Proceedings of The South African Sugar Technologists' Association - June 1988

FLUE GAS FOR CARBONATATION

J. P. LAMUSSE
Sugar Milling Research Institute

Abstract (b) The lowercarbon dioxide content of flue gas(about 12%

Flue gas is used for carbonatation in five refineries in by volume) compared to kiln gas (about 30%) which
requires the compression and piping of a larger volume
southern Africa. The gas which contains about 12% CO2 by
volume is scrubbed to remove sulphur compounds and to of gas.
cool the gas to about 50·C. Water scrubbing is sufficient for Flue Gas Scrubbing
the gas from bagasse fired boilers but a second scrubbing The composition of flue gas and the type of scrubbing
with a 5% sodium carbonate solution is required if the boil- required will depend on the type of fuel burnt. In the case
ers are oil or coal fired. The volume of flue gas required (at of coal or oil, the flue gas will contain sulphur (mainly in
50·C and 70 kPa) is about 140 m- per ton of solids in melt. the form of sulphur dioxide) which must be washed off be-
fore the flue gas can be used for carbonatation. If the flue
Introduction gas is obtained from a bagasse fired boiler, it will have a low
Although no referencehas been found on where and when sulphur content and can be used after scrubbing with water
flue gas was first used for carbonatation in sugar refining, only.
the process appears to have been developed in Britain from It is obviously advantageous to draw off the flue gas after
whereit spread to carbonatation refineries all over the world. any scrubber with which the boiler is equipped. If it is a wet
Before the advent of flue gas carbonatation the carbon scrubber, the gas will require little additional washing, but
dioxide required for clarification was produced by burning it is safer to have a separate water scrubber before the com-
limestone in kilns. This p~ocess is still used in beet juice pressors.In the scrubbersthe gasis washedwith water which
clarification and 10 plantation white sugar production from removes 99% of the fly ash and most of the sulphur in the
cane in Taiwan. In South Africa, two back-end refineries case of bagasse fired boilers. With coal and oil fired boilers
(Gledhowand Pongola)still burn limestone for carbon diox- the residual sulphur content of the flue gas after the first
ide production for refining. The use ofliquid carbon dioxide sc~bbing m~y be high enoughto ~arrant a second scrubbing-
has been investigated by a local back-end refinery but was WIth 5% sodium carbonate solution. The sodium carbonate
found to be much more expensive than kiln gas. solution is normally recycled and Chapman (in ReP) quotes
There are few references on carbonatation using flue a consumption of 50 to 75 grams of soda 'ash per ton of
gas-> 3, 4 and the scrubbing and compression of the gas are sugar melted, while Hulett Refinery reports 13 to 16 grams.
generally not describedin any detail in the availableliterature. An analysis of S02 in flue gas carried out at this refinery
showed an initial value of 400-500 ppm which was reduced
The process is used in five refineries in southern Africa to 0,5 ppm after the first (water) scrubbing and to less than
(Dwangwa, Hippo Valley, Ubombo Ranches, Malelane,and 0,1 ppm after the sodium carbonate scrubbing.
the Durban Tongaat-Hulett refinery) but the equipment and
~ond~tions vary within fairlywide limits. An attempt is made
The scrubbers should be designed for maximum contact
10 this paper to define the operating conditions and the ca-
between gas and water. There are a number of designs in
pacityof the equipment required to assist in the optimisation which this requirement is met, and sketches of three types
of flue gas carbonatation. Opinions expressedare not always of scrubbers found in southern African refineries are shown
substantiated by references and are often based on the au- in Figure 1. The first three operate on flue gas from bagasse
thor's evaluation of practices at various refineries and on fired boilers, while the fourth handles gas from a coal fired
unpublished studies and reports made available by the boiler and consists therefore of two stages (a) the water
refineries. scrubber and (b) the sodium carbonate scrubber.
To avoid a fall off in gas washing efficiency at lower flow
Advantages and disadvantages rates, the scrubbers should not be oversized and two or more
units in parallel are preferred to a single large unit.
In comparison with lime kilns, the main advantages of
flue gas carbonatation are: Material of construction varies with the different instal-
lations. The hot gas piping is normally of stainless steel and
(a) The lower capital cost due to elimination of the lime the cool gas piping, after scrubbing, of mild steel or plastic.
kiln and limestone handling equipment. The Durban refinery has successfully used 3 mm thick mild
steel pipingfor both the hot and cold gaseswith the hot pipe
(b) The loweroperatingcost especially wherelimestone has lagged to keep the temperature above the dew point. The
to be transported 'over long distances as is the case in scrubbersare usuallyof mild Steel after bagasse burning boil-
South Africa. Even after making allowance for the fact ers, although baffles and other wetted parts should preferably
that the lime required for both the raw house and the he of 430 stainless steel. In certain scrubber designs (Figure
refinery, plus an excess that can be sold, is a by-product 1) the walls of the vessel below water level are lined with
of carbon dioxide production from limestone, the costs ceramic.
of materials were estimated to be in the ratio of 1 23
to 1 in favour of flue gas. ' Chapman mentions that water containing silt or calcium
These advantages must be balanced against the following carbonate can be used in the scrubber which then has to be
disadvantages: of a suitable design to prevent blocking of nozzles. etc..by
solids. A local refinery is planning a modification to its flue
(a) Additional scrubbing with sodium carbonate solution gas scrubbing which now uses injection water to convert to
if sulphur-containing fuels are burnt. neutralised final effluent. The volume of water required for

