CA2205493C - Method for production of sodium bicarbonate, sodium carbonate and ammonium sulfate from sodium sulfate - Google Patents

Abstract

The invention provides several processes for generating sodium carbonate compounds and ammonium sulfate in which the compounds are in a commercially viable and substantially pure form. In one embodiment, the process involves salting out sodium compounds in order to arrive at a high purity ammonium sulfate fertilizer.
Several different processes are disclosed which include sodium ion reduction by ion exchange, refrigeration, ammonia shifting and evaporation. The processes disclosed also relate to adaptation of the processes to flue gas desulfurization and gypsum production. The processes disclosed herein result in the production of ammonium sulfate in a purity previously unobtainable by prior art methods.

Description

M~THOD FOR PRODUCTION OF SODIUM BICARBONAI E, SODIUM CARBONATl~ AND AMMONIUM SULFATE~
PROM SODIUM SULFAT~

This is a div~sional appl.~ n of C~n~ n patent applir~ti~n colles~ n-ling to PCT/CA 96/00420 filed June 21, 1996.

This invention relates to a process for generating sotlillm calbonate compounds and ~mmonillm sulfate in a commercially viable and sul,sl~ lly pure form.

Several processes have been developed to m~nllf~rt~re aL~i metal c~l~ate and v~iu~ sulfate co~..pQ.~r-l~L~ Thesc metho~3C have ~liffl~-ulty in ~l~]U~ g ~...~ P.~I~c which are in pure or near pure state for commercial use.

Stiers, in U.S. Patent No. 3,493,329, issued r~l Ual~ 3, 1970, te~-rhes a methodof m~kir~ SO lillm c~l.o~tG. The Stiers method is a co-~rec~ A~ method and cannot provide for selective ~re~ Jil~l;Qn of desired products since the salts are rec;p~cal salts and form a double salt. In the Stiers metho(l) the desire is to remove the sulfate anion to use it for the llan~pol~tion of 50.1;....~ c~ti~n~ from sodium chlori~le to the bic~t~l-up p~ocess as so~ m slllf~te. In ~d~lih~n to the above, the Stiers process involves the coillilluous re~ g of the mother liquor which requires that the ~mmr~illm sulfate in the liquor be cQ..~ ously removed or reduceA from the process stream. - If the ~mm-~nium sulfate reaches a s~lul~tion point in the bicall,o.~A~ e stage, A.. o.~iulll sulfate will co-~lec;p;l~te with the sodium sulfate in the form of a double salt compound or two inseparable salts.

Stiers rlemQ.~ ates a process to generate two salts and double salts rather thana pure single salt, the latter being much more desirable from a comm~rcial point of view.

The present invention is dilected to ci~i..lllvenling the previously encounterediffiCllltieS of ~ciproc~til~ salt pairs.

CA 0220~493 1997-06-18 More recent attempts have been made to develop methods for producing sodium bicarbonate and ammonium sulfate from sodium sulfate in substantially pure quality such that these products can be used as commercial grade baking soda, and fertilizer.

Canadian Application Serial Number 2,032,627 offers an innovative technique to produce the desirable pure products. This method employed a number of evaporative and cooling techniques to alter the solubility of sodium sulfate andammonium sulfate in solution and selectively precipitate the desired pure components.
Lab bench scale batch testing of this method demonstrated effective results, however, continuous pilot scale testing clearly identified undesirable limitations to the process as specified. More specifically, the process is difficult to operate in a consistent and continuous mode and as such is highly susceptible to ammonia sulfate contamination with sodium sulfate, resulting in a commercially undesirable double salt product.

In greater detail of the teachings of the Canadian application, it is taught that brine remz~ining after screening sodium sulfate has a temperature of 95~C and issaturated with both sodium and ammonium sulfate and that by cooling the mixture of both brines in a crystallizer from 95~C to 60~C, the solubility of ammonium sulfate is decreased while the solubility of sodium sulfate increases. The result is that more ammonium sulfate precipitates while keeping sodium sulfate in solution.

By following the teachings, the mixed solution is supersaturated with sodium sulfate due to evaporations at 95~C and specifically results in the production of double salt when the ammonium sulfate crystallization step of 60~C is attempted as a continuous process.

The processes of the present invention have applicability in the fertilizer, refinery, environmental and chemical engineering industries.

CA 0220~493 1997-06-18 One aspect of the present invention is to provide an improved process for the recovery of substantially pure sodium bicarbonate and ammonium sulfate suitable for commercial purposes. Another aspect of the present invention is to provide a process for use on a continuous commercial scale which overcomes inherent difficulties with product contamination.

A further aspect of one embodiment of the present invention is to provide a process for producing sodium bicarbonate and sodium carbonate, which process comprises:
reacting within a reactor sodium sulfate in aqueous solution with ammonia and carbon dioxide to precipitate sodium bicarbonate and form a first mother liquor;separating the sodium bicarbonate and drying it to produce sodium bicarbonate product or calcining it to convert it to sodium carbonate;
subjecting the first mother liquor from the precipitation of the sodium bicarbonate to evaporation to precipitate unreacted sodium sulfate, forming a second mother liquor;
cooling the second mother liquor from the precipitation of the unreacted sodium sulfate to precipitate a double salt of sodium sulfate/ammonium sulfate and water, forming a third mother liquor;
subjecting the third mother liquor from the precipitation of the double salt to evaporation to precipitate a substantial pure ammonium sulfate in a purity of greater than a~luxhllately 73 wt%, forming a fourth mother liquor;
adding the double salt to the first mother liquor from the precipitation of sodium bicarbonate prior to the evaporation; and adding the fourth mother liquor to the second mother liquor from the evaporation to precipitate unreacted sodium sulfate.

