Carbonatation Process for Liquor Contaminant Removal
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Solution Overview
Problem
Standard carbonatation processes in industries such as sugar refining are inefficient, with low CO2 usage efficiency, variability, and slow reaction times, often requiring multiple stages and larger vessels, which increases costs and operational complexity.
Innovation Solution
A carbonatation process using a high concentration of CO2 (at least 25% CO2) to accelerate the reaction, control precipitate size through residence time and pH management, and recycle CO2 to enhance efficiency, allowing for a single-stage process in a smaller vessel with improved contaminant removal and filtration capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If standard carbonatation processes are used, then the process is simple to operate, but CO2 usage efficiency is low and reaction time is slow
Solution Approach 1:
The patent applies parameter changes by controlling the pH profile of the liquor throughout the carbonatation process. By maintaining pH within specific ranges (8.0-10.0 during carbonatation, then 10.0-11.0 during settling), the process optimizes both reaction speed and CO2 efficiency. This pH control mechanism enables faster carbonatation while improving CO2 usage efficiency to above 70%.
Solution Approach 2:
The patent implements dynamic control of the carbonatation process by adjusting pH in different stages. The process dynamically transitions from a carbonatation stage (pH 8.0-10.0) to a settling stage (pH 10.0-11.0), allowing the system to adapt conditions for maximum efficiency at each phase. This dynamic approach resolves the contradiction between speed and efficiency.
2Reliability
If standard carbonatation processes are used, then equipment size is large, but process variability is high
Solution Approach 1:
The patent reduces vessel size by implementing intensive carbonatation with controlled pH parameters. By maintaining higher CO2 concentration and optimizing pH profiles, the process achieves complete carbonatation in smaller vessels with residence times of 15-30 minutes, reducing variability through standardized parameter control.
Solution Approach 2:
The patent employs feedback control through pH monitoring and adjustment during the carbonatation process. By continuously monitoring pH and adjusting conditions to maintain target ranges, the process achieves consistent results in smaller vessels, reducing variability while improving reliability.
3Productivity
If multiple stages are used, then contaminant removal is thorough, but device complexity increases
Solution Approach 1:
The patent combines carbonatation and settling operations into a single integrated vessel by controlling pH profiles across different time periods. The same vessel performs both functions: carbonatation at pH 8.0-10.0 followed by settling at pH 10.0-11.0, eliminating the need for separate vessels and reducing overall system complexity while maintaining thorough contaminant removal.
Solution Approach 2:
The patent uses dynamic pH control within a single vessel to achieve multiple functions. By changing pH conditions over time (first carbonatation phase, then settling phase), the system performs sequential operations in one vessel, maintaining high contaminant removal efficiency without increasing device complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach increases CO2 usage efficiency to at least 70%, enables precise control of the process, significantly reduces reaction time, and facilitates the use of smaller equipment, making carbonatation more viable and cost-effective by producing larger, filterable precipitate particles.
Implementation Method 1
Carbonatation is used in a variety of different processes to remove impurities such as, but not limited to, unwanted ions or high molecular weight compounds from liquids. The processes generally involve the addition of a metal or ammonium hydroxide whose carbonate is as least partially insoluble under the conditions employed. Carbon dioxide (CO2) is also added, resulting in the formation of an insoluble carbonate as a precipitate
Implementation Method 2
separating the precipitate formed by the carbonatation of the metal or ammonium hydroxide from the liquor
Implementation Method 3
separated from the liquid, for example by filtration
Data Source
AI summary
The invention relates to a process for the removal of contaminants from a liquor, the process comprising: introducing a metal or ammonium hydroxide into the liquor; introducing the liquor into a reaction vessel; bubbling a carbon dioxide gas comprising at least 25% carbon dioxide through the liquor within the reaction vessel; and separating the precipitate formed by the carbonatation of the metal hydroxide from the liquor, the precipitate comprising at least some of the contaminants from the liquor; wherein, on average, the liquor is resident within the reaction vessel for a period of no more than about 60 minutes. The invention also relates to a process for the removal of contaminants from a liquor, the process comprising: introducing a metal or ammonium hydroxide into the liquor and bubbling a carbon dioxide gas comprising at least 25% carbon dioxide through the liquor to form a precipitate by carbonatation in a period of no more than about 60 minutes. The carbonatation processes may be included in sugar refining or water softening and/or decontamination processes. A use of a carbon dioxide gas comprising at least 25% carbon dioxide in a carbonatation process for removing contaminants from a hydroxide-treated liquor is also provided, wherein the process forms a precipitate in a period of no more than about 60 minutes.