51
Proceedings of The South African Sugar Technologists' Association - June 1988

Gas

i __
Water jets
out

I L __ ;g
~asout~{::'NJI\ ,,9t'L~ r== Gas in

~ f l--
o
~
0
~....-Water jets Coke
o bed

Water
level
gauge
glass

FIGURE 1 (a) FIGURE 1 (b)

i Gas
out

L_____ Water
in

I ~I==+-

/\

Water
level

FIGURE 1 (c)

52
Proceedings of The South African Sugar Technologists' Association - June 1988

5% Sodium waterl
In
carbonate

Gas
out Gas
out

s.s. angle
iron packing
Ceramic
raschig
rings

Water level
Gas
in
--_.--
Ceramic
Sodium carbonate
lining Water scrubber
scrubber
FIGURE 1 (d)
FIGURE 1 Sketches of various types of scrubbers found in refineries in southern Africa.

scrubbing is not quoted in any of the references which are recommended by Chapman and Huse (in Ref. 1). These
available, but two local refineries use about 0,9 m- per ton pumps are of all iron construction or with cast iron casing
of sugar melted, equivalent to a gas to water ratio of about and stainless steel rotor and shaft. If the flue gas contains
100-150 to 1. sulphur, it is recommended that the sealing water of liquid
The function of the scrubbers is not only to clean the gas, ring compressors be treated with sodium carbonate to main-
but also to cool it and Alberino' suggests that the outlet gas tain a pH of not less than 8. At the Durban refinery the
temperature should be maintained at 50·C by adjusting the carbonate solution from the scrubber is used as sealing liquid
water flow rate. The South African refineries report a gas in the compressors.
temperature of 50 to 60·C at the saturators. The lower the The gas pressure and its carbon dioxide content should
gas temperature, the higher the CO2 supply at a given flow be constant at the saturators and since the carbon dioxide
rate because of the effect of temperature on gas density, but content of flue gas varies with the boiler loading, it is rec-
the cooling effect of the gas in the saturators has to be com- ommended that piping be provided to tap off flue gas from
pensated by a higher heat input through the saturator more than one boiler. The boiler with the most stable load
calandria. should then be selected. The gas main from the compressors
to the saturators should be provided with a pressure con-
A separator is required on the gas outlet from the scrub- troller at the saturators, and with a by-pass opening into the
bers only if reciprocating compressors are used.
gas pump suction to maintain a constant pressure. In the
A sketch of the scrubbing plant at Dwangwa in Malawi event of the pressure running too high, especially when the
is shown in Figure 2. pH controller throttles gas to the saturator, the excess gas is
recirculated. In some local refineries, the excess gas is bled
Compression to atmosphere by pressure release valves. Alberino ' men-
The compressors are installed between the scrubbers and tions that at Savannah refinery surplus gas is returned to the
the saturators. They keep the scrubbers under a slight vac- inlet of the scrubber.
uum, generally of the order of 25 to 50 mm of water. The The volume of gas required will depend on three main
delivery pressure depends on the friction loss in the piping factors:
and on the liquid head in the saturators. It is typically about
70 kPa at the saturators. (a) The amount of lime added to the melt which in turn
Various types ofcompressors are found in local refineries. depends on the quality of the melt.
For example, Gledhow uses reciprocating compressors (after (b) The percentage of CO2 in the flue gas after scrubbing.
a lime kiln), Malelane has Roots type blowers, while the
other refineries use liquid ring compressors which are also (c) The efficiency of CO2 use in the saturators.

53
Proceedings of The South African Sugar TechnologistsAssociation - June 1988

r---,
I I
I I
I I
I I
I I
BOile,' & 21 Stack Scrubbing Venturi Mist
tank scrubber separator
I I
I I Cyclone
I I separator
I I r--""'---,

I I CO2
I I receiver
I I
J- _I
\
I \
I \
L l

<; to ash dis@Q-----,'-- ""'"

CO2 SCRUBBING PLANT

FIGURE 2 Flue gas scrubbing plant. Dwangwa Sugar Factory.

