Bleach plant scaling

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Barium sulphate scaling in the bleach plant

Sunday, May 13th, 2007

Barium sulphate is another problematic scale in the bleach plant. Barium enters the mill with wood/bark (especially hardwood) and water. Barium scaling depends on the kappa number, the pH and the concentration of Ba and SO4 in the bleaching stage. The problem of BaSO4 scaling has been observed when switching from chlorine to ECF bleaching. In the D0 stage, pH is controlled by the addition of H2SO4 or generator waste acid, thereby increasing the concentration of SO4. Scaling normally takes place in acid stage washers. Some BaSO4 scales contain radium sulphate; radium is a radioactive element which can be found in wood and ground water.

The solution to inorganic scaling is to reduce its source; i.e., have a wood supply low in metals (good debarking), control pH in the D0 stage, have good white liquor clarification, use good quality chemical make-up, use chelant or scale inhibitors and use treated water for showers. If scales have formed, the required removal measures are hydroblasting or chemical boil-outs.



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Oxalate scaling

Sunday, April 29th, 2007

In a kraft mill, large amounts of oxalate ions [C2O4]-2, are formed in oxygen delignification, as well as in the D, Z and, to a lesser extent, in the E and P stages in bleaching. In the bleach plant, CaC2O4 scales can form in the acid stage. CaC2O4 solubility depends on the concentration of the Ca, and the pH range, and it increases with temperature. Upset conditions, such as high lime mud carry-over with white liquor, can cause CaC2O4 scaling in the bleach plant. While CaC2O4 scaling was not a problem in chlorine bleaching at low pH, chlorine dioxide stages with a higher pH have encountered scaling problems. Oxalate scaling is also associated with the closure of the bleach plant, and has been reported in various bleaching stages, including the Q stage.

CaC2O4 is not expected to precipitate in the black liquor evaporators, since CaCO3 has a lower solubility in the evaporator environment and will precipitate instead. However, in a closed mill, where bleach plant filtrates are recycled to the recovery cycle, the possibility of Na2C2O4 scaling exists. Solubility data are available for Na2C2O4 and show that the solubility in black liquor depends on the temperature and the total Na concentration*. The recycle of bleaching effluent could double the amount of oxalate in the black liquor. Under normal operating conditions, when the dry solids content of black liquor are between 50-55%, burkeite (2Na2SO4.Na2CO3) starts to precipitate, reducing the concentration of Na and preventing the formation of sodium oxalate. However, when the amount of oxalate is increased due to the recycle of bleaching filtrates, the risk of Na2C2O4 scaling is increased. Since the solubility of Na2C2O4 increases with temperature, crystallization is expected to take place in the bulk solution and not on heat transfer surfaces. This could cause plugging problems in the evaporator tubes.

* Deposition of sodium oxalate in black liquor evaporation, P. Ulmgren and R. Radestrom, 2001, Int. Chem. Rec. Conf.



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Calcium carbonate scaling

Saturday, April 14th, 2007

Calcium contributes to scaling in various operations in a pulp and paper mill. CaCO3 is water insoluble, and has inverse solubility with temperature. Consequently, it forms on heat transfer surfaces such as digester heaters and black liquor evaporators. CaCO3 scales are also seasonal, and not easy to deal with. Calcium enters the mill through wood/ bark, chemical make-up and water. Depending on the type of wood, the method of pulping used and the efficiency of clarification for the white liquor, the calcium concentration can be high in the digester. Scaling is initiated when the concentration of free Ca and free carbonate exceed the solubility limit, to form calcite (CaCO3). In green liquor processing, where large amounts of Na2CO3 are present, pirssonite (Na2CO3.CaCO3.2H2O) forms.

Calcium can form water soluble compounds with components of black liquor. Many of these compounds are not thermally stable and break-up at high temperatures, resulting in supersaturation of CaCO3 in black liquor, which leads to scaling. The scaling tendency is high in the temperature range 110-140 C, where most evaporators operate. There is a patented method for calcium deactivation, in which black liquor is heated and stored at high temperatures to break up the calcium compounds and reduce scaling tendency

Calcium is purged with tall oil soap, the dregs, the grits and the pulp in the recovery cycle. CaCO3 scaling can also occur in bleaching in stages employing high pH. In the bleach plant, the acid sewer is rich in calcium and other metals. If acidic effluents are recycled to the recovery cycle, a metals removal system is required.



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