This invention relates to smelt processing, to Kraft wood pulping processes, to Kraft wood pulping mills, to black liquor recovery processes and apparatuses, and to related fields.
Conversion of wood into wood pulp is typically done using the Kraft process. Wood chips are cooked in a mixture containing water, sodium hydroxide, and sodium sulfide. This mixture, commonly referred to as white liquor, assists with separating the cellulose fibers (wood pulp) from the lignin holding the fibers together. The separated cellulose fiber are then removed, leaving behind a waste product, typically referred to as black liquor.
Reclamation and reuse of the cooking chemicals from the black liquor is desirable to control costs associated with the paper-making process. During the recovery process, the black liquor is concentrated into a solution containing approximately 65 to 80 percent solids. The concentrated solution is sprayed into the internal volume of a chemical reduction furnace, also sometimes referred to as a recovery boiler. The black liquor is burned in the recovery boiler to recover the spent pulping chemicals and to produce steam and power for use in various processes. The combustion results in the formation of a molten smelt pool at the bottom of the boiler primarily consisting of sodium carbonate (Na2CO3) and sodium sulfide (Na2S). Molten smelt having a density of about 2000 kg/m3 and a surface tension of about 0.21 N/m continuously flows out of the boiler at about 780 to 830° C. (1440 to 1530° F.) through several spouts at a flow rate of about 1 Us per spout. Preferably, the smelt streams are broken up by a shatter jet into small droplets of a few millimeters.
The shattered smelt droplets fall into a dissolving tank where they dissolve in a weak wash (water recycled from the causticizing plant) to form a green liquor. The interaction between molten smelt and green liquor can be loud and violent. In extreme cases, dissolving tank explosions occur and may cause equipment damage, personnel injuries, and boiler shutdowns. These extreme cases are undesirable, prompting increasingly stringent regulations. Development of new and improved smelt nozzles and methods for effective and safe dissolving tank operation are a top priority in pulp mill operation.
Certain improvements are disclosed herein.
In some illustrative embodiments disclosed herein as nonlimiting examples, a smelt shattering apparatus comprises an inlet orifice, an outlet orifice, a fluidic pathway between the inlet orifice and the outlet orifice, and a convergence divergence zone located between the inlet orifice and the outlet orifice. In some such embodiments, a first separable section includes the inlet orifice, and a second separable section includes the outlet orifice and a divergence zone of the convergence divergence zone. In some embodiments, there may be a second outlet orifice in fluidic communication with the inlet orifice. In some such embodiments, the first outlet orifice may have a cross-sectional dimension and the second outlet orifice is located a distance of between about 4 and about 10 times of the cross-sectional dimension from the first outlet orifice.
In some illustrative embodiments disclosed herein as nonlimiting examples, a smelt shattering nozzle comprises an inlet orifice, an outlet orifice, and a fluidic pathway between the inlet orifice and the outlet orifice having a constriction. In some such embodiments, the nozzle comprises a first section including the inlet orifice, and a second section including the outlet orifice, with the first section and the second section secured together to define the fluidic pathway with the constriction defined at an interface between the first and second sections. In some such embodiments, the portion of the fluidic pathway in the second section widens from the interface to the outlet orifice. In some such embodiments, the portion of the fluidic pathway in the first section has a larger diameter than the portion of the fluidic pathway in the second section. In some embodiments the portion of the fluidic pathway extending from the inlet orifice to the constriction narrows leading into the constriction.
In some illustrative embodiments disclosed herein as nonlimiting examples, a smelt shattering apparatus comprises a plurality of smelt shattering nozzles as set forth in the immediately preceding paragraph. The outlet orifices of the smelt shattering nozzles have a diameter, and a spacing between the outlet orifices of the plurality of smelt shattering nozzles is less than or equal to eight times the diameter.
In some illustrative embodiments disclosed herein as nonlimiting examples, a method is disclosed of smelt shattering. A smelt shattering apparatus is provided, including an inlet orifice, an outlet orifice, a fluidic pathway between the inlet orifice and the outlet orifice, and a convergence divergence zone located between the inlet orifice and the outlet orifice. A fluidic stream is flowed thru the fluidic pathway to produce a fluidic jet. The fluidic jet is contacted with a smelt stream to convert the smelt stream to shattered smelt. The shattered smelt is disposed in a dissolving tank. In some embodiments, the fluidic stream comprises steam. In some embodiments, the method further includes producing the smelt stream using a Kraft pulp mill by burning black liquor in a recovery boiler.
With reference to
Numerous studies have been conducted on dissolving tank safety. The results have shown that molten smelt droplets often do not explode immediately when they meet water, but rather, remain stable in water for a few seconds before they explode. It was further observed that the explosion of one droplet may trigger the explosions of other droplets nearby, leading to a chain of multi-droplet explosions. These findings imply that 1) droplet-scale or “mini” smelt-water explosions are needed for effective smelt dissolution in the dissolving tank, and 2) large-scale explosions caused by either one large piece of molten smelt or many small droplets in a small, confined area can be violent.
A thermodynamic model, based on Hicks-Menzies principles was developed to calculate the energy released by a large smelt-water interaction in the dissolving tank. The results showed that the conversion ratio (CR), which is the ratio of the total explosion energy to the available thermal energy stored in the smelt, increases with increasing green liquor temperature and green liquor-to-smelt volume ratio. This implies that to reduce the probability of a dissolving tank explosion, the shatter jet design needs to be optimized so that molten smelt droplets can be uniformly distributed over a large area on the green liquor.
Smelt shatter jet designs and shattering practices vary widely from mill to mill with no clear guidelines in the industry for nozzle design, configuration, and operation. Typically, nozzles operate with saturated steam (3.5 to 15.5 bar, corresponding to 50 to 225 psig; and at 150 to 250° C., corresponding to 300 to 480° F.) and the resulting shatter jets are directed vertically downward or slightly against the direction of smelt flow.
