1.

Scaling of final concentrator

Explain the reasons for scaling (=deposit precipitation on heat surfaces) of Final Concentrator producing heavy liquor of 80 % ds. How you alleviate scaling?

Reasons 1. Too big evaporation rate 2. Too high temperature in Final Concentrator owing to the overcapacity or evaporator fouling 3. Burkeit, 2Na2SO4*Na2CO3, precipitation

Helping 1. Reduce capacity 2. Reduce capacity, wash Concentrator 3. a) Check Reduction rate, norm. 96-97,5 Causticizing rate, norm 80-83 %. Note that a poor reduction rate and a poor causticizing rate increase Burkeit formation when the critical concentration of black liquor is surpassed. Burkeit give salt deposits rapidly. b) Check that the fetching of fly ash crystals work. Fly ash crystal nucleuses adsorb burkeit salts to bigger crystals and concentrator heat surfaces are kept clean a longer time.

4. Other fouling materials from the other departments: CaCO3 from Causticizing plant, fibre from Pulp washing (the black liquor filter bypassed), soil material among chips if logs are not washed before chipper etc compare the lecture slides)

2. Safety when malodorous gases are collected Personal safety What you must consider when you go to Methanol Distillation room when there is alarming of H2S at 10 ppm? Plant safety What may be reasons for explosions in Diluted gas and Concentrated gas collections and combustions?

Personal safety: See Slides 5-9 of Malodorous gas collection Plant safety: Diluted Gas collection: gas concentration more than LEL (mixed with concentrated gases) gases (malodorous gases and methanol) concentrated in storage tank upper parts during mill shut down. Closed gas collection used. gas blower exploded with static electricity or friction sparks when the blower started with above gases after mill shut down diluted gas stack explosion when diluted gases hit hot flue gases from Lime Kiln during start up turpentine scrubber malfunctioned (when pine cooked) HAZOP (the deviation analysis for process conditions) is recommended Concentrated gases: too low speed is nozzle of gas incinerator (seam pressurizing malfunctioned) flame arrestor stained with organic matters and caught into fire and flame has propagated backwards flame detecter malfunctioned or ventilation time too short after failed ignition gas lines before incinerator are not properly drained, water entered incinerator causing disturbances in combustion HAZOP (the deviation analysis for process conditions) is recommended

3. Recovery boiler

a. Heating surface plugging: reasons ? how to keep it under control?

Reasons: 1. Too big firing liquor burning rate in Recovery Boiler 2. Liquor guns positioned too upwards 3. Firing liquor too hot (may cause so called suspension combustion in the upper part of furnace) 4. Primary air flow too big compared with the others air flows 5. Cl an K contents too high in black liquor affecting to the sticky temperature of fly Remedy: 1. Reduce burning 2. Adjust liquor guns clearly downwards 3. Increase black liquor flashing in Evaporation Plant so that the temperature of firing liquor is about 135-140 C 4. Reduce primary air flow 5. Increase fly ash removal to sewage (Or in the worst case acquire Cl and K removal system: Fly ash leaching process) 6. Intensify and optimize the soot blowing (adjust sequence soot blowing. Use the computer to optimize the soot blowing). 7. At mill shut down use soot blowers for water washing.

b. Water circulation in recovery boiler?

Boiler water is circulated from the drum via the down comers into the wall tubes of the furnace where water/steam mixture rises back into the drum. This is called the natural circulation (no circulation pump is used). There are also the natural circulations for: Drum - Screen tubes-drum if the water screen is applied Drum Generating tubes - Drum

c. Reduction rate ? Reduction rate = Na2S/(Na2S + Na2SO4 ) Usually 96-97,5% The good reduction rate is obtained with the hot and carbon containing smelt bed

4. Quality supervision of end products in Causticizing Plant and Lime Kiln. How you optimize the slaking and causticizing processes and lime reburning in Lime Kiln so that so white liquor and burnt lime are of good quality as concern to process runability and economy?

Causticizing: Avoid overliming, i.e. overdosing of burnt lime, in slaking. Causticizing degree should be 80-83 %. If the degree is more there will be free Ca(OH)2 which plugs wire cloth of DC-filter rapidly. If the causticizing rate is lower there will be more Na2CO3 in white liquor and black liquor giving rise to Burkeut deposits on heat surfaces of evaporators. Avoid rapid changes in process flows to minimize variations of the white liquor properties (sulfidity, causticizing degree). Note that the higher causticizing rate = NaOH/(NaOH+Na2CO3) gives a lower sulfidity = Na2S/(Na2S + NaOH). The variations interfere the digester operation.

Lime Kiln: Keep stabile flame temperature in Lim Kiln. The flame temperature fluctuations may cause ring and ball formation in the temperature region where the calcination reaction is beginning in the kiln (800 C). Too high flame temperature gives sintered burnt lime with a lower reactivity in slaking. Rest carbonate (CaCO3) content of burnt lime should be 2-4 % so that it is reactive in slaking. If content is lower, lime is sintered and has hard surface. If the content is higher the causticizing power is lowered, also dead load is increased in Calcium Cycle. Still higher CaCO3 content of lime gives plugging problems on filter cloth

Bonus: Boiling point rise (BPR)

The 1-stage evaporation plant (evaporator and condenser) data when black liquor is evaporated: BPR dT(eff)=driving force 5 10 How much more as % the plant can evaporate water instead of black liquor? In the both cases the steam temperature in the heating element = 100 C (saturated) and the condensing temperature of outlet vapour = 85 C . The heat transfer coefficients: for black liquor U for water 1,2*U Apply the evaporation equitation = U*A*dTeff)/i where i = latent entalphy=constant

Solution: Evaporation with black liquor = U*A*10/i Evaporation with water = 1,2U*A*(10+5)/i = U*A*(15*1,2)/i More evaporation as % = (18 10)/ 10*100 = 80 % (The pressure loss= dT loss of vapour pipes are not considered)