Project Synopsis
Evaluate and design scrubber process improvement modifications to reduce fugitive emissions of hazardous gases during QAQ production campaigns.
Project Summary
Process Engineering Associates, LLC (PROCESS) was contracted by a US producer of dyes and pigments who wished to evaluate several improvement projects at one of their production facilities which produces Quinacridone Alpha Quality (QAQ).
One of the items being evaluated is to reduce the generation of fugitive emissions of hazardous gases (chlorine and chlorine dioxide) during QAQ production campaigns that pose a threat to operators in the immediate area. Fugitive emissions are caused by over-pressure in the extraction tank due to fouling of the scrubber column packing.
The proposed solution was a larger volume scrubber hold tank that can accommodate a greater volume of scrubber solution. The larger volume of scrubber solution, above what is currently used for QAQ production, will inhibit, by virtue of excess reactants and dilution, and the formation of salts that contribute to scrubber fouling.
The work performed in this effort is the basic process design of the larger sized hold tank applied to the scrubber column.. The chemistry of the hold tank was modeled using OLI software. The OLI modeling verified that greater volumes of solution (caustic, HYPO, and water), mitigates the formation of solid precipitates that foul the scrubber packing. The primary mechanism is providing all the caustic and HYPO solution to maintain concentrations above permit values and using “fresh” water to dilute the solution to maintain low sodium salt concentrations.
PROCESS developed an equipment specification for a new hold tank for the purpose of soliciting preliminary tank quotations. In addition, a layout sketch of the proposed arrangement and a red-lined P&ID were also developed. PROCESS also generated the technical portion of a Statement of Work (SOW) package to be used by the Client to solicit quotes from third party EPC and/or MEP companies to further design and install the modifications.
Industry Type
Dye and Pigment Manufacturing
Utilized Skills
- Process technical evaluations
- Process improvements design
- Scrubber system design.