These factors are discussed below: Flue gas requirements have been calculated in Appendix
The stoichiometric requirement of CO 2 can be calculated 1 for a refinery with a liming rate of 1% CaO on melt solids,
from the formula: a CO 2 concentration in gas of 12%, and an efficiency of CO 2
absorption of 30% in the saturators. The value obtained was
CaO + CO 2 = CaC0 3 143 m' per ton of melt.
The amount of lime (CaO) required ranges from 0,4% to
1,2% on melt solids according to Chen.' Hulett Refinery
reports values ofO,5 to 0,7 but, for design purposes, it may Summary and Recommendations
be safer to use a value of 1% especially if the refinery may
have to process lower quality sugar than South African VHP. (a) Flue gas for scrubbing should be drawn from a boiler
The percentage of CO 2 by volume in flue gas is reported with a steady load to obtain an even concentration of
CO 2 (about 12% by volume).
to average 12% at Malelane' with values as high as 16%
before the boiler scrubber and 14% after the compressors. (b) With bagasse fired boilers a single water scrubber is
Occasional measurements at Ubombo and Hippo Valley in- sufficient. A gas to water ratio of 100 to 1 should be
dicate a CO 2 content ofabout 11 and 12% respectively, while provided. Poor quality water can be used for scrubbing.
the Tongaat-Hulett refinery (coal fired boilers) reports 10 to
11%. A value of 12% has been used in the gas volume cal- (c) A second scrubbing with 5% sodium carbonate solution
culation (Appendix 1). is required for flue gas from sulphur containing fuels
(coal or oil). The solution is recycled and the sodium
The efficiency of CO 2 use is difficult to measure and al- carbonate requirements can range from 13 to 75 grams
though efficiencies of 100% have been claimed in line mix- per ton of sugar melted, depending on the sulphur con-
ers,' both Huse and Chapman use values of 30% for tent ofthe fuel and the efficiencyof the water scrubbing.
conventional saturators. The efficiency will obviously be af-
fected by the design of the saturators (number of units, gas (d) The gas piping can be of mild steel, but the hot section
distribution, liquid head) and by the brix and temperature must then be lagged to keep the temperature above dew
of the melt. point.
The volume of carbon dioxide gas required for refining
quoted by various authors is listed below: (e) Several designs of scrubbers are available. The scrub-
bers can also be of mild steel but wetted parts should
Huse (in Ref. 2) 142 m- per ton of sugar in melt preferably be of stainless steel.
Chapman (in Ref. 2) 162 m' per ton of sugar in melt
Alberino ' 168 m' per ton of sugar in melt (f) The gas after scrubbing should be at 50 to 60·C. With
Although the temperature and pressure of the gas are not bagasse fired boilers a volume of 143 m' per ton of melt
is adequate. Gas pressure at the saturators is about
specified, this volume can be assumed to be at approxi-
70 kPa.
mately 50·C and atmospheric pressure. They should be com-
pared to the 60 to 85 m 3 reported by the Durban refinery. (g) Liquid ring compressors are recommended.

54
Proceedings of The South African Sugar Technologists' Association - June 1988

Acknowledgement (2) CO2 concentration in gas after scrubber = 12%

(3) Water vapour concentration in gas by vol. = 8%
Information used in this paper was obtained from the (4) Efficiency of CO, absorption in saturator = 30%
refineries in South Africa, Zimbabwe, Swaziland and Ma-
(5) Temp. gas after scrubber = 50'C
lawi. The assistance received from Mr D. Tayfield is
acknowledged. Basicformula CaO + CO2 = CaC0 3
Molecular weights (40 + 16) + (12 + 32) = (40 + 12 + 48)
i.e. 56 + 44 100
REFERENCES
Assume 100 tons of Brix in melt per hour
I. Alberino, JW (1961). Carbonatation at the Savannah sugar refinery, Wt. of CaO required = 0,0I X 100 = I ton h-I
SIT vol xx, No. I p 55.
2. Baikow, VE, Manufactureand refining of raw cane sugar, Elsevier, Am-
Stoichiometric wt. of CO2 = I X ~: X 1000 = 786 kg h-I
sterdam, 1982. Actual CO2 required @ 30%efficiency
3. Chen, JCP, Cane sugar handbook, lIth ed., John Wileyand Sons, New 786
York, 1985. = - = 2620 kg h-I
4. Lyle, 0, Technology for Sugar Refinery Workers, Chapman and Hall, 0,3
London, 1957. 2620
5. Wiehe, HF and Pillay, JV (1986). Summaries of talks presented at the = - - = 59 5 kg moles h-I
colloquim on refining at the SMRI on 24 October, 1985, SMRI Tech 44 '
Rep No. 1432. @ 22,4 mvrnole gas volume = 59,5 X 22,4 = 1333 m3 h-I at STP
Flue gas requirement after correction for temperature,
APPENDIX 1 CO2 and water vapour content
1333 I (273 + 50)
Calculation orc02 Requirements and Compressor Capacity = 0,12 X 0,92 X •(273)
Assumptions: = 14285 m! h-I
(I) Maximum liming rate = 1%CaO on melt solids or 143mvton brix in melt

55