Method and apparatus for regeneration of flue gas scrubber caustic solutions

• US 7,247,284 B1
• Filed: 02/24/2005
• Issued: 07/24/2007
• Est. Priority Date: 02/24/2004
• Status: Expired due to Fees

• Current Assignee: Karl A. Seck
• Original Assignee: Karl A. Seck
• Inventors: Seck, Karl A.
• Primary Examiner(s): Vanoy; Timothy C.
• Application Number:
  US11/066,857
• Time in Patent Office: 880 Days
• Field of Search: 423/182, 423/183, 423/243.01, 423/243.08, 423/555, 233/04
• US Class Current: 423/182
• CPC Class Codes: C01D 1/20 Preparation by reacting oxides or hydroxides with alkali metal salts
• CPC Class Codes: C01F 11/464 Sulfates of Ca from gases containing sulfur oxides

Abstract

A process to regenerate wet flue gas scrubber purge liquid into NaOH caustic suitable for make-up caustic for the scrubber is disclosed. Further, sulfur is removed from waste effluent in the form of gypsum with the process described herein. Lime is added to the spent, sodium sulfate-containing purge liquid to result in the formation of gypsum and sodium hydroxide.

Claims

1. A method for regeneration of caustic soda from a flue gas purge liquid containing sodium sulfate, said method comprising the steps of:

receiving an influent flow of said purge liquid from a flue gas scrubber that removes sulfur dioxide from a waste gas stream;

adding lime to said influent flow of said purge liquid so as to react a portion of said sodium sulfate therein to gypsum and caustic soda;

collecting said gypsum as a solid from said purge liquid;

extracting said caustic soda as a solution from said purge liquid;

returning a remainder portion of said purge liquid from which said gypsum and caustic soda have been removed to said influent flow of said purge; and

supplying said caustic soda solution to said flue gas scrubber for use in removing sulfur dioxide from said waste gas stream.

2. The method of claim 1, wherein the step of extracting said caustic soda solution from said purge liquid comprises the step of:

passing said purge liquid over a sulfate membrane that preferentially rejects sulfate ions in said purge liquid and that allows said caustic soda solution to pass therethrough.

3. The method of claim 2, wherein the step of collecting said solid gypsum from said purge liquid comprises the steps of:

precipitating said gypsum as a particulate from said purge liquid; and

filtering said particulate gypsum to obtain said solid gypsum.

4. The method of claim 3, wherein the step of precipitating said gypsum as a particulate comprises:

crystallizing said particulate gypsum in a reactor vessel; and

separating said particulate gypsum from a clear component of said purge liquid in a thickener.

5. The method of claim 4, wherein the step of adding said lime to said influent flow of said purge liquid comprises:

adding an aqueous lime slurry to said influent flow on an upstream side of said reactor vessel.

6. The method of claim 4, wherein the step of filtering said particulate gypsum comprises:

filtering said particulate gypsum following separation in said thickener.

7. The method of claim 3, wherein the step of adding said lime to said influent flow of said purge liquid comprises:

adding said lime in an amount sufficient to yield from about 5% to about 30% by weight of said sodium sulfate in said purge liquid as gypsum.

8. The method of claim 7, wherein the step of adding said lime comprises:

adding said lime in an amount sufficient to yield about 10% by weight of said sodium sulfate in said purge liquid as gypsum.

9. The method of claim 7, further comprising the steps of:

withdrawing water from said influent flow of said purge liquid so as to increase a concentration of sodium sulfate therein prior to adding said lime to said purge liquid.

10. The method of claim 9, wherein the step of withdrawing water from said influent flow of said purge liquid comprises the step of:

passing said influent flow over a reverse osmosis membrane that permits water to pass therethrough out of said purge liquid.

11. The method of claim 9, wherein the step of withdrawing water from said influent flow of said purge liquid comprises:

withdrawing water from said influent flow in an amount sufficient to concentrate said sodium sulfate to from about 15% to about 30% by weight of said purge liquid.

12. The method of claim 2, wherein the step of supplying said caustic soda solution to said flue gas scrubber comprises:

passing said extracted caustic soda solution over a reverse osmosis membrane so as to increase a concentration of caustic soda in said solution.

13. The method of claim 12, wherein the step of passing said extracted caustic soda solution over said reverse osmosis membrane comprises:

passing said extracted caustic soda solution over said reverse osmosis membrane so as to remove water in an amount sufficient to concentrate said caustic soda to from about 5% to about 25% by weight of said solution.

14. A method for regeneration of caustic soda from a flue gas purge liquid containing sodium sulfate, said method comprising the steps of:

receiving an influent flow of said purge liquid from a flue gas scrubber that removes sulfur dioxide from a waste gas stream;

passing said influent flow over a reverse osmosis membrane so as to increase a concentration of sodium sulfate in said purge liquid;

adding an aqueous lime slurry to said purge liquid having said increased concentration of sodium sulfate therein, in an amount sufficient to yield from about 5% to about 30% by weight of said sodium sulfate as gypsum;

crystallizing said gypsum in a reactor vessel so as to form particulate gypsum that precipitates from said purge liquid;

thickening said particulate gypsum so as to separate said particulate gypsum from a substantially clear component of said purge liquid;

filtering said separated particulate gypsum so as to form a solid gypsum product;

passing said substantially clear component of said purge liquid over a sulfate membrane that permits caustic soda from said clear component to pass therethrough so as to be extracted from said purge liquid, leaving a remainder component of said purge liquid that contains unreacted sodium sulfate;

returning said remainder component of said purge liquid to said influent flow of said purge liquid;

passing said caustic soda solution extracted from said purge liquid over a reverse osmosis membrane so as to concentrate said caustic soda in said solution by removing water therefrom; and

providing said concentrated caustic soda solution back to said flue gas scrubber for use in removing sulfur dioxide from said waste gas flow.

15. The method of claim 14, wherein the step of adding aqueous lime slurry to said purge liquid comprises:

adding said aqueous lime slurry in an amount sufficient to yield about 10% by weight of said sodium sulfate in said purge liquid as a gypsum.

16. The method of claim 14, wherein the step of passing said influent flow of said purge liquid over said reverse osmosis membrane comprises:

passing said influent flow of said purge liquid over said reverse osmosis membrane so as to remove an amount of water sufficient to concentrate said sodium sulfate in said purge liquid to from about 15% to about 30% on a weight basis.

17. The method of claim 14, wherein the step of passing said caustic soda solution over said reverse osmosis filter comprises:

passing said caustic soda solution over said reverse osmosis filter so as to remove an amount of water sufficient to concentrate said caustic soda in said solution to about 5% to about 25% by weight.