium chlorate, the acid is anhydrous hydrochloric acid and the driving medium is water. In another preferred embodiment, an aqueous chlorite solution is also introduced into the reaction chamber concurrently with the chlorate solution and the gaseous acid. In yet another preferred embodiment, an aqueous chlorite solution is introduced into the reaction column subsequent to mixing of the water with the chlorine dioxide. In still another embodiment, an aqueous chlorite solution is introduced into the driving medium. In a further embodiment, a second acid is introduced into the reaction chamber. These and other objects of the present invention will become apparent from a reading of the following specification, taken in conjunction with the enclosed drawings. Fig. 1 is a diagrammatical representation showing the reaction column in which the reagents are introduced to prepare chlorine dioxide Fig. 2 is an alternate embodiment of Fig. 1 showing the introduction of a chlorite solution into the reaction chamber. Fig. 3 is a further embodiment of Fig. 1 showing the introduction of a chlorite solution into the reaction column subsequent to the reaction chamber. The instant invention provides a continuous, low cost, rapid process for the production of high yields of chlorine dioxide for use in disinfecting, odor controlling, bleaching and industrial applications. A generator 10, similar to the reactor disclosed by Hicks is United States Patent No. 4,247,531, is used in the present invention. Referring now to Fig. 1, the reactor 10 includes piping or tubing having an inlet 12 for introduction of a driving medium 13 into the reactor 10. The driving medium 13 may be a fluid including a gas or a liquid such as water. The driving medium 13 enters the inlet of a venturi tube 14, passes through the outlet of said tube 14 and into a portion of a reaction chamber 15 which is in fluid communication therewith. A zone of reduced pressure is created by the flow from the restriction in the venturi tube into the larger chamber. Details of the reaction chamber 15 will be described later in the present application. The driving medium 13 intermixes with reactants present in the reaction chamber 15 and drives the reactants into a venturi throat 16, through the throat 16 and through the reaction column 17. The reaction chamber 15 includes the portion surrounding the outlet of the venturi tube 14 and extends outwardly therefrom. The major portion of the reaction chamber 15 includes a tubing or pipe connected adjacent to the outlet of the venturi tube 14. The reaction chamber 15 extends outwardly from the venturi tube 14 and has at least two inlet ports connected thereto. A first inlet port 20 has a means 21 for controlling introduction of a first reactant 22 into the reaction chamber 15. The controlling means also excludes, from the reaction chamber 15, environmental factors such as moisture, air, etc. The controlling means may be a check valve or other means known to persons skilled in the art. The second inlet port 25 also has a means 26 for controlling introduction of a second reactant 27 and for excluding environmental factors. The controlling means 20 is capable of controlling the introduction of liquids and/or gases. A cooling jacket 28 may be disposed about the reaction chamber 17 at a location between the venturi tube 14 and the inlet ports 21, 25 to moderate temperatures in the reaction chamber 15, if desired. The dimensions of the reaction chamber 15 permit intimate mixing of the first reactant 22 with the second reactant 27 and also permit expansion of the reaction products. The diameter of the piping in the reaction chamber 15 is small enough to insure good mixing and velocity but large enough to prevent a significant pressure difference between the venturi tube 14 and the inlet ports 20, 25. In a preferred embodiment, the first reactant 22 is an aqueous solution of sodium chlorate (NaClO₃) and the second reactant 27 is gaseous anhydrous hydrogen chloride. These react to produce chlorine dioxide in high yield. The reaction occurs almost instantaneously, in approximately one one-hundredth (0.001) to one-tenth (0.1) of a second. This rapid reaction is attributed to the use of the anhydrous gaseous acid and not to the temperature, pressure, reagent concentrations or turbulence of the mixing. The reaction also produces chlorine. The use of aqueous hydrogen chloride (hydrochloric acid) has