A process of selectively precipitating sodium bicarbonate and ammonium sulfate from a sulfur compound containing sodium, wherein the process comprises the steps of:

~ CA 0220~493 1997-06-18 (a) providing a source of a sulfur compound containing sodium;
(b) contacting the compound with carbon dioxide gas and ammonia or ammonium ions to generate a solution;
(c) maintaining the solution at a temperature sufficient to form a single precipitate of sodium bicarbonate to reduce the amount of aqueous sodium ions without precipitation of competing sodium precipitates;
(d) removing the sodium bicarbonate precipitate from the solution;
(e) removing sodium sulfate; and (f) precipitating ammonium sulfate.

By controlling temperatures and pressures, once a bicarbonate precipitate is formed, the filtrate may be subjected to a purification step wherein the rem~ining sodium ions are substantially removed or made to be held in solution prior to the precipitation of ammonium sulfate. This results in a cleaner precipitate of ammonium sulfate and therefore results in a more commercially desirable product, which product exceeds purity measures not previously encountered with the prior art processes. In a purification possibility, the filtrate may be supersaturated with ammonia in aconditioning reactor which operates at a substantially cooler temperature, for example, 7~C. This is one example of an appropriate temperature, a suitable range is between about 20~C to about -40~C. This procedure results in the formation of a mixed salt of ammonium sulfate and sodium sulfate, both of which are insoluble at this temperature and this excess of ammonia. Once precipitated, the filtrate, therefore having a lower concentration of sodium cations inherently leads to a less contaminated precipitated ammonium sulfate.

Several different processes are possible which include sodium ion reduction by ion exchange, refrigeration and evaporation among others. These will be discussed hereinafter. The processes disclosed also relate to adaptation of the processes to flue gas desulfurization and gypsum production. The processes disclosed herein result in CA 0220~493 1997-06-18 the production of ammonium sulfate in a purity previously unobtainable by prior art methods.

Desirable results have been obtained when the conditioning step increases the ammonium concentration from about 10% to about 50%. The mixed salt precipitate, double salt or pure sodium sulfate may be recycled back into the original feed stream with the source of sodium sulfate.

It has been found that by mAking use of the basic bicarbonate recovery process, that the process can be augmented for additional fields of utility, for example, tail gas desulfurization. This has been broadly indicated hereinabove with respect to thedesulfurization of the acid gas stream.

Flue gas desulfurization hereinafter FGD, an example of which employs dry sorbent is generally known in the art. This employs the use of sodium bicarbonate typically for 10% to 90% sulfur component reduction. The bicarbonate is initially calcined by the flue gas heat, which is typically in the range of 350 F to 750 F, to sodium carbonate. This then reacts to form sodium sulfate. Because the sorbent is dry, finely ground powder, there is no negligible cooling effect with the flue gas and as such, the stack temperature can be maintained for emission dispersion. Also, the sodium sulfate may be recovered in a baghouse or an electrostatic precipitator with or without the flyash. The sorbent must be processed to a fine particle size, typically 15 ,um and then must be stored under dry conditions to prevent holdup and enhance manageability of the dried sorbent in silos and other equipment.

A further embodiment of the present invention is directed to a process which can utilize a wet scrubbing system and eliminate the corrosion problems, landfill problems and other handling difficulties associated with lime.

CA 0220~493 1997-06-18 The method may employ either bicarbonate or carbonate or a mix thereof. As a further advantage, the process according to the present invention eliminates the drying and sizing step previously encountered in prior art methods.

Furtherstill, utility has been found in application of the overall procedure in m~king gypsum, for example, of a commercial or landfill grade. By adding lime into the saturated solution of ammonium sulfate, ~y~um can be removed as a precipitate.

By practicing the above method, it has been found that selective precipitation of the single salts at high level of commercial purity is achievable on a continuous basls.

The process is further enhanced by providing an ammonia and carbon dioxide chemical recovery scheme for minimi7ing the chemical consumption to enhance commercial viability. It has been further found that by m~king use of the basic bicarbonate recovery process, that the process can be used for additional fields of utility, for example tail gas desulfurization, flue gas desulfurization by wet or dry sorbent injection techniques and further application for m~king commercial or landfill grade gypsum and fully recovering the ammonia chemical.

Having thus described the invention, reference will now be made to the accompanying drawings illustrating preferred embodiments and, in which:

Figure 1 is a graphical representation of the solubility of sodium bicarbonate, ammonium sulfate and sodium sulfate expressed as pure components in solution at various temperatures;
Figure 2 is a flow chart illustrating the preparation of saturated sodium sulfate brine from the natural sodium sulfate source known as Glaubers salt and from a by-product sodium sulfate source;

CA 0220~493 1997-06-18 Figure 3 is a flow chart illustrating the sodium bicarbonate production unit andgas recovery scheme;
Figure 4 is a flow sheet illustrating the separation scheme for production of ammonium sulfate fertilizer in both the liquid and solid crystal form;
Figure 5 is an alternate embodiment illustrating how the process can be adapted to Tail Gas Desulfurization scheme;
Figure 6 is a further alternate embodiment of the process set forth in Figure 5;Figure 7 is a flow sheet that illustrates how the process can be adapted to regenerate sodium bicarbonate from captured sodium sulfate in a FGD scheme usinga Dry Sorbent Injection (DSI) technique;
Figure 8 is an alternate embodiment illustrating how the process can be adapted for use in a Wet Scrubbing Flue Gas Desulfurization scheme to regeneratethe sodium bicarbonate from the captured sodium sulfate solution;
Figure 9 is a further embodiment by which the process can be adapted to produce gypsum and fully recover the ammonia chemical;
Figure 10 is a flow chart illustrating one possible process route for effecting the method according to the present invention;
Figure 11 is an alternate embodiment of Figure 2;
Figure 12 is an alternate embodiment of Figure 2;
Figure 13 is a further alternate embodiment of the process as set forth in Figure 2;
Figure 14 is a still further alternate embodiment of the process of Figure 2 illustrating a tail gas treatment;
Figure 15 is a further alternate embodiment of the process as set forth in Figure 6 illustrating an acid gas treatment;
Figure 16 is a further alternate embodiment of the process where gypsum is produced;
Figure 17 is yet another embodiment of the process according to the present invention illustrating a scrubbing process;

CA 0220~493 1997-06-18 Figure 18 is a schematic illustration of the overall process using an ion exchange unit operation;
Figure 19 is a schematic illustration of the overall process using an ion exchange unit operation and a feed conditioning operation;
Figure 20 is an alternate of the schematic illustration shown in Figure 19; and Figure 21 is a schematic illustration of the overall process in which a refrigeration unit operation is provided.

