Concentrator and crystallizer evaporation system
An aqueous stream cleaning system including a circulation pump to receive a waste fluid and/or a concentrated liquid bottoms stream, and expel a circulation stream. The aqueous stream cleaning system can also include a primary heat exchanger to receive the circulation stream from the circulation pump. The primary heat exchanger can have a plurality of heat exchange plates that define an internal surface area for heat transfer from a distillate stream to the circulation stream to produce a cooled distillate stream and a heated circulation stream. The plurality of heat exchange plates can be spaced to facilitate free flow of solids in the circulation stream between the plurality of heat exchange plates. A mass flow rate and pressure of the circulation stream can be configured to minimize build-up of solids in the primary heat exchanger. The aqueous stream cleaning system can further include an evaporation unit to receive the heated circulation stream from the primary heat exchanger. The distillate stream is formed when steam in the heated circulation stream evaporates in the evaporation unit, and the concentrated liquid bottoms stream is formed from a portion of the heated circulation stream that does not evaporate.
1. An aqueous stream cleaning system, comprising:
a waste fluid pump in fluid communication with a waste fluid source and configured to expel a waste fluid stream;
a circulation pump configured to receive at least one of the waste fluid stream and a concentrated bottoms stream, and expel a circulation stream;
a primary heat exchanger configured to receive the circulation stream from the circulation pump, said primary heat exchanger having a plurality of heat exchange members that define an internal surface area for heat transfer from a pressurized distillate stream to the circulation stream;
an evaporation unit configured to receive a heated circulation stream from the primary heat exchanger, wherein a cooled distillate stream is formed when the heated circulation stream evaporates in the evaporation unit, and the concentrated bottoms stream is formed from a portion of the heated circulation stream that does not evaporate; and
a recirculation loop comprising a recirculation stream having an inlet from the waste fluid stream prior to the circulation pump, wherein the recirculation stream rejoins the waste fluid stream upstream of the inlet.
2. The cleaning system of claim 1 , further comprising a controller configured to control the mass flow rate of the circulation stream or the mass flow rate of the distillate stream such that
a ratio of the mass flow rate of the circulation stream to the mass flow rate of the distillate stream is greater than about 300, and wherein the heat exchange members comprise
a plurality of heat exchange plates, wherein the plurality of heat exchange plates are substantially flat and are spaced at least 6.0 mm from one another.
3. The cleaning system of claim 2 , further comprising:
a compressor to receive the distillate stream from the evaporation unit and expel the pressurized distillate stream to the primary heat exchanger, after which the cooled distillate stream condenses.
4. The system of claim 2 , wherein a ratio of the mass flow rate of the circulation stream to the mass flow rate of the distillate stream ranges from about 300 to 500.
5. The system of claim 2 , wherein the plurality of heat exchange plates are substantially flat and are spaced from one another between about 6 mm to 12 mm and wherein the plurality of heat exchange plates have a thickness of at least about 0.8-0.9 mm.
6. The system of claim 2 , wherein the heat exchange plates are placed within the heat exchanger such that no portion of an individual heat exchange plate is in contact with an adjacent heat exchange plate.
7. The system of claim 2 , wherein the velocity of the circulation stream through inlet ports of the heat exchanger is less than about 20 feet per second.
8. The system of claim 2 , further comprising a secondary heat exchanger in fluid communication with the distillate stream, said secondary heat exchanger operative to heat the waste fluid prior to said waste fluid being received by the circulation pump.
9. The system of claim 2 , further comprising a source of make-up steam in fluid communication with the primary heat exchanger.
10. The system of claim 9 , wherein the primary heat exchanger is divided into two sections to transfer heat to the circulation stream, a first heat donating section in fluid communication with the pressurized distillate stream and a second heat donating section in fluid communication with the make-up steam.
11. The system of claim 10 , wherein the first section comprises about 75-85 percent of the total heat donating surface area to transfer heat to the circulation stream and the second section comprises about 15-25 percent of the total heat donating surface area to transfer heat to the circulation stream.
12. The system of claim 3 , further comprising an inducer disposed prior to a circulation pump inlet extending into inlet piping of the circulation pump, said inducer creating a rotational direction of flow of the waste fluid prior to being received by the circulation pump.
13. The system of claim 3 , wherein the waste fluid is communicated to inlet piping of the circulation pump at a direction that is not parallel to the inlet piping to induce a rotational direction of flow of the waste fluid.
14. The cleaning system of claim 1 , further comprising a controller configured to control the mass flow rate of the recirculation stream such that a ratio of the mass flow rate of the recirculation stream within the recirculation loop to the mass flow rate of the waste stream received by the circulation pump ranges from about 4 to 6.
15. The cleaning system of claim 1 , wherein said recirculation loop has an outlet at the waste fluid source.
16. The cleaning system of claim 1 , further comprising a secondary heat exchanger in fluid communication with the cooled distillate stream, said secondary heat exchanger operative to heat the recirculation stream.
17. The cleaning system of claim 1 ,
further comprising a controller configured to control the mass flow rate of the circulation stream or the mass flow rate of the distillate stream such that a ratio of the mass flow rate of the circulation stream to the mass flow rate of a distillate stream is greater than about 300; and wherein the evaporation unit is
a cylindrical evaporation unit configured with an inlet to receive the heated circulation stream from the primary heat exchanger, said inlet disposed tangentially about the periphery of the evaporation unit and angled downward with respect to a sidewall of the evaporation unit.
18. The cleaning system of claim 17 , further comprising a vortex breaker disposed about the evaporation unit proximate to a top of the accumulated concentrated bottoms within the evaporation unit.
19. The cleaning system of claim 17 , further comprising an adjustable height vortex finder disposed about a top of the evaporation unit.
20. The cleaning system of claim 17 , wherein the inlet comprises a removable orifice valve or plate disposed within a flange about an exterior of the evaporation unit.
21. The cleaning system of claim 17 , wherein the inlet comprises an elongate hollow member extending into the evaporation unit, a plurality of apertures being disposed about a bottom of the hollow elongate member.
22. The cleaning system of claim 1 , further comprising:
a first compressor configured to receive the distillate stream from the evaporation unit and expel the pressurized distillate stream to the primary heat exchanger, wherein said compressor comprises a plurality of seals defining an area between an oil chamber and a steam chamber, and a fluid inlet in fluid communication with the area between the oil chamber and the steam chamber; and
a volume of pressurized fluid propagated through the fluid inlet into the area between the oil chamber and the steam chamber.
23. The cleaning system of claim 22 , wherein the fluid is pressurized at between 5 and 15 pounds per square inch.
24. The cleaning system of claim 22 , further comprising a fluid outlet disposed within the area between the oil chamber and the steam chamber.