US20110262343A1 - Process for preparation of calcium thiosulfate liquid solution from lime, sulfur, and sulfur dioxide - Google Patents
Process for preparation of calcium thiosulfate liquid solution from lime, sulfur, and sulfur dioxide Download PDFInfo
- Publication number
- US20110262343A1 US20110262343A1 US12/764,843 US76484310A US2011262343A1 US 20110262343 A1 US20110262343 A1 US 20110262343A1 US 76484310 A US76484310 A US 76484310A US 2011262343 A1 US2011262343 A1 US 2011262343A1
- Authority
- US
- United States
- Prior art keywords
- calcium
- sulfur
- slurry
- thiosulfate
- lime
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- RAHZWNYVWXNFOC-UHFFFAOYSA-N Sulphur dioxide Chemical compound O=S=O RAHZWNYVWXNFOC-UHFFFAOYSA-N 0.000 title claims abstract description 244
- FAYYUXPSKDFLEC-UHFFFAOYSA-L calcium;dioxido-oxo-sulfanylidene-$l^{6}-sulfane Chemical compound [Ca+2].[O-]S([O-])(=O)=S FAYYUXPSKDFLEC-UHFFFAOYSA-L 0.000 title claims abstract description 111
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 title claims abstract description 85
- 239000011593 sulfur Substances 0.000 title claims abstract description 82
- 238000000034 method Methods 0.000 title claims description 107
- 230000008569 process Effects 0.000 title claims description 93
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 title claims description 10
- 235000008733 Citrus aurantifolia Nutrition 0.000 title abstract description 43
- 235000011941 Tilia x europaea Nutrition 0.000 title abstract description 43
- 239000004571 lime Substances 0.000 title abstract description 43
- 238000002360 preparation method Methods 0.000 title description 24
- TXKMVPPZCYKFAC-UHFFFAOYSA-N disulfur monoxide Inorganic materials O=S=S TXKMVPPZCYKFAC-UHFFFAOYSA-N 0.000 