Hydrochloric Acid Regeneration via Solution Segmentation
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Solution Overview
Problem
Conventional HCl regeneration processes, such as spray roasting, have high energy requirements due to excessive water evaporation and inefficient metal concentration, leading to increased energy consumption.
Innovation Solution
A method where the hydrochloric acid solution is split into two partial flows, with only one partial flow undergoing pyrohydrolytic treatment in a spray roasting reactor, while the other is fed to an absorption column, allowing for increased metal concentration and reduced energy usage by minimizing water evaporation and fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the entire metal-containing hydrochloric acid solution undergoes pyrohydrolytic treatment in a spray roasting reactor, then complete acid recovery is achieved, but excessive water evaporation occurs causing very high energy requirements
Solution Approach 1:
The spent pickling solution is divided into two partial flows: a first partial flow (e.g., 20-50% of total) is fed to the spray roasting reactor for pyrohydrolytic treatment, while a second partial flow is fed directly to the absorption column. This segmentation allows only the necessary portion of solution to undergo energy-intensive treatment, reducing overall energy consumption while maintaining adequate acid recovery efficiency.
2Use of energy by moving object
If pre-concentration of waste pickling liquor is performed to maximum possible metal concentration, then water evaporation is minimized, but the conventional spray roasting system cannot achieve sufficient metal concentration
Solution Approach 1:
By segmenting the solution flow and directing only a portion to pyrohydrolytic treatment, the system can concentrate metals more effectively in the treated stream without the dilution effect of processing the entire volume. This enables achieving higher metal concentrations with reduced water evaporation requirements.
Solution Approach 2:
The system changes the operational parameters by adjusting the ratio of partial flows and optimizing the concentration conditions for the first partial flow entering the reactor. This allows operating at optimal metal concentration levels that maximize energy efficiency while achieving sufficient pickling liquor regeneration.
3Productivity
If a large volume of waste pickling liquor is processed through spray roasting, then complete acid regeneration is achieved, but waste gas volume and power consumption increase significantly
Solution Approach 1:
The waste pickling liquor is segmented into two streams: one for intensive pyrohydrolytic treatment and another for direct absorption. This segmentation reduces the total volume requiring energy-intensive processing, thereby lowering power consumption and waste gas generation while maintaining adequate acid regeneration capacity through the combined output of both streams.
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 reduces energy requirements by approximately 25%, lowers power consumption, and achieves higher metal concentrations in the hydrochloric acid, enhancing the pickling effect and reducing waste gas volume.
Implementation Method 1
The first partial flow of the metal-containing, hydrochloric acid solution undergoes pyrohydrolytic treatment in a spray roasting reactor
Implementation Method 2
absorption and/or condensation of the gaseous hydrogen chloride thus formed
Implementation Method 3
The metal-containing, hydrochloric acid solution undergoes concentration by evaporation according to the invention
Data Source
AI summary
The subject matter of the present invention is a method to extract or recover hydrochloric acid from hydrochloric acid solutions containing metal by means of pyrohydrolytic treatment, followed by absorption and/or condensation of the gaseous hydrogen chloride thus formed in order to form hydrochloric acid. According to the invention, a first partial flow of the hydrochloric acid solution containing metal undergoes pyrohydrolytic treatment and a second partial flow of the metal-containing solution is fed to the absorption column. A device for implementing the process according to the invention is also the subject of the present invention.