been found to be ineffective in producing chlorine dioxide under the same conditions, even when the feed rate of the hydrochloric acid (HCl) is increased six fold. Increasing the feed rate of the anhydrous hydrogen chloride by a factor of 2 or 3 so that the mole ratio of sodium chlorate to acid increased from approximately 1:2 to a ratio of 1:2.5 or 1:3 did not significantly alter the percent yield of chlorine dioxide. The invention will be better understood by referring to the following specific examples, but it is not intended to be limited thereby. For instance, although the examples utilize anhydrous hydrogen chloride, other anhydrous acids such as sulfur trioxide (SO₃) may be used. EXAMPLE 1 A 40% w/w solution of sodium chlorate is fed into an inlet port to the reaction chamber at a rate of 94.0 kg (207 lbs.) per day of 100% NaClO₃. The external diameter of the chamber is 1.9 cm (3/4 inch) (d), and it has a length (1) prior to entrance of the venturi tube outlet of 0.9 m (36 inches). Also fed to the chamber concurrently with the sodium chlorate solution, and into a second inlet port, is a gas stream of anhydrous hydrogen chloride at a rate of 33.1 kg (73 lbs.) per day (Fig. 1). Based upon the chlorate feed, the theoretical capacity of the generator is 59.5 kg (131 lbs.) per day of chlorine dioxide. Based upon the anhydrous HCl, the theoretical capacity of the generator is 29.7 kg (65.5 lbs.) per day chlorine dioxide. Water flow (the driving medium) through the generator is 26.1 liters (6.9 gallons) per minute. After chemical feed commences, the generator is allowed to stabilize for 1 minute prior to sampling. Sample taken are immediately analyzed by the AWWA Standard method 4500-E-ClO₂ except with the addition that water flow is known, allowing for the calculations of mass yields. The effluent of the generator contains 565 ppm of chlorine dioxide, 483 ppm of chlorine, 1190 ppm of chlorate, 0 chlorite, and has a pH of 2.0. This corresponds to a production rate of 21.1 kg (46.8 lbs.) per day of chlorine dioxide. Based upon chlorate feed, this is a yield of 35.7%. Based upon the anhydrous HCl feed, this corresponds to a yield of 71.5%. EXAMPLE 2 (COMPARATIVE) EXAMPLE 1 is duplicated exactly except that 31% hydrochloric acid is substituted for the anhydrous HCl. A 40% w/w solution of sodium chlorate is fed into an inlet port to the reaction chamber at a rate of 94.0 kg (207 lbs.) per day of 100% NaClO₃. The external diameter of the chamber is 1.9 cm (3/4 inch) (d), and it has a length (1) prior to entrance of the venturi tube outlet of 0.9 m (36 inches). Also fed to the chamber concurrently with the sodium chlorate solution, and into a second inlet port, is a stream of 31% hydrochloric acid at a rate of 106.7 kg (235 lbs.) per day. Please refer to Fig. 1 for configuration of the generation unit. Based upon the chlorate feed, the theoretical capacity of the generator is 59.5 (131 lbs.) per day chlorine dioxide. Based upon the HCl, the theoretical capacity of the generator is 29.7 (65.5 lbs.) per day chlorine dioxide. Water flow (the driving medium) through the generator is 26.1 liters/min (6.9 gallons per minute). After chemical feed commences, the generator is allowed to stabilize for 1 minute prior to sampling. Samples taken are immediately analyzed by the AWWA Standard method 4500-E-ClO₂ except with the addition that water flow is known, allowing for the calculations of mass yields. The effluent of the generator contains 0 ppm of chlorine dioxide, 0 ppm of chlorine, and has a pH of less than 1.0. No reaction of any kind is observed. Even though the 31% hydrochloric acid feed rate is increased 6 times, no reaction is observed. EXAMPLE 3 A 40% w/w solution of sodium chlorate is fed into an inlet port to the reaction chamber at a rate of 91.7 kg (202 lbs.) per day of 100% NaClO3. The external diameter of the chamber is 1.9 cm (3/4 inch) (d), and it has a length (1) prior to entrance of the venturi tube outlet of 0.9 m (36 inches). Also fed to the chamber concurrently with the sodium chlorate solution, and into a second inlet port, is a gas stream of anhydrous hydrogen chloride at a rate of 47.7 kg (105 lbs.) per day (Fig. 1). Based upon the chlorate feed, the theoretical capacity of the generator is 58.1 kg (128 lbs.) per day chlorine dioxide. Based upon the anhydrous HCl, the theoretical capacity of the generator is 44.0 kg (97 lbs.) per day chlorine dioxide. Water