Project Synopsis
Perform an FEL-0 design of a pilot scale process to electro-chemically dissolve steel slag and produce calcium and magnesium hydroxide as part of a larger carbon sequestration process, as well as evaluate an additional downstream metals recovery process for a startup technology development company.
Project Summary
Process Engineering Associates, LLC (PROCESS) was contracted by the client, a clean technology startup, to provide an FEL-0 design of a pilot scale process to electro-chemically dissolve steel slag and produce calcium and magnesium hydroxide as part of a larger carbon sequestration process. The client had performed lab scale testing to validate their process chemistry and wanted to identify options for scaling up.
Due to the unique nature of the process, PROCESS began the project by performing a literature review and survey of existing technologies available to achieve the clients process goals. The client desired to generate acid (required for steel dissolution) and base (required for calcium and magnesium hydroxide precipitation) in situ via water hydrolysis. Various electrochemical reactor styles were evaluated. Advantages and drawbacks of each reactor type were evaluated and presented to the client.
After an electrolytic cell style was agreed upon, PROCESS developed a heat and material balance (HMB) and process flow diagram (PFD) that included the electro-chemical reactor and associated equipment. OLI Flowsheet was selected to model the process due to the complex aqueous chemistry and solids precipitation involved.
PROCESS also evaluated and recommended an electrolytic cell vendor for the client to engage based on the vendors wide experience in electrochemistry and pilot scale, modifiable reactor cells. PROCESS developed a basis of design for the client to use as they engaged with the vendor.
Finally, PROCESS summarized the above literature review, design basis, and process design in a letter report, along with an outline of the critical operating parameters to monitor for the new pilot scale plant.
Once the project was completed, the client asked PROCESS to evaluate an additional metals recovery process downstream from the previously evaluated electro-chemical process. PROCESS performed a review of the existing technologies for metals concentration and recovery and provided vendor recommendations for the client to consider for further testing and evaluation. Advantages and drawbacks of the various technologies were provided in a written report.
Industry Type
Process Technology Development
Utilized Skills
- FEL-0 pilot-plant preliminary design
- Technical literature search.