Similar numerals in the drawings denote similar elements.

The chemistry involved according to the present invention can be resolved into the following equations:
CO2+ H2O ~ H+ + HCO3-NH3 + H2O ~ NH4+ + OH-Na2SO4 + 2NH3 + 2H2O + 2CO2 ~ 2NaHCO3 + (NH4)2SO4 Referring now to Figure 1, shown is a graphical representation of the solubilitycurves for pure components including sodium bicarbonate, ammonium sulfate and sodium sulfate. The data are expressed as a function of solution temperature. As is evident from the drawing, the solubility of the bicarbonate and the sodium sulfate have an overlapping area in which there will be a precipitation of both of these compounds.
As indicated herein previously, the zones where solubility values are in conflict and the interaction effects of the mixed solution solubilities have posed a significant amount of difficulty in the prior art when one was attempting to obtain a substantially pure precipitate of sodium bicarbonate and ammonium sulfate without the formation of a sodium sulfate precipitate, double salts, hydrated salts or any mixed combination.

It has been found that if one simply obeys the solubility data, sodium bicarbonate and ammonium sulfate can be precipitated from a solution containing the CA 0220~493 1997-06-18 -molecular species indicated hereinabove without contamination of one precipitate with the other and further without the simultaneous precipitation of the sodium sulfate and double salts as a cont~min~nt.

If the sodium bicarbonate solution is maintained at a temperature sufficient to prevent sodium sulfate precipitation. In view of the data in Figure 1, sodium bicarbonate can be precipitated while the unreacted sodium sulfate remains in solution. If the temperature drops prior to the precipitation of the sodium bicarbonate, a precipitate of sodium sulfate solvate or decahydrate will plate out of solution offering tremendous operating difficulties.

In a chemical system as set forth with respect to the above equations, the system is generally a complex quaternary system, having a reciprocal salt pair relationship as follows:

2(NH4)HCO3 + Na2SO4 r' 2NaHCO3 + (NH4)2SO4 In aqueous solutions above a~roxilllately 30~C ammonium bicarbonate is unstable and dissociates in solution as ions. This reduces the system to a complex tertiary system with complications related to hydrate and double salt formation.

The first step in the process is to complete the reaction to drive the equilibrium in the final equation such that the substantially pure sodium bicarbonate crystals are formed. As is well known in the art, numerous possible methods can be practiced for contacting the ammonia and the carbon dioxide with the sodium sulfate solution. As an example, the ammonia may be introduced into a solution of the sodium sulfate and carbon dioxide dispersed through the solution or the carbon dioxide dispersed through the saturated sodium sulfate solution and the ammonia subsequently added or bothcomponents may be dispersed through the solution simultaneously. Another possible CA 0220~493 1997-06-18 -alternative includes the use of ammonium carbonate or ammonium carbonate compound.

Referring now to Figure 2, shown is one possible process route according to the present invention. A natural source of sodium sulfate can be found in vast reserves of Glaubers salt (sodium sulfate decahydrate). Figure 2 schematically illustrates a mechanism of concentrating and conditioning the sodium sulfate feed brine from Glaubers salt feed stock. The process is globally referenced by numeral 120.

In greater detail, Figure 2 shows the basic scheme by which sodium sulfate by-product can be introduced to the process. As an example, flyash, from commercial steam boilers containing various levels of sodium sulfate may be collected from hot flue gas streams and transferred into a collection silo 10. From silo 10, the flyash can be separated by commercially known dry or wet methods, globally indicated by 12, whereby the material may be transferred into an atmospheric mixing container 14, which container 14 is maintained at a temperature from between about 32~C and 42~C. Coarse insolubles, e.g. rocks, sand clay fines, are separated at 16 and 17. Finer material is flocculated and separated from the sodium sulfate solution once passed through a clarifier 18. The final brine or filtrate, represented by numeral 40, is then further clarified and further filtered by filters 19, if necessary, to polish the solution free of ultra-fine insolubles and potential heavy metals. Insolubles are removed and disposed of by suitable means. Heat energy is typically applied to the melting tank 22.
Evaporation may also be required in tank 22 to achieve a sodium sulfate concentration at the desired maximum solution solubility. Circulating pump 24 is required to prevent the formation of encrustations in the sulfate brine preparation unit by reducing the temperature increase of the circulating melt solution.

One of the main difficulties previously encountered in the prior art, was that the temperature of the sodium bicarbonate formation reaction was not maintained within the above-mentioned parameters. The result of this is the formation of a CA 0220~493 1997-06-18 solvate or hydrate commonly referred to as Glaubers salt (Na2SO4- 10H2O) and theformation of ammonium bicarbonate. By maintaining the temperature within the above-stated range, these compounds do not form and therefore do not affect the sodium bicarbonate formation process. In addition, at this temperature, a maximum amount of salt can be put in solution which reduces the feed circulation rate required of brine 40.

