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ExtrAcid
ExtrAcid® is the first system that recycles waste acid under pressure using innovative patented loop systems producing high concentrated acid and process steam at the same time.
INTRODUCTION
Waste acid from various chemical processes has to be recycled by removing water and other impurities from the acid. By dewatering the concentration rides from less than 15% to higher values of typically 98%.
Typical Acid concentration systems (SAC or SAS or dewatering systems) are separated in to lower concentration of up to 70%, medium and high concentration systems.
BENEFITS AT A GLANCE
- • Energy recovery by steam production
- • Innovative patented 2 loops design
- • Flexible inlet concentration
- • From 5 to 98%
- • Handles impurities
- • Small footprint
- • Optimized capex and opex
APPLICATIONS FOR ExtrAcid®
- • Titanium Dioxide
- • Gas drying/purification
- • Nitration processes
- • Mining
- • High purity acids
PATENTED DESIGN
The design of the ExtrAcid® system is patented covering the process including the loops for steam production and the usage of SIC material in the required pressure and temperature ranges.
TURN ACID WATER INTO PROCESS STEAM
Well-known is that recycling by vacuum evaporation of water consumes high energy resources. Although the energy consumption has been optimized in recent years valuable energy cannot be recovered due to low temperature levels.
The innovative ExtrAcid® process system is the first that can significantly reduce the energy consumption by producing valuable process steam.
IMPURITIES
As waste sulfuric acid has many different sources it often contains organic or inorganic impurities other than water which have to be removed. Dependent on the nature of the process typical examples are HF, H₂O₂ or Fe.
It is important to know the kind and amount of the impurities before the design of the ExtrAcid® system. Some organics like H₂O₂ are decomposed into water and O₂ if the temperature is increased sufficiently. Others like HF stay in the vapor phase and can be separated this way. Some need special treatment like purification by crystallization.
ExtrAcid® can offer many solutions to this wide range of challenges. Due to the universal chemical resistance of our main material, it is suitable for HF applications, due to high temperatures it burns many organics into its elements or separates by evaporation.
PURIFICATION BY CRYSTALLISATION
A usual task for the treatment of waste acid coming from the production of Titanium Dioxide is the Fe load in the waste. It can be reduced by forming Ferrous sulphate Monohydrate. These kind of processes can easily be added to the ExtrAcid® system.
Process Comparison
Compare ExtrAcid and ExtrAlkali processes
Process Type
ExtrAcid:
Acid Concentration/Dewatering
ExtrAlkali:
Caustic Soda Concentration
Concentration Range
ExtrAcid:
5% to 98%
ExtrAlkali:
30% to 98.5%
Temperature Range
ExtrAcid:
Up to 450°C
ExtrAlkali:
Up to 500°C (evaporators)
Pressure Range
ExtrAcid:
Up to 40 barg
ExtrAlkali:
Up to 20 bar (evaporators), vacuum to 10 bar
Energy Recovery
ExtrAcid:
Steam production (up to 10 bar), Energy recovery ratio up to 70%
ExtrAlkali:
Up to 48% energy saving with multiple effects, Steam recovery
Design Features
ExtrAcid:
Innovative patented 2 loops design, Pressure operation
ExtrAlkali:
Up to 8 effects available
Key Benefits
ExtrAcid:
• Energy recovery by steam production
• Flexible inlet concentration
• Handles impurities (HF, H₂O₂, Fe)
• Small footprint
• Optimized capex and opex
ExtrAlkali:
• No Nickel pick up
• Energy recovery by steam production
• Longer life time, less maintenance
• Small footprint
• Optimized capex and opex
Applications
ExtrAcid:
• Titanium Dioxide
• Gas drying/purification
• Nitration processes
• Mining
• High purity acids
ExtrAlkali:
• NaOH up to 99%
• KOH up to 99%
• HCl up to 25%
• CaCl₂ up to 72%
Material
ExtrAcid:
NoMoCorr® SIC (Silicon Carbide)
ExtrAlkali:
NoMoCorr® SIC (Silicon Carbide)
Flow Rates
ExtrAcid:
2 up to 200 MTPD SA97
Size of 200 MTPD: 2.4m x 2.7m x 12m height (skid mounted)
ExtrAlkali:
Tailor-made concept, modular structure of different sizes
Special Features
ExtrAcid:
• Organics mostly decomposed at high evaporation temperatures
• Purification by crystallization possible
• Can handle HF applications
ExtrAlkali:
• Payback less than 2 years for revamping
• Flaking or Prilling options
| Feature | ExtrAcid | ExtrAlkali |
|---|---|---|
| Process Type | Acid Concentration/Dewatering | Caustic Soda Concentration |
| Concentration Range | 5% to 98% | 30% to 98.5% |
| Temperature Range | Up to 450°C | Up to 500°C (evaporators) |
| Pressure Range | Up to 40 barg | Up to 20 bar (evaporators), vacuum to 10 bar |
| Energy Recovery | Steam production (up to 10 bar), Energy recovery ratio up to 70% | Up to 48% energy saving with multiple effects, Steam recovery |
| Design Features | Innovative patented 2 loops design, Pressure operation | Up to 8 effects available |
| Key Benefits | • Energy recovery by steam production • Flexible inlet concentration • Handles impurities (HF, H₂O₂, Fe) • Small footprint • Optimized capex and opex | • No Nickel pick up • Energy recovery by steam production • Longer life time, less maintenance • Small footprint • Optimized capex and opex |
| Applications | • Titanium Dioxide • Gas drying/purification • Nitration processes • Mining • High purity acids | • NaOH up to 99% • KOH up to 99% • HCl up to 25% • CaCl₂ up to 72% |
| Material | NoMoCorr® SIC (Silicon Carbide) | NoMoCorr® SIC (Silicon Carbide) |
| Flow Rates | 2 up to 200 MTPD SA97 Size of 200 MTPD: 2.4m x 2.7m x 12m height (skid mounted) | Tailor-made concept, modular structure of different sizes |
| Special Features | • Organics mostly decomposed at high evaporation temperatures • Purification by crystallization possible • Can handle HF applications | • Payback less than 2 years for revamping • Flaking or Prilling options |
SIC – THE UNIVERSAL ANTI CORROSION MATERIAL
Our SIC products are manufactured from pure directly sintered SIC, the so-called SSiC. They no longer contain free silicone, which limits chemical resistance and thermal conductivity. SIC offers nearly universal chemical resistance and high thermal conductivity. Extreme surface hardness allows protection against abrasion and results in high flow rates with increased thermal efficiency. Like hardly any other corrosion resistant material, SSiC is excellently suited for extreme high temperature applications.
ExtrAcid and ExtrAlkali are the first full Systems with extensive usage of SSiC at high temperatures and pressures.
- • Universal Chemical resistance
- • Highest thermal conductivity
- • No abrasion
- • No contamination
- • Extremely hard ceramic
- • Low wall thickness
- • Low fouling rates
- • High velocities
- • High thermal shock resistance
- • Many designs possible
- • High temperature resistance
- • Low surface roughness
- • No aging / no fatigue
KEY PROPERTIES
- • Density > 3 120 kg/m³
- • Thermal conductivity: 130 W/(m.K)
- • Heat exchanger up to 450 °C and 40 barg
- • Vickers hardness: 19,2 GPa (500g load) > Tensile Strength: 210 Mpa
- • Young's modulus: 420 GPa
APPLICATIONS
- • Separators
- • Pipes
- • Compensator
- • Thermowells
- • Columns