flow through the generator is 26.1 liters (6.9 gallons) per minute. After chemical feed commences, the generator is allowed to stabilize for 1 minute prior to sampling. Samples taken are immediately analyzed by the AWWA Standard method 4500-E-ClO₂ except with the addition that water flow is known, allowing for the calculations of mass yields. The effluent of the generator contains 1010 ppm of chlorine dioxide, 780 ppm of chlorine, 570 ppm of chlorate, 0 chlorite, and has a pH of 1.9. This corresponds to a production rate of 38.2 kg (84.1 lbs.) per day of chlorine dioxide. Based upon chlorate feed, this is a yield of 65.6%. Based upon the anhydrous HCl feed, this corresponds to a yield of 87%. EXAMPLE 4 EXAMPLE 3 is duplicated except that the sodium chlorate solution is fed at a rate of 93.1 kg (205 lbs.) per day of 100% NaClO₃ and the gas stream of anhydrous hydrogen chloride is fed at a rate of 68.1 kg (150 lbs.) per day. The mole ratio of NaClO₃ to acid is 1:2. The effluent of the generator contains 1298 ppm of chlorine dioxide and 941 ppm of chlorine. Based upon the anhydrous HCl feed, this corresponds to a yield of 82.6%. EXAMPLE 5 EXAMPLE 3 is duplicated except that the sodium chlorate solution is fed at a rate of 93.1 kg (205 lbs.) per day of 100% NaClO₃ and the gas stream of anhydrous hydrogen chloride is fed at a rate of 79.4 kg (175 lbs.) per day. The mole ratio of NaClO₃ to acid is 1:2.5. The effluent of the generator contains 1332 ppm of chlorine dioxide and 1107 ppm of chlorine. Based upon the anhydrous HCl feed, this corresponds to a yield of 83%. EXAMPLE 6 EXAMPLE 3 is duplicated except that the sodium chlorate solution is fed at a rate of 94 kg (207 lbs.) per day of 100% NaClO₃ and the gas stream of anhydrous hydrogen chloride is fed at a rate of 95.3 kg (210 lbs.) per day. The mole ratio of NaClO₃ to acid is 1:3.0. The effluent of the generator contains 1374 ppm of chlorine dioxide and 1240 ppm of chlorine. Based upon the chlorate feed, as the limiting reagent, this corresponds to a yield of 87%. EXAMPLE 7 Increasing the size of the reaction chamber produced no significant effects. A 38% w/w solution of sodium chlorate is fed into an inlet port to the reaction chamber at a rate of 592.0 kg (1304 lbs.) per day of 100% NaClO3. The external diameter of the chamber is 3.8 cm (1.5 inch) (d), and it has a length (1) prior to entrance of the venturi tube outlet of 1.3 m (48 inches). Also fed to the chamber concurrently with the sodium chlorate solution and into a second inlet port, is a gas stream of anhydrous hydrogen chloride at a rate of 408.6 kg (900 lbs.) per day (Fig. 1). Based upon the chlorate feed, the theoretical capacity of the generator is 375.0 kg (826 lbs.) per day chlorine dioxide. Based upon the anhydrous HCl the theoretical capacity of the generator is 375.0 kg (826 lbs.) per day chlorine dioxide. Water flow through the generator is 227 liters (60 gallons) per minute. After chemical feed commences, the generator is allowed to stabilize for 1 minute prior to sampling. Samples taken are immediately analyzed by the AWWA Standard method 4500-E-ClO₂ except with the addition that water flow is known, allowing for the calculations of mass yields. The effluent of the generator contains 962 ppm of chlorine dioxide, 877 ppm of chlorine, and has a pH of 2.0. This corresponds to a production rate of 321.4 kg (708 lbs.) per day of chlorine dioxide. Based upon chlorate feed this is a yield of 85.7%. EXAMPLE 8 EXAMPLE 7 is duplicated except that the sodium chlorate solution is fed at a rate of 546.2 kg (1,203 lbs.) per day of 100% NaClO₃ and the gas stream of anhydrous hydrogen chloride is fed at a rate of 444.9 kg (980 lbs.) per day. The mole ratio of NaClO₃ to acid is 1:2.3. The effluent of the generator contains equals 927 ppm of chlorine dioxide and 718 ppm of chlorine. Based upon the chlorate feed, this corresponds to a yield of 87.7%. EXAMPLE 9 EXAMPLE 7 is duplicated except that the sodium chlorate solution is fed at a rate of 358.2 kg (789 lbs.) per day of 100% NaClO₃ and the gas stream of anhydrous hydrogen chloride is fed at a rate of 425.9 kg (938 lbs.) per day. The mole ratio of NaClO₃ to acid is 1:3.5. The effluent of the generator contains 540 ppm of chlorine dioxide and 602 ppm of chlorine. Based upon the chlorate feed, this corresponds to a yield of 77.9%. EXAMPLE 10 EXAMPLE 1 is repeated exactly except that nitric acid in the amount of a