With reference to Figure 3, once the insolubles have been removed by the clarifier and filters, and the brine 40 is concentrated to its highest salt saturation level, the solution or brine 40 is presaturated in tank 42 with ammonia and carbon dioxide and then is passed, for example, pumped by pump 41, into at least a first main reactor 44 or multiple reactors where the formation of the sodium bicarbonate occurs. The temperature within the reactor 44 may vary depending on the reactor configuration.
The final temperature of the solution will be progressively reduced to about 21~C with the brine feed temperature to the reactor 44 being maintained above 32~C. The final temperature of the solution m~imi7es the bicarbonate yield and prevents cont~min~tion with Na2SO4. Pressure in reactor 44 will preferably be maintained at approximately 350 kPa(g) to approximately 1750 kPa(g). Although not essential, this ensures the ammonia remains dissolved in solution. A crystallizer 46 may be included downstream to effect crystallization of the sodium bicarbonate. Once the crystals have formed, they may be removed from the reactor 44 and/or crystallizer 46 through afilter means 48 which may comprise a pressure or non-pressure-type filter. Once the crystals are removed, they may be passed to a further filtration medium (not shown), an example of which may be a filtration screen or rotary centrifuge device (not shown), at which point the formed crystals may be washed with saturated sodium bicarbonate brine or methanol as indicated at 50 and dried with dryer 54 or calcined to form sodium carbonate. A high yield is achievable. The wash may be then returned via line 52 to the mixing container 14. The formed bicarbonate crystals, denoted by 56, may be then removed from the system for further uses.

CA 0220~493 1998-04-28 The filtrate or brine 58 from the first reactor 44 is reheated to appln~ tely 80~C to 95~C in a gas recovery boiler 60, where reactivated ammonia and carbon dioxide ga~es are rele~-ce~l from the brine. The gases are routed to a gas recovery contactor 62 where they are subjected to the raw sodium sulfate feed brine and absorbed into solution to ~iesalul~te the feed 41 to the bicarbonate reactor 44. This process reduces the chemical c~ plion requirements.

The filtrate solution, denoted by numeral 64, in Figure 4 is subjected to a first evaporation step at a temperature of, for ~Y~mple, greater than 59~C in evaporator 66 to condition the brine by red-lcin~ the level of unreacted and residual sodium ion in the solution. As the saturation level of the brine is obtained, sodium sulfate cryst~ from the solution before the saturation level of ~ on;wll sulfate or double salt is achieved. The sodium sulfate crystals are filtered at filter 68 from the first evaporation brine and washed and dried as sodium sulfate product of high purity or recycled as indicated by 70 as feed stock.

The ~lltrate 70 from the first evaporation for brine conditioning is then cooledto app~ tely 20~C where cryst~lli7~tion of sodium sulfate and ~mmonium sulfate occurs in the form of a hydrated double salt (Na2SO~-(NH4)2SO4-4H20) or double salt/pure salt mix in crystallizer 72. The double salt crystals are filtered by filter 74 from the cooled brine and redissolved into the first evaporator feed brine 64 via line 76. At this point the brine 77 obtained after filtering off the double salt, cont~in~
~igni~ntly reduced levels of sodium to effect concentration and/or cryst~lli7~ion of sub~ lially pure ammonium sulfate as a solid or liquid form. This product may bethen removed from the system via line 88 as a liquid and stored in vessel 90 or transferred to a fertilizer evaporator 78 or crystallizer 80 to be transferred to the solid crystal form.

If a solid crystal form is desired, then the near saturated ammonia sulfate brine is exposed to a final evaporation step with step in cryst~lli7er 80 to precipitate out the CA 0220~493 1997-06-18 ammonium sulfate in a substantial crystal size and purity of greater than 73 wt%, allowing it to be immediately used as agricultural fertilizer. The crystals are filtered with filter 82. The saturated filtrate solution from the second evaporation step is recycled via line 84 to mix with the feed brine 77 to the double salt cooler/ crystallizer to further enhance the concentration process. The filtered crystals may then be dried with dryer 86.

Advantageously, a liquid fertilizer stored in vessel 90, which may be heated, affords the user the opportunity of blending the liquid product with other fertilizer components and further permits crystallization of the product as a mixed desired form.
The liquid in vessel 90 may optionally be subjected to further evaporation and concentration to create a supersaturated fertilizer solution.

Although the process as discussed herein has been indicated to be primarily conducted in water, it will be understood by those skilled in the art that any suitable solvent can be used provided the choice of solvent does not vary the solubility relationship necessary to effect the process. As alternatives, glycol or glycol/water mixtures may be employed as the solvent.

With further reference to Figures 3 and 4, the overall process may include an additional washing step for washing the sodium bicarbonate and ammonium sulfate precipitates separately. In one possible configuration, the sodium bicarbonate which is formed in the reactor, may be passed into contact with a washing material, anexample of which may be a source of methanol. The resulting filtrate may then bereturned to a separation container. Similarly, the ammonium sulfate crystals, may be passed through a second independent source of methanol with the filtrate being returned to a separation container. The ammonium sulfate crystals and bicarbonate can be used for further uses.

CA 0220~493 1997-06-18 Figure S shows a variation on the process where the bicarbonate recovery systems as set forth herein previously can be combined to be useful in a sulfur recovery plant. Generally speaking, the area designated by numeral 100 in Figure S
illustrates conventional apparatus employed for sulfur recovery from an acid gasstream by employing the modified Claus process, consisting of a single or multiple variation of thermal and catalytic recovery steps. Generally, the Claus process includes a feed of acid gas, globally denoted by numeral 102, which is passed into a container numeral 104, for removal of sour water. The stream is then passed into a reaction furnace and waste heat exchanger, denoted by numeral 106, where the thermal conversion occurs. The stream is then passed into a first catalytic stage conversion system, numeral 108, and subsequently into a further conversion, denoted by numeral 110 which may comprise "n" stages. Liquid sulfur is removed from the stages at 112. The stream is reheated and passed into a mixing unit 114 and thenfurther into a collection device 116, which may comprise an electrostatic precipitator or baghouse. The solids from the collection device 116 are passed into a silo 118 and subsequently into a feed preparation on it specifically set forth as Figure 2 at tank 16.
From the feed preparation tank 16, the feed is processed in accordance with the bicarbonate recovery system, globally denoted by numeral 122 and specifically set forth in the description for Figure 3. The produce may then be transferred into a fertilizer recovery unit 124, the details of which have been set forth in the description for Figure 4. The resulting product is commercial grade fertilizer. As an option, the sodium bicarbonate feed from the bicarbonate recovery unit 122 may be passed into a drysorbent injection unit 126 and the bicarbonate then reintroduced into the system via line 128.

