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ENCO ENGINEERING GmbH

Sgenstrasse 97
CH-7001 Chur
Telefon 081 254 12 12
Telefax 081 254 12 13
e-mail enco@enco.ch
Internet http://www.enco.ch

Polyaluminium chloride (PAC) is increasingly used in water treatment. Against the


conventional use of aluminium sulphate it is showing distinct advantages.
A polyaluminium chloride plant is an investment opportunity with attractive returns
in a growing market.
Enco Engineering is presenting in the following basic information for a polyalumin-
ium chloride project.
The process technology is licensed by a European producer. The process as of-
fered is following newest technologies and achieving products of excellent quality.
It has substantial advantages against a conventional PAC process.
The technology is presently applied in seven plants in Europe producing 20'000
tons per annum each and one producing 100'000 tons per annum.
ENCO ENGINEERING GmbH

PROCESS FEATURES The second product produced in the plant will


therefore be a polyaluminium chloride with a
The proposed improved PAC process is giving Al2O3-content of 9 % and a basicity of approx.
the following advantages against a conventional 66 %. It is produced out of poly aluminium chlo-
process: ride 18 % by a special process achieving the
PAC with a concentration of 18 % Al2O3 requested high basicity.
(1-2 % higher than most other products) Appearance: liquid with straw yellow colour
PAC with a concentration of 9 % Al2O3 Al2O3 8.8 9.2 %
PAC with a higher basicity Cl- 9.8 11 %
Low production cost SO42- 1.2-1.4 %
No by-products (no acidic calcium sul- Basicity 62 68 %
phates difficult to dispose of). Spec. Weight(20C) 1.18 1.22 g/ml
Solidification point - 10C

PLANT CAPACITY
PROCESS DESCRIPTION
A typical plant capacity for a polyaluminium
chloride plant is 30'000 tons/ annum The process for the manufacturing of polyalu-
minium chloride consists of the reaction and
with 90 tons/day in 24 hours operation. polymerization between alumina (aluminium
oxide hydrate) and hydrochloric acid at high
temperature and pressure.
PRODUCT SPECIFICATION
Polyaluminium Chloride 18 % Al2O3 The hydrochloric acid is fed to the reactor as
first ingredient. The amount depends on the
Appearance: liquid with straw-yellow colour batch capacity and on the concentration of the
General Formulae [Al2(OH)2.7 Cl3.3]n raw material. Alumina is fed to the reactor as
Al2O3 17 19 % second ingredient, under continuous stirring.
Cl- 21 22 % After completion of feeding the reactor system is
closed and heating is started.
Basicity 36 42 %
Specific Weight (20 C) 1.36 1.38 g/ml
The heating of the reactor is carried out in two
Viscosity (20 C) 40 60 cP
steps. Low pressure steam is used first, to avoid
pH (29 C) 0.4 1.2
thermal shock that may damage the internal
Solidification point - 10 C glass lining of the reactor.

The primary product resulting from the polym- As the reaction temperature is reached the po-
erisation process at standard reaction conditions lymerisation step starts under stirring and con-
has a content of 18-19 %. stant temperature. At the end of the reaction the
product is cooled again step wise with a warm
This product is adjusted to the commercial as- water circuit to avoid thermal shock.
say of 17 - 17.5% Al2O3 and sold as such for
most applications. The product is then fed by a high pressure
Polyaluminium Chloride 9 % Al2O3 pump to the filter-press. The filtered product is
transferred to a storage tank.
For drinking water treatment plants without units
for addition of silicates, fungicides or
polyelectrolytes preferably a PAC of 9 to 10%
Al2O3 is used. By adjustment of the assay it is
possible to change the size of the resulting
flocks and consequently the sedimentation
velocity. The corresponding PAC product has
also a high so called "Basicity".

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ENCO ENGINEERING GmbH

CONSUMPTION FIGURES depend on the quality of the alumina raw mate-


rial. It is usually below 1 %.
The consumption figures for 1000 kg of Poly- Off-gas from reactors and tanks containing hy-
aluminium chloride 18 % are as follows: drochloric acid is washed in a scrubber.
Raw Materials
Alumina kg 280 OFFSITES
Hydrochloric Acid (33 %) kg 700
To serve the needs of the process units, the
Utilities following utility units are required:
Steam kg 180 - Storage facilities for raw materials, chemi-
Power kWh 15 cals, consumables and product
Cooling water m3 20 - Power supply
Compressed air Nm3 3 - Steam boiler
Demineralized water m3 0.3 - Cooling tower
- Demineralized water supply
- Instrument air supply
RAW MATERIALS, CHEMICALS AND - Compressed air supply
UTILITIES
Alumina Specification (typical analysis) SPACE REQUIREMENTS
Formula Al2O3.3H2O or Al(OH)3 The main part of the plant is foreseen to be in-
Al2O3 content 61 63 % stalled in an open air structure. Only the control
Humidity 36% room will be installed inside a building.
Impurities SiO2 10 150 ppm For the process plant an area of approx.
Fe2O3 5 120 ppm 20 x 20 m will be required, without storage silos.
CaO 10 150 ppm
ZnO 5 35 ppm
LABOUR REQUIREMENTS
Hydrochloric Acid Specification (typical )
For operation of the process plant including
HCl content 32 35 % supervision the following staff will be required:
Specific Weight 1.165 1.175 kg/l
per shift total
HF absent
Supervisor 1
Cl2 content max. 0.1 %
Operator 1 4
Hg content absent
The supervisor could partly be used for other
For the production of PAC ideally hydrochloric
plant sections within the complex.
acid of 35 % is used. With such a concentration
the product will be a PAC with a concentration of
19 % Al2O3, with an important economical ad-
vantage. PROJECT TIME SCHEDULE