molar equivalent to the anhydrous HCl is also fed into the reaction chamber. Yield increased from 35%, based upon chlorate feed, to 56%, demonstrating a synergistic effect between the acids. A feed of nitric acid alone produced no reaction with the sodium chlorate. Although Example 10 provides for the introduction of nitric acid as the additional acid, other acidic materials may be used. These acidic materials include sulfuric acid, aqueous hydrochloric acid, phosphoric acid, acetic acid, alkali earth metal dihydrogen phosphate, metal dihydrogen phosphate, alkali earth metal monohydrogen phosphate, alkali metal earth monohydrogen sulfate and metal monohydrogen sulfate. The generator 10 was further modified as shown in Fig. 2 to provide a third inlet port 30 into the reaction chamber 15 very near or adjacent to the portion of the reaction chamber which surrounds the venturi tube 14. The third inlet port 30 has a third means 31 of controlling the introduction of a third reactant 32 into the reaction chamber 15 so that the third reactant 32 may mix with the first reactant 22, the second reactant 27 and the reaction products, prior to the mixing with the driving medium 13. This embodiment is further exemplified as follows wherein the third reactant is aqueous sodium chlorite and the effluent from the generator contains no chlorite. EXAMPLE 11 A 35% w/w solution of sodium chlorate is fed into an inlet port to the reaction chamber at a rate of 592.0 (1,304 lbs.) per day of 100% NaClO₃. The external diameter of the chamber is 3.8 cm (1.5 inch) (d), and it has a length (1) prior to entrance of the venturi tube outlet of 1.7 m (66 inches). Also fed to the chamber concurrently with the sodium chlorate solution and into a second inlet port, is a gas stream of anhydrous hydrogen chloride at a rate of 408.6 kg (900 lbs.) per day. An aqueous stream of 25% NaClO₂ is fed into the reaction chamber through a third inlet port at a rate of 495.3 kg (1,091 lbs.) per day of 100% NaClO₂ (Fig. 2). The theoretical capacity of the generator is 744.6 kg (1,640 lbs.) per day chlorine dioxide. Water flow through the generator is 227 liters (60 gallons) per minute. After chemical feed commences the generator is allowed to stabilize for 1 minute prior to sampling. Samples taken are immediately analyzed by the AWWA standard method 4500-E-ClO₂ except with the addition that water flow is known, allowing for the calculations of mass yields. The effluent of the generator contains 1,332 ppm of chlorine dioxide, 630 ppm of chlorine, and 0 ppm of chlorite. This corresponds to a production rate of 444.9 kg (980 lbs) per day of chlorine dioxide and a combined chlorate-chlorite yield of 60%. A further modification to the generator is shown in Fig. 3. An additional inlet port 40 is provided which is connected to the reaction column 17 at a point toward the end of the reaction column 17 downstream from the venturi throat 16. Included is an additional means 32 to control the introduction of an additional reactant 42 into the reaction column 17. The additional reactant 42 in the embodiment exemplified below is aqueous sodium chlorite. No chlorite is present in the effluent from the generator and the relative amount of chlorine produced is much less than in the embodiment in which no chlorite is used. EXAMPLE 12 EXAMPLE 11 is duplicated except that the sodium chlorite solution is fed at a rate of 1,736 lbs. per day of 100% NaClO₂ into the water stream downstream from the venturi throat. The water flow was 196.8 liters/min (52 gpm). The effluent from the generator contains 3,373 ppm of chlorine dioxide, 177 ppm of chlorine and 0 ppm of chlorite ion. Based on the anhydrous HCl feed, this corresponds to a yield of 96% of chlorine dioxide. EXAMPLE 13 EXAMPLE 12 is duplicated except that the aqueous sodium chlorate is fed at a rate of 494.4 kg (1,100 lbs.) per day of 100% NaClO3, the anhydrous hydrogen chloride is fed at a rate of 340.5 kg (750 lbs.) per day, and the aqueous sodium chlorite is fed at a rate of 485.5 kg (1,010 lbs.) per day of 100% NaClO₂. The effluent from the generator contains 2,090 ppm of chlorine dioxide, 35 ppm of chlorine and 0 ppm of chlorite ion. A yield of 87% of chlorine dioxide is obtained based on the combined sodium chlorate and sodium chlorite feed. The additional reactant such as a chlorite solution may also be introduced into the generator concurrently with the driving medium. Thus, an