It is well known to those skilled in the art that the Claus process is useful for desulfurization. Generally speaking, the process is effected in two steps, namely:

CA 0220~493 1997-06-18 H2S + 2 ~2 ~ H20 + S~2 2H2S + SO2 T 2H2~ + XSX

This generally results in an elemental sulfur recovery of a~proxilllately 90% to96% in a liquid sulfur state. The rem~ining sulfur containing component is recovered in sulfur recovery techniques such as tail gas cleanup units. By employing the recovery process as set forth herein previously, sodium bicarbonate can be introduced into the oxidized tail gas stream containing residual sulfur compounds and results can therefore be the production of ammonium sulfate as indicated in Figure 5. By combining themodified Claus process with the processes as set forth herein, the result is the overall sulfur removal of the order of at least 95% or greater.

Turning to Figure 6, shown is a variation on the process in Figure 5, but for a lower volume production sulfur plant, typically having production levels of less than 10 tonnes per day (MTD) where economic constraints preclude the recovery of elemental sulfur as shown in Figure 5.

The acid gas stream may be as an alternative directly treated with liquid sodiumbicarbonate or carbonate solution for desulfurization and form an alternate sulfur product.

In Figures 7 and 8, shown are variations on the overall processes according to the present invention.

With more specific reference to Figure 7, there is illustrated an effective scheme whereby the recovery process as set forth herein, can be employed to regenerate dry sodium sulfate captured from a particulate collection device 150 such as an electrostatic precipitator or baghouse and produce sodium bicarbonate to be injected into the flue gas stream to primarily reduce sulfur components from sulfur CA 0220~493 1997-06-18 sources such as an industrial boiler 180 and released by means of a stack 152. The practice of injecting a dry chemical into the hot flue gases is commonly referred to as DSI. By adapting the recovery process, discussed with respect to Figure 3, to the DSI
technique, the overall scheme becomes a continuous regenerable process with no waste streams or landfill requirements, no appreciable losses, and all by-products are immediately commercially useable. Using dry sodium bicarbonate as the reagent offers the additional advantages of further recovery of other undesirable components such as N OD H C1 and SO3 from the flue gases, and improve the performance of the downstream collection device 150 (i.e. ESP or baghouse). The dry sorbent technique in addition, will not appreciably affect the temperature of the flue gases, thereby maintaining or improving the effluent emission dispersion from the stack 152.

The sodium sulfate containing flyash compound is transferred from the collection device 116 and stored in a silo 118 (Figure 6) and blended into the feed preparation tank 16 of the process denoted by 120 (Figure 6). The feed is processed in the bicarbonate recovery system 122 and the sodium bicarbonate is passed into a dry sorbent injection unit 126 and reintroduced into the system via line 128. By-product from the bicarbonate recovery unit 122 is transferred to the fertilizer recovery unit 124, the resulting product is commercial grade fertilizer.

Figure 8 illustrates a scheme by which the process can be modified to produce a specific sodium carbonate or bicarbonate mixed or pure solution which can be adapted for use in a wet scrubber. Flue gas from the industrial boiler or tail gas unit, globally denoted by numeral 180, iS passed onto an electrostatic precipitator orbaghouse 182 or other recovery device to remove flyash at 184. A water wash container 186 is provided to circulate wash water in a single or multi level upper section of a wet scrubber 188 and accumulated levels of precipitates and fluids are drawn off and passed to the lower section of the wet scrubber 188. Separate vessels may also be employed to effect the desired result. Once sodium sulfate at the desired concentration level is collected from the bottom of the wet scrubber 188 as a product CA 0220~493 1997-06-18 of the scrubbing procedure, it is then further transferred to feed preparation tank 190 for thickening and clarification to a saturated state for feeding into reactor 20 (not shown) from the bicarbonate recovery unit, globally referenced as 122 and shown as Figure 3. From the reactor in the bicarbonate recovery unit 122, sodium bicarbonate is filtered from the solution and washed in either open screen, pressure type orcombination of these (generally shown at 48 in Figure 3). The bicarbonate precipitate is washed and reduced to less than 10% liquid and then fed as a slurry into a bicarbonate slurry container 96 at appr~ llately 700 kPa(g). At this point, the bicarbonate slurry in container 96 is mixed with clean water supplied to container 96 from a feed water supply container 98. The feed water is maintained at a temperature of approximately 48~C. The slurry is continually mixed and ranges in a concentration from about 20 wt% to about 40 wt%. The slurry is then transferred to a high pressure solution container 200 at a pressure of a~lu~inlately 1050 kPa(g), where a saturated solution is formed. A saturated bicarbonate solution is created using additional feed water from container 98 which is heated to appr~ ately 176~C by an injection water heater 102. The final saturated concentrated solution is then injected into wet scrubber 188 by means of line 201 for sulfur dioxide removal.

The temperature, pressure and concentration of reagent in the final injection solution can be varied to control the level of SO2 removed, the desired pH of the system solutions and the final flue gas temperature exiting the wet scrubbing process.
As a further example, the pressure of the injection system can be reduced to near atmospheric conditions prevalent in the wet scrubber 188. The temperature can then be reduced to near 49~C to eliminate water heater 102 and the high pressure reactor 200. This will result in a cooler final flue gas temperature resulting from the evaporative cooling effect which may or may not be detrimental to any specific application.

It will be appreciated that the wet scrubber 188 can take any form of contactingthe reactant solution with the sulfur containing flue gas, for example, spray dryers, etc.

CA 0220~493 1997-06-18 Further, the sodium carbonate or other suitable sodium compounds can be used as a replacement or combined in various ratios with sodium bicarbonate to effect or enhance the wet and dry scrubbing techniques. The conversion can easily be accomplished by calcining the bicarbonate in a dry form or by increasing the temperature in a liquid form to alter the bicarbonate to carbonate form. The carbon dioxide used in the process can be recovered in a recovery process as set forth herein.