Using hydrochloric acid of 32 % a PAC of 18 % The estimated time from start of the engineering
Al2O3 will be obtained, with hydrochloric acid of to plant completion and operation is in the range
31 % a PAC of 17.7 % Al2O3. of 15 months.

Impurities in the hydrochloric acid do not disturb,


if the produced PAC will be used in treatment of
urban or industrial waste water or for the treat-
ment of sludge.

EFFLUENTS
The process is not producing any liquid efflu-
ents. Acidic washing water from the filter press
etc. will be recycled to the process. Crude
polyaluminium chloride is filtered in a filter press,
where small amounts of solids are removed.
The quantity of the solids, mostly silicates, will

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ENCO ENGINEERING GmbH

APPLICATIONS OF PAC Industrial Process Water Treatment


Textile and paper industries as well laundries
Polyaluminium chlorides are synthetic polymers require a pre-treated raw water. PAC allows
dissolved in water. They react to form insoluble elimination of any suspended materials without
aluminium poly-hydroxides which precipitate in use of alkalisation compounds.
big volumetric flocks.
Industrial Waste Water Treatment
The flocks absorb suspended pollutants in the
water which are precipitated with the PAC and PAC has excellent absorption capabilities for
can together be easily removed. coloured materials and other pollutants.
It is widely applied in treatment of waste waters
Stable PAC resulting from defined reaction con- from small, medium or big industries, without
ditions can be stored at ambient temperature using any alkalisation compounds. The obtained
and easily be transported by normal transport sludge can easily be dewatered in dryers, centri-
facilities like trucks or railway. Dosing of PAC fuges or a filter press.
can also be achieved easily.
Urban Waste Water
Flocculent in Drinking Water Treatment In urban waste water treatment PAC is used in
the primary sedimentation step, in the biological
In the production of drinking water PAC is re- oxidation step and also in the fourth step, filtra-
placing aluminium sulphate. Due to its polymer tion after phosphate precipitation.
structure treatment with PAC achieves bigger
flocks and higher sedimentation velocity, easily With PAC treatment it possible to keep a waste
separated by filtration through a sand or an acti- water treatment unit in operation without biologi-
vated carbon filter. cal oxidation step.
PAC flocks are able to adsorb acidic bio- A further special application is the dewatering of
materials as usually present in river water or in the sludge in filter press without application of
rain water collecting pits. Treatment with PAC polyelectrolytes.
results in a very clean drinking water with low Paper Industry
values for TOC (total organic carbon) and an
extremely low aluminium ion content (less than In the paper industry PAC has three important
0.3 ppm). applications: PAC is applied in the preparation
of cellulose batches with inorganic loads, espe-
Additionally PAC treatment replaces treatment cially with recycling paper. It has the property of
with iron salts. It is producing a drinking water dispersing resins, avoids breaking of the paper
which is perfectly colourless and is removing on the drying cylinder and helps in dewatering.
any material with so called "after flocculating" PAC is used for a better distribution of the cellu-
properties, i.e. after PAC filtration no sediments lose fibres, a better distribution and fixing of
will reappear as sometimes occurring with other pigments added to the paper mass and conse-
flocculants. quently less turbid effluents after filtration. Alu-
The possible slightly higher unit price of PAC is minium sulphate has to be used at a pH of appr.
compensated by a 4.5 and allows only the production of acidic
papers, whereas PAC allows to work at a pH of
lower dosage requirement 6.5 -7.5, producing papers with neutral pH,
no requirement for any neutralising which is a high advantage for papers for books,
agent (soda, lime) drawing paper and other documents. Such a
higher quality of the treated water paper will not get any yellow colour also after
years.
Using PAC instead of aluminium sulphate re-
sults in getting a PAC is used in the water effluents obtaining
good results without the necessity to use a bio-
shorter flocculation time logical oxidation step.
smaller amount of sludge
PAC produced in the process as offered is not
reduced number of back washing steps containing any sulphates and therefore there
with a significant saving of already treated are no incrustation of calcium sulphate. Such
water. sulphate- less PAC develops at the presence of
reducing bacteria no corrosive and bad smelling
Against the aluminium sulphate in powder form, hydrogen sulphide.
PAC solution is a product ready to use and with
constant assay.

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