Separation processes, operation

Crude oil is a simple example of a mixture (Figure 13-3). It is composed of hundreds of different hydrocarbons. Process operators separate the different components in the crude oil by heating it to the boiling point in a distillation column. 

Given the choice of a batch rather than continuous process, does this need a different approach to the synthesis of the reaction and separation and recycle system In fact, a different approach is not needed. We start by assuming the process to be continuous and then, if choosing to use batch operation, replace continuous steps by batch steps. It is simpler to start with continuous process operation... 

The third source of process waste after the reactor and separation and recycle systems is process operations. 

The CO2 Acceptor process, also developed under AGA/DOE sponsorship, by the ConsoHdation Coal Co., uses steam to gasify lignitic coal. Heat is supphed by the exothermic reaction between CO2 and calciaed dolomite [17069-72-6]. The dolomite is calciaed ia a separate fluidized bed. This process operates ia a 40 t/d pilot plant, but there are no plans for commercialization as of this writing. 

Refining Processes. AH the reduction processes yield an impure metal containing some of the minor elements present in the concentrate, eg, cadmium in 2inc, or some elements introduced during the smelting process, eg, carbon in pig iron. These impurities must be removed from the cmde metal in order to meet specifications for use. Refining operations may be classified according to the kind of phases involved in the process, ie, separation of a vapor from a Hquid or soHd, separation of a soHd from a Hquid, or transfer between two Hquid phases. In addition, they may be characterized by whether or not they involve oxidation—reduction reactions. 

The processing operations for fluid or manufactured milk products include cooling, centrifugal sediment removal and cream (a mixture of fat and milk semm) separation, standardization, homogenization, pasteurization or sterilization, and packaging, handling, and storing. 

Flow Sheets. AH minerals processing operations function on the basis of a flow sheet depicting the flow of soHds and Hquids in the entire plant (6,13,14). The complexity of a flow sheet depends on the nature of the ore treated and the specifications for the final product. The basic operations in a flow sheet are size reduction (qv) (comminution) and/or size separation (see Separation, size), minerals separation, soHd—Hquid separation, and materials handling. The overaH flow sheet depends on whether the specification for the final mineral product is size, chemical composition, ie, grade, or both. Products from a quarry, for example, may have a size specification only, whereas metal concentrates have a grade specification. 

Sizing of the cmshed and ground product is a necessary step prior to any mineral processing operation, and in the production of a product having a specific size. Controlling the size of material fed to other equipment is important. AH equipment has an optimum size range of material that it can handle most efficiently. Size separation can be achieved either by screening (for coarser particles) or by classification (for fines) (see also Separation, size). 

The hydrocyclone, commonly referred to simply as cyclone, is a nonmechanical sedimentation-type classifier (2,6,10,27) (Fig. 7). It has no moving parts or power attachments directly connected to it. The hydrocyclone has become the workhorse of most mineral processing operations because of its simplicity, short residence time, compactness, and low cost of operation. It is, however, characterized by lack of sharpness of separation. Equipment... 

To avoid generation of waste brines and the associated serious problem of brine disposal, the potash industry in the former FRG began converting some operations to electrostatic separation, a dry process for separating potassium salts from other soluble salts (24,25). 

In 1974, Monsanto brought on-stream an improved Hquid-phase AIQ. alkylation process that significantly reduced the AIQ. catalyst used by operating the reactor at a higher temperature (42—44). In this process, the separate heavy catalyst—complex phase previously mentioned was eliminated. Eliminating the catalyst—complex phase increases selectivities and overall yields in addition to lessening the problem of waste catalyst disposal. The ethylben2ene yields exceed 98%. 

These processes are aH characterized by low isobutane conversion to achieve high isobutylene selectivity. The catalytic processes operate at conversions of 45—55% for isobutane. The Coastal process also operates at 45—55% isobutane conversion to minimize the production of light ends. This results in significant raw material recycle rates and imposing product separation sections. 

Both air and oxygen processes can be designed to be comparable in the following areas product quaUty, process flexibiUty for operation at reduced rates, and on-stream rehabiUty (97,182). For both processes, an on-stream value of 8000 h/yr is typical (196). The rehabiUty of the oxygen-based system is closely linked to the rehabiUty of the air-separation plant, and in the air process, operation of the multistage air compressor and power recovery from the vent gas is cmcial (97). 

In the use of temperature measurement for control of the separation in a distillation column, repeatability is crucial but accuracy is not. Composition control for the overhead product would be based on a measurement of the temperature on one of the trays in the rectifying section. A target would be provided for this temperature. However, at periodic intervals, a sample of the overhead product is analyzed in the laboratory and the information provided to the process operator. Should this analysis be outside acceptable limits, the operator would adjust the set point for the temperature. This procedure effectively compensates for an inaccurate temperature measurement however, the success of this approach requires good repeatability from the temperature measurement. 

Mixed liberated particles can be separated from each other by flotation if there are sufficient differences in their wettability. The flotation process operates by preparing a water suspension of a mixture of relatively fine-sized particles (smaller than 150 micrometers) and by contacting the suspension with a swarm of air bubbles of air in a suitably designed process vessel. Particles that are readily wetted by water (hydrcmhiric) tend to remain in suspension, and those particles not wetted by water (hydrophobic) tend to be attached to air bubbles, levitate (float) to the top of the process vessel, and collect in a froth layer. Thus, differences in the surface chemical properties of the solids are the basis for separation by flotation. 

The plates are dried and cured under controlled temperature and humidity conditions producing no wastewater or particulate emissions. Cured plates are sent to a three-process operation that involves manual separation of the plates, stacking them with non-conducting separators, and the welding on of metallic lead battery leads (pronounced leeds ) and lead terminals. The plates are then assembled Into battery cases. 

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