Turning to Figure 9, showing schematically is a further embodiment according to the present invention. The embodiment shown, a lime mixing container 70 is provided for retaining lime in any form, e.g. a slurry or powder form to be introduced into reactor 202 via line 71. By providing this addition to the recovery unit, commercial or landfill gypsum can be produced along with sodium bicarbonate as illustrated in the flow chart in Figure 9. As a further feature, the arrangement shown may include ammonia recovery unit 204 which will include the usual gaseous recovery means well known to those skilled in the art. This is useful since the ammonia is liberated subsequent to precipitation of gypsum and therefore can be easily recovered and recycled into the process for sodium bicarbonate production.

As a consequence of reactor, evaporator and crystallizer vessel size, temperature stratification may exist within the reactors and evaporators as set forth herein or the cryst~lli7ing vessels used to enhance the crystal growth, stability and yield. In order to avoid undesirable effects caused by hydrate or solvate precipitation in large vessels, the process can be performed in multiple vessels to circumvent these difficulties.

Referring now to Figure 10, shown is one possible process route according to the present invention. A source of sodium sulfate, such as flyash, for example, from commercial steam boilers containing various levels of sodium sulfate may be collected from hot flue gas streams and transferred into a collection silo, globally denoted by numeral 10 in the drawings. From the silo, the flyash may be transferred at a CA 0220~493 1997-06-18 controlled rate into an atmospheric mixing container 12, which container is maintained at a temperature from between about 32~C and 42~C. The light and heavy insolubles are removed in a slurry form from the mixing container 12 at 14. The brine or filtrate is then transferred to a clarifier 16 and further filtered if necessary to polish the solution free of fine insolubles. Fine insolubles are removed from the clarifier at 18.

Once the insolubles have been removed by the clarifier 16, the solution or brinewhich contains a small percentage of ammonia is passed into a first main reactor 20 where the formation of the sodium bicarbonate occurs. The final temperature of the solution will be progressively reduced to about 21~C with the brine feed temperature to the reactor being maintained above 32~C. Pressure in reactor 20 will preferably be maintained at appru~illlately 0 kPa to almost 1750 kPa to ensure the ammonia remains in solution to effect the reaction. A crystallizer may be included downstream to effect crystallization of the sodium bicarbonate. Once the crystals have formed, they may be processed as set forth with respect to Figure 3 via filtration screen 24.
The wash may be then returned via line 26 to the mixing container 12. The formedbicarbonate crystals may be then removed from the system via line 28 for further uses.

The filtrate or brine from the first reactor is reheated back to a~ o~ lately 32~C. The solution is maintained at a temperature of at least 32~C and then passed into reactor 32. Once in reactor 32, the brine solution is subjected with excessammonium at a concentration of approximately 20 weight percent.

The pressure in the reactor is carefully controlled by varying the injection of ammonia (approximately 450 kPa) thereby controlling the desired concentration ofexcess ammonium. In reactor 32, the injection of the solution with ammonia shifts the equilibrium solubility of the solution of the reaction, denoted hereinabove, to favour the formation of ammonium sulfate precipitate. The temperature in the reactor ismaintained at 32~C to keep free sodium cations soluble and to prevent contamination of the ammonium sulfate with undesirable solvates. When desired, the ammonia CA 0220~493 1998-04-28 concentration can be altered by ch~nging the ~res~le control. Similar to the descri~lion for reactor 20, reactor 32 may include a crystallizer dowl~sl~eam to effect the formation of ammonium sulfate crystals. Once formed, the crystals may be passed onto a ~)leSSUl'C filter medium 34 and washed with suitable wash. The so-formed ~mm-~nium sulfate crystals can then be removed by line 36 for further uses. The wash may be retumed to the mixing co~ 12 via line 38 for filrther uses. The ammonium c~ g filtrate lG~ .i.,e after the precipilalion of the ~mmQnium sulfate crystals, may be flashed off, compressed and condensed and collected in to a surge drum 40as is known in the art. Once collected, the ammonia solution may be used for jeclion in the system.

The final recovered solution, containing soluble levels of ammonia can be re~led to the mixing container 12 to complete the con~il-uous operation.

By practising the above method, a purity of ammonium sulfate greater than 50% by weight is achievable.

Advantageously, the ammonia can be substantially recovered for reuse which has positive economic advantages for the entire process.
.
Figure 11 shows a further variation on the process accofding to Figure 10. In Figure 11, the brine conditioning step is employed between reactors 20 and 32. The brine conditioning step is effective to purify the feed stream for introduction into reactor 32 for eventual formation of ammonium sulfate by the further reduction of sodium ion concentration from the feed stream entering into reactor 32.

Once the sodium bicarbonate reaction has been completed, the bicarbonate ~recipilate is removed as set forth herein with respect to Figure 10 and the brine is tran,rell~d to intermetii~te reactor 42. In reactor 42, the concentration of the~mmoni~ iS increased to saturate the solution while the temperature of the reactor is CA 0220~493 1997-06-18 lowered to a~l uxilllately 7~C. This results in the formation of a precipitate comprising either pure sodium sulfate, or a mixed precipitate of sodium sulfate and ammonium sulfate. These precipitates are then filtered by filter 44 and the crystals eventually passed back into contact with mixing container 12. The filtrate is fed to reactor 32 and maintained under at least the same pressure conditions as indicated for Figure 10. Once in reactor 20, the filtrate undergoes the reaction as indicated hereinabove, the result is the formation of ammonium sulfate precipitate, however, the precipitate is formed in an environment where the sodium cation concentration issignificantly reduced in view of the intermediate process using intermediate reactor 42.
The result of the process is a solution concentration of a ammonium sulfate which will effect a precipitate of a concentration greater than 73% by weight.

Referring now to Figure 12, shown is a further alternate arrangement by which the process may be practised. In Figure 12, the overall process may include a separate washing step for washing the sodium bicarbonate and ammonium sulfate precipitates separately. In one possible configuration, the sodium bicarbonate which is formed in reactor 20, may be passed into contact with a washing material, an example of which may be a source of methanol 50. The resulting filtrate may then be returned to mixing container 12 via line 52.

