Graphical strategies for design of evaporation crystallization networks for environmental wastewater applications

This paper introduces graphical strategies for the design of an evaporation/crystallization network for ternary wastewater environmental applications. Sources, sinks and other streams are located on a ternary composition diagram. While a source is any wastewater stream that has the potential to be recycled, a sink is any unit in the process that can accept sources. The proposed methodology is extremely simple to understand and implement, as it only requires basic solid-liquid phase equilibria data and uses lever arm principles to generate alternative process designs. Geometric constructions are carried out on the ternary composition diagram and the respective lever arms are used to determine intermediate flow rates in the evaporation/crystallization network. The relative locations and flow rates of the sources and sinks under consideration, as well as the unique shape of the solid-liquid equilibrium, drive the design of the separation (via evaporation/crystallization) network. Some generic structures are proposed for a typical evaporation and crystallization network. Once the general problem statement has been defined, special cases consisting of a single source-single sink, single source-two sinks and two sources-single sink are described. These special cases are representative of commonly occurring industrial wastewater design problems. Several graphical insights are listed that allow one to represent evaporation and crystallization operations on a ternary triangular composition diagram and avoid mathematical complexity. The possibility of bypassing a part of the initial feed streams is also considered. Certain feasible composition regions are identified on the ternary composition diagram for cases dealing with multiple sources and sinks. The methodology is useful in pre-screening and eliminating certain sources/sinks and is readily applicable to cases with lower number of sources and sinks. A case study involving the ammonium nitrate manufacturing process is included to demonstrate the broad applicability and value of the proposed approach.