Evaporator scaling

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Review of sodium salt scaling in the recovery cycle

Monday, October 13th, 2008

I have covered this subject under different postings in the past [March and April 2007]. However, this is an up to date review with some new information regarding the nature of scaling in black liquor evaporators [1].

Sodium salt scaling takes place in black liquor [BL] evaporators, smelt dissolving tanks and green liquor lines. Scaling occurs when crystals nucleate from solution on pipe walls or heat transfer surfaces. In a solution containing no precipitated salt, nucleation occurs when the solution become supersaturated to the point where the metastable limit for the system is exceeded. The level of supersaturation depends on the solution, the process, the number of hetero-nuclei, the heating rate, the residence time and, sometimes, the shear rate [1]. Click to continue »



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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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Scaling of sodium salts in black liquor evaporators

Sunday, April 1st, 2007

Another area in a kraft mill which suffers from solubility problems is the evaporation of black liquor. Evaporator scaling problems are mostly due to the precipitation of sodium salts. The two important components are sodium sulphate and sodium carbonate; they precipitate together to form a range of double salts, including burkeite (2Na2SO4.Na2CO3). Sodium carbonate is another component of the scales formed. The solubility limit depends on the solids content, the total sodium content, the ratio of carbonate to sulphate, as well as the soluble organics and the operating temperature. Sodium carbonate content is influenced by the efficiency of causticizing, and the sodium sulphate content depends on the reduction efficiency in the recovery boiler and the sodium/sulphur make up. Other components such as Ca, Al, Si, fibre and soap also contribute to the fouling problem. For example, if the soap removal efficiency is poor, Ca scaling can be a problem.

Exessive scaling and frequent cleaning reduce evaporator capacity, and place a limit on the recovery boiler capacity. To prevent scaling, it is important to achieve a steady operation, to make sure that the evaporators always operate below the solubility limit of burkeite. To prevent precipitation on heat transfer surfaces, homogenous crystal nucleation in the bulk liquor is required.



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