Similarly, the ammonium sulfate crystals formed in reactor 42, may be passed through a second independent source of methanol 54 with the filtrate being returned to mixing container by line 56. The ammonium sulfate crystals and bicarbonate can then be used for further uses.

Referring now to Figure 13, shown is a further variation on the schematic process shown in Figure 10. In the process shown in Figure 13, the filtrate recovered from the sodium bicarbonate reaction can be made to be substantially pure liquidproduct, e.g. a fertilizer in the near saturated state. This facilitates blending the liquid product with other fertilizer components or permits crystallization of the product in CA 0220~493 1997-06-18 the desired form. The liquid product may be passed from reactor 20 to the brine conditioning container 42 where the temperature of the solution is reduced to a~ xi~ tely 7~C as set forth herein previously with respect to Figure 11. In this embodiment, the ammonia concentration is increased from about 10% to about 50%
or greater by weight to therefore provide a supersaturated solution. The result is the precipitation of contaminated sodium sulfate or mixed salts of ammonium and sodium sulfate. The filtrate in this situation is substantially saturated liquid ammonium sulfate which can then be passed on to a storage unit 60. As a further alternative, a user may simply pick up the liquid ammonium sulfate or alternatively, the ammonium sulfate may be pumped into a conventional evaporator (crystallizer) 62 to afford mixing the liquid with additional fertilizer components to have the final product crystallized.

The brine conditioning can be performed in a single step or it may be conditioned in multiple steps to achieve increased removal of sodium cations; this inherently leads to increased purity of the ammonium sulfate fertilizer. The above-mentioned steps can be any combination of known (salting out) steps i.e. evaporation, addition of excess ammonia, ion exchange, cooling among other techniques.

Typically, the evaporation is carried out at a temperature of greater than 59~C
while other unit operations are carried out at a temperature less than 59~C.

Figure 14 shows a variation on the process where the bicarbonate recovery systems can be combined to be useful in a sulfur recovery plant. The area designated by numeral 70 in Figure 14 illustrates conventional apparatus employed for sulfur recovery from an acid gas stream by employing the modified Claus process, consisting of a single or multiple variation of thermal and catalytic recovery steps.

By employing the recovery process as set forth herein previously, sodium bicarbonate can be introduced into the tail gas stream containing residual sulfur compounds and results can therefore be the production of ammonium sulfate as CA 0220~493 1997-06-18 indicated in Figure 14. The overall modified Claus process, denoted by numeral 70 can be combined with the overall process for producing ammonium sulfate, the group of steps of which is generally indicated by numeral 115 in the figure. The broad steps as illustrated in the figure are generally common steps to those shown in Figures 10 and 11. By combining the modified Claus process with the processes as set forth herein, the result is sulfur removal of the order of at least 95% or greater.

Figure 15 illustrates a further process variation for a lower volume 10 MTD
production sulfur plant. The steps for the process are similar to those for Figure 14 and the treatment of the sulfur compound is generally denoted by the sequence ofevents as indicated by numeral 115.

The acid gas stream may be as an alternative directly treated with liquid sodiumbicarbonate or carbonate solution for desulfurization and form an alternate sulfur product.

Turning to Figure 16, shown schematically is a further embodiment. A lime mixing container 70 is provided for retaining lime in any form, e.g. a slurry, powder, etc. to be introduced into reactor 32 via line 72. By providing this addition to the bicarbonate process, commercial or landfill gypsum can be produced along with sodium bicarbonate as illustrated in Figure 16. The arrangement shown may include ammonia recovery unit 74 which will include the usual gaseous recovery means well known to those skilled in the art. This is useful since the ammonia is liberatedsubsequent to precipitation of gypsum and therefor can be easily recovered.

Turning to Figure 17, shown is a further variation on the overall processes. In Figure 17, a FGD process using a wet scrubbing system for desulfurization, employs sodium carbonate or bicarbonate as the active reagent.

CA 0220~493 1997-06-18 In the embodiment illustrated, flue gas from the industrial boiler or tail gas unit, globally denoted by numeral 90, is passed onto an electrostatic precipitator or baghouse 92 or other recovery device to remove flyash at 93. A water wash container 94 is provided to circulate wash water in the upper section of the scrubber and accumulated levels of precipitates and fluids are drawn off from container 94 and passed to the lower section of the scrubber 95. Once sodium sulfate is collected from the bottom of scrubber 95 as a product of the scrubbing procedure, it is then further transferred to mixing container 12 for thickening and clarification to a saturated state for feeding into reactor 20. From reactor 20, sodium bicarbonate is filtered from the solution and washed in either open screen, pressure type, vacuum type, centrifuge or cyclone type filters or any combination of these (generally shown at 97). The bicarbonate precipitate is washed and reduced to less than ~0% liquid and then fed as a slurry into a bicarbonate slurry container 96 at appru~imately 700 kPa. At this point, the bicarbonate slurry in container 96 is mixed with clean water supplied to container 96 from a feed water supply container 98. The feed water is maintained at a temperature of appluximately 48~C. The slurry is continually mixed and ranges in a concentration of between about 20% by weight to about 40% by weight. The slurry is then transferred to a high pressure solution container 100 at a pressure of appru~imately 1050 kPa, where a saturated solution is formed. A saturated bicarbonate solution is created using additional boiler feed water from container 98 which is heated to approximately 176~C by an injection water heater 102. The final saturated concentrated solution is then injected into wet scrubber 95 for sulfur dioxide removal.

The temperature, pressure and concentration of reagent in the final injection solution can be varied to control the level of SO2 removed and the final flue gas temperature exiting the wet scrubbing process. As a further example, the temperature and pressure can be reduced to near atmospheric conditions prevalent in the scrubber.
The temperature can be reduced to 45~C to eliminate water heater 102 and the high pressure reactor 100. This will result in a cooler final flue gas temperature resulting CA 0220~493 1997-06-18 from the evaporative cooling effect which may or may not be detrimental to any specific application.

