2 Vol 2 No 2
2 Vol 2 No 2
2 Vol 2 No 2
Jian Zhang
Hydrogel process
A zeolite gel is defined as a hydrous metal
aluminosilicate prepared from aqueous solution, reactive
solids, colloidal sols, or reactive aluminosilicates such as the
residue structure of meta-kaolin and glasses. For hydrogel
process, the typical starting raw materials include an aqueous
solution of sodium silicate (Na4SiO4), H2O, Al2O3-3H2O to
form sodium aluminate (NaAlO2), and sodium hydroxide [13].
These are mixed with water in a tank, followed by gel makeup reactor, then gel aging and crystallization, as shown in
Figure 1.
Figure 1 Hydrogel process flow sheet for the manufacture of zeolite 4A from
reactant hydrogel [14]
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IRACST Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.2, No. 2, April 2012
Figure 2 Kaolin conversion process, Process flow sheet for producing zeolite
4A and 5A [2]
Figure 1 Hydrogel process flow sheet for the manufacture of zeolite 4A from
reactant hydrogel [14]
EUE =
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IRACST Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.2, No. 2, April 2012
Changes in the flow sheet that would increase the EUEs would
enhance green processing and reduce undesirable waste
stream.
D. Heat Integration
Heat integration involves the use of hot exit streams
that need to be cooled to heat cold streams that need to be
heated. However heat exchangers (and capital costs) are
needed. A validated simulation model is a valuable tool in
assessing the economic benefits of the heat integration. In the
kaolin conversion process, considerable heat can be recovered.
The required heat exchanger surface area and heat duty are
obtained using a heat exchanger block in ASPEN Plus. Based
on Qi [21] the heat transfer coefficient was assumed to be 100
W/m2K.
II. Goal/Objectives
The overall goal of this study is to simulate the
manufacturing processes of zeolite through hydrogel process
and via kaolin conversion process, and suggest approaches to
apply green processing technology into the process. The
objectives are:
- Develop simulation packages that characterize technical
performance of each process.
- Evaluate atom efficiency and processes that would improve
the element utilization efficiency.
- Implement heat integration as a tool for energy efficiency.
- Do preliminary cost estimation.
- Evaluate the financial soundness of the above green
processing technologies.
III. Approach/Methodology
Three simulation packages were used. These are:
a) ASPEN Plus from ASPEN Technology. Inc
b) EES (Engineering Equation Solver) from F-Chart
c) Microsoft Excel. This was mainly used for costing
calculations, overall mass balance check, elemental efficiency,
and heat integration calculations.
A. EES Application
EES was used to verify the consistency of the
technical data obtained from literature. Those information
include Kerrs model [14] for batch process of producing
zeolite A, Lius model [15] for continuous processes of
forming zeolite A, and Hus synthesis kinetics model [16, 17]
of zeolite A. Based on EES results [30], ASPEN Plus package
was used to study those kinetic models. The simulation results
of the present work were in very good agreement with
literature values, thus validating our models. The models
developed and tested in this study can only be used to simulate
zeolite A manufacturing. Attempts to compare the present
model with the kinetics models of Dufour [18, 19] and Freund
[20] resulted in large differences [30].
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IRACST Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.2, No. 2, April 2012
4.
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IRACST Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.2, No. 2, April 2012
Element unitlzation
efficiency
W/O recycle
With recycle
0.8
0.6
0.4
0.2
0
AL
Si
Na
O
H
Elements
Figure 7 Element efficiency difference between with water recycling and
without water recycling (hydrogel process)
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IRACST Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.2, No. 2, April 2012
Elements efficiency
0.80
0.60
0.40
0.20
0.00
Si
Al
Na
Elements
Ca
lb / lb of zeolite A
4.00
3.50
3.00
2.50
2.00
1.50
1.00
0.50
0.00
3.67
NaOH feed per pound of
zeolite lb NaOH /lb
Zeolite 5A
H2O feed per pound of
zeolite 5A lb NaOH /lb
Zeolite 5A
0.48
before recyle
0.24
0.08
after recyle
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IRACST Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.2, No. 2, April 2012
2.
3.
4.
5.
REFERENCES
Figure 12 Product zeolite 5A cost composition, without heat
recovery.
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IV. Conclusions
1.
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IRACST Engineering Science and Technology: An International Journal (ESTIJ), ISSN: 2250-3498,
Vol.2, No. 2, April 2012
A32(6), pp1807-1825.
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