aqueous sodium chlorite solution may be used as the driving medium 13 and introduced into inlet 12 to the venturi tube 14. Thus, the present invention provides a highly efficient rapid process for production of chlorine dioxide with minimal amounts of by-products such as chlorine and chlorite. Because of the efficiency of the process, the present invention for production of six tons of chlorine dioxide is very small, occupying a volume of approximately 4.2 cubic meters (150 cubic feet). A 6 ton per day unit based on chlorite typically as disclosed by Hicks et al (U.S. Patent No. 4,247,531) occupies a volume of approximately 4.2 cubic meters (150 cubic feet) and a 6 ton per day unit based on chlorate as typically disclosed by Day et al (U.S. Patent No. 2,484,402) occupies a volume of approximately 396.5 cubic meters (14,000 cubic feet). The use of anhydrous hydrogen chloride is a major factor in the present invention and provides significant increases in the yield of chlorine dioxide over the prior art which used only aqueous hydrochloric acid. Thus, the present invention incorporates the advantages of small size, ease of use, rapidity of generation and low capital expenditures of the chlorite process with low cost of materials of the chlorate process.

Claims: A process for the rapid preparation of chlorine dioxide under reduced pressure, wherein an aqueous chlorate solution is mixed with a stream of an acid, characterized by the steps of providing a reaction column (17) having a venturi tube (14) therein, the venturi tube (14) having an inlet (12) and an outlet, a reaction chamber (15) being connected to the reaction column (17) adjacent to the venturi tube (14), the reaction chamber (15) being in fluid communication with the outlet of the venturi tube (14); introducing the aqueous chlorate solution into the reaction chamber (15), introducing the stream of acid being a gaseous stream of anhydrous acid into the reaction chamber (15) concurrently with introduction of the chlorate solution wherein chlorine dioxide is rapidly produced within the reaction chamber (15), transferring the chlorine dioxide to the reaction column (17) at the outlet of the venturi tube (14) and introducing a driving medium into the inlet (12) of the venturi tube (14) such that mixture of the driving medium and the chlorine dioxide takes place at the outlet of the venturi tube (14). The process of claim 1, further characterized in that the step of introducing the gaseous stream of acid is the introducing of a halogen acid. The process of claim 2, further characterized in that the halogen acid introduced is anhydrous hydrogen chloride. The process of claim 1, further characterized in that the step of introducing the driving medium is the introducing of a gas as the driving medium. The process of claim 1, further characterized in that the step of introducing the driving medium is the introducing of a liquid as the driving medium. The process of claim 1, further characterized in that an aqueous chlorite solution is introduced into the driving medium. The process of claim 1, further characterized by introducing a second acid into the reaction chamber (15). The process of claim 1, further characterized by introducing an aqueous chlorite solution into the reaction chamber (15) concurrently with the chlorate solution and the gaseous stream of acid and transferring the chlorine dioxide and the chlorite solution to the reaction column (17) at the outlet of the venturi tube (14). The process of claim 1, further characterized in that the step of providing the reaction column (17) includes providing the reaction column (17) having a first end and a second end, the venturi tube (14) being disposed near the first end of the reaction column (17), and introducing a chlorite solution in the reaction column (17) near the second end of the reaction column (17) wherein the chlorite reacts with any chlorine present to produce chlorine dioxide and a minimum amount of chlorine is present. The process of claim 1, further characterized in that the chlorine dioxide is produced in approximately one one-hundredth to one-tenth second.

Inventors: BECHBERGER EDWARD J, HILLIARD DICK L, MASON JOHN Y, MATCHIM DORMAN N, BECHBERGER, EDWARD J., HILLIARD, DICK L., MASON, JOHN Y., MATCHIM, DORMAN N.
Applicants: RIO LINDA CHEM CO INC, RIO LINDA CHEMICAL COMPANY, INC.
Application year: 1991
Main classification: C01B11
IPC codes: C01B11