In addition, it will be appreciated that the wet scrubber 104 can take any form of contracting the reactant solution with the sulfur containing flue gas, for example spray driers, etc.

As an alternative to reducing sodium ion content, the excess ammonia treatment may be replaced by an ion exchange unit operation. In this operation, sodium ions can be replaced with ammonium ions to preclude the formation of undesirable sodium compounds inter alia.

As is known in the art, the design of ion exchange depends on three broad parameters, namely, resin type, resin capacity and selectivity. As an option, byemploying the ion exchange in an operation, the resin may be initially loaded through the use of a regenerative solution, for example, ammonium carbonate with ammonium ions. When a fluid stream of ammonium and sodium sulfate encounters the resin, which is loaded with ammonium, there will be a proclivity to exchange sodium. This proclivity will also advantageously ensure that the fluid always encounters fresh resin only loaded with ammonium.

The ion exchange scheme can be used in any number of locations in the process as set forth herein previously to enrich the stream with ammonia ions inexchange for sodium. An example of the process using an ion exchange scheme for treatment of brine from the reactor is shown in Figure 18. The ion exchange scheme preferably uses several columns in different operating modes, examples of which include exchange, regeneration and standby. The example shown in Figure 18 employs a reactor unit 220 in the production of resin regenerating solution using ammonia containing condensed water from the fertilizer evaporator-crystallizer unit as one of the feed components. The exit liquor from the resin regeneration may be CA 0220~493 1997-06-18 recycled in the system. Figures 19 and 20 show additional examples of the location for the ion exchange unit together with optional conditioning steps using the conditioner 42 as set forth herein previously.

It will be appreciated by those skilled that Figures 18 through 20 are only exemplary of those positions where the ion exchange system 220 could be employed.

Figure 21 illustrates an overall schematic view of a further option employing cooling to effect the desirable results according to the present invention. Refrigeration may be used as a further alternative to the techniques of evaporation, ammonia shifting or ion exchange to reduce sodium ion content to thereby result in a stream having a higher concentration of ammonium sulfate. One possible scheme is to cool the feedstream by the cross exchange with a much colder stream. As an example, the feed may be cooled within a range of 0~C to -40~C. A desirable temperature is -11~C.
Due to the subfreezing ranges required for the cooling, a standard closed loop refrigeration system may be used to cool the liquid in exchange with the feed.
Propane and ammonia refrigerants, glycols and any other acceptable refrigerant that remains functional in the given temperature range can be employed in the system.
Figure 21 illustrates one possible arrangement where the refrigeration unit operation is broadly denoted by numeral 222. At cold temperatures, the solubility of the components present in the system is substantially reduced. Salts that can not be held by the solution precipitate. The primary precipitate will be hydrated sodium sulfate and lesser quantities of ammonium and sodium bicarbonate. The exiting liquid phase 224, exiting from the refrigeration unit 222, will contain less sodium ions than the liquid phase entering into the refrigeration unit operation as a result of the precipitation of sodium compounds. Some ammonium sulfate may precipitate should the concentration in the feed solution be high and the temperature low enough.
Although this is the case, proportionally more ammonium compounds remain in the liquid phase than the sodium compounds. The result is a liquid phase having much CA 0220~493 1997-06-18 less sodium ion content to be used for the production of ammonium sulfate. This is a distinct advantage by incorporating the refrigeration operation 222 based on the phase relationship of the compounds in the system. The precipitated solids may be separated from the liquid phase of the cold stream by means of any suitable solid separation device (not shown). The solids can be recirculated through the system as indicated by numeral 226.

It has been found that the refrigeration scheme can be further augmented by adding excess ammonium in the conditioning step with a concentration range varying up to 20% by weight and typically 10% by weight depending on the residual level of sodium desired in the fertilizer evaporator feed brine.

Although embodiments of the invention have been described above, it is not limited thereto and it will be apparent to those skilled in the art that numerous modifications form part of the present invention insofar as they do not depart from the spirit, nature and scope of the claimed and described invention.

Claims (9)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:

1. A process for producing sodium bicarbonate, sodium carbonate and ammonium sulfate from sodium sulfate, wherein the process comprises the steps of:
reacting within a reactor sodium sulfate in aqueous solution with ammonia and carbon dioxide to precipitate sodium bicarbonate and form a first mother liquor;separating the sodium bicarbonate and drying it to produce sodium bicarbonate product or calcining it to convert it to sodium carbonate;
subjecting the first mother liquor from the precipitation of the sodium bicarbonate to evaporation to precipitate unreacted sodium sulfate, forming a second mother liquor;
cooling the second mother liquor from the precipitation of the unreacted sodium sulfate to precipitate a double salt of sodium sulfate/ammonium sulfate and water, forming a third mother liquor;
subjecting the third mother liquor from the precipitation of the double salt to evaporation to precipitate a substantial pure ammonium sulfate in a purity of greater than approximately 73 wt%, forming a fourth mother liquor;
adding the double salt to the first mother liquor from the precipitation of sodium bicarbonate prior to the evaporation; and adding the fourth mother liquor to the second mother liquor from the evaporation to precipitate unreacted sodium sulfate.

2. A process according to claim 1, wherein said process is conducted at a temperature of at least 59°C.

3. A process according to claim 1, further including the step of recovering unreacted ammonia and carbon dioxide.

4. A process according to claim 3, wherein the process further comprises recycling to the reacted carbon dioxide and ammonia from the mother liquor from the precipitation of the sodium bicarbonate prior to evaporation.

5. A process according to claim 3, wherein said carbon dioxide is removed by pH modification.

6. A process according to claim 3, wherein said carbon dioxide is removed by heating.

7. A process according to claim 1, wherein at least a part of carbon dioxide andammonia are fed into the reactor in the liquified state.

8. A process according to claim 1, wherein at least a part of carbon dioxide andammonia is fed into the reactor in the gaseous form.

9. A process according to claim 1, wherein the content of the reactor is maintained at a pH of from about 7 to about 9.