With reference to
In some cases a shatter jet 26 may miss a portion or all the smelt flow 12 due to a change in smelt flow characteristics. Thus, a shatter jet having wide coverage is also desirable. Further, while smelt shattering should attain optimum droplet distribution, there is also a desire to minimize steam consumption to reduce operating cost.
Thus, it is recognized herein that a shatter jet nozzle should desirably be capable of meeting multiple criteria: i) generating high shattering energy, ii) enabling wide coverage, and iii) minimizing steam consumption. Disclosed herein are embodiments of a shatter jet nozzle and methods of performing smelt shattering that address these multiple criteria, e.g. having sufficient shattering energy to handle both normal smelt flow and upset conditions, providing wide coverage, and minimizing steam consumption.
With reference to
The fluidic pathway 22 has a constriction or throat 44 which divides the fluidic pathway 22 into a convergence zone 46 between the inlet orifice 40 to the throat 44 and a divergence zone 48 between the throat 44 to the outlet orifice 42. The terms “constriction” and “throat” are used interchangeably herein to refer to the narrowed portion of the fluidic pathway 22 separating the convergence zone 46 and the divergence zone 48. In general, the steam flows at a high pressure and low velocity in the convergence zone 46 as the steam converges into the constriction or throat 44; then the steam diverges as it exits the throat 44 so that the steam in the divergence zone 48 is at a lower pressure and higher velocity compared with the respective high pressure and low velocity in the convergence zone 46. The divergence zone 48 widens from the constriction or throat 44 to the outlet orifice 42. The convergence zone 46, that is, the portion of the fluidic pathway 22 extending from the inlet orifice 40 to the constriction 44, optionally narrows leading into the constriction 44, although it may in other embodiments be of constant inner lumen diameter (see, e.g.
The complex fluid dynamics of the shatter jet nozzle 20 enable and allow the steam flow to reach sonic velocity at a throat or constriction 44 and higher at the exit, i.e. outlet orifice 42. Factors, including outlet diameter Do, a throat diameter Dth of the constriction or throat 44, an expansion angle Adiv of the divergence zone 48, and nozzle length, enable customization of the shatter jet nozzle 20 for use with various smelt flow characteristics.
A converging-diverging (CD) nozzle with a suitably designed throat-to-outlet orifice area ratio R:
achieves higher impact pressure with the given steam flow than a cylindrical hole nozzle, due to its more effective jet expansion that achieves same strength at lesser steam consumption. The flow rate of a nozzle can be calculated by:
where m is the mass flow rate, Cd is the discharge coefficient, A is the cross-sectional area of the choke point (i.e.,
γ is the heat capacity ratio of steam, and ρo is the density at the inlet pressure Po and temperature.
To achieve wide coverage, multiple outlet orifices 42 may be placed adjacent to each other to attain a wider pressure profile. (See, e.g. embodiment of
With reference to
To evaluate the performance of the CD multi-jet nozzles, various design parameters were examined, while a conventional multi-hole (non-CD) nozzle was also tested for performance comparison. A summary of the experimental conditions is listed in Table 1.
In the experimental setup used in this study, compressed air was used in the experiments to simulate steam. A pitot tube array was placed in front of the nozzle being tested to measure the jet peak impact pressure, which is an indication of shatter jet strength. The position of the pitot tube could be adjusted in the x-, y-, and z-directions. Variation of the x- and y-position generates a jet pressure profile, and the varying z-position changes the distance between the nozzle and the pitot tube.
With reference to
With reference to
With reference to
With reference to
In summary, the disclosed shatter jet design (e.g. as embodied by illustrative shatter jet nozzle 20 of
With reference now to
While
The shatter jet nozzle 120 of
Spacing geometry between outlet orifices 42 enable widening of the steam patterns while maintaining a desired impact pressure profile. In at least one embodiment the spacing ΔD between orifice outlets 42 of the dual jet nozzle 120 is 4Do, where Do is the diameter of the orifice outlet 42 (Do is labeled only in
While the above description constitutes the preferred embodiment of the present invention, it will be appreciated that the invention is susceptible to modification, variation and change without departing from the proper scope and fair meaning of the accompanying claims.
This application claims the benefit of U.S. Provisional Application No. 63/076,665 filed Sep. 10, 2020 and titled “SMELT SHATTERING METHOD AND APPARATUS”. U.S. Provisional Application No. 63/076,665 filed Sep. 10, 2020 and titled “SMELT SHATTERING METHOD AND APPARATUS” is incorporated herein by reference in its entirety.
Number | Name | Date | Kind |
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3184916 | Ravel | May 1965 | A |
20080290193 | Hursen | Nov 2008 | A1 |
20100102139 | Hursen | Apr 2010 | A1 |
Number | Date | Country |
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113741557 | Dec 2021 | CN |
102019135375 | Jun 2021 | DE |
Entry |
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Taranenko, Shattering Kraft Recovery Boiler Smelt by a Steam Jet, 2013, University of Toronto. (Year: 2013). |
Jin et al., Development of converging-diverging multi-jet nozzles for molten smelt shattering in kraft recovery boiler, Mar. 2021, TAPPI, vol. 20 No.3 (Year: 2021). |
Taranenko et al., A laboratory study of recovery boiler smelt shattering, Aug. 2014, TAPPI Journal, vol. 13 No.8 (Year: 2014). |
CN113741557A English translation, 2020. (Year: 2020). |
Number | Date | Country | |
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20220074142 A1 | Mar 2022 | US |
Number | Date | Country | |
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63076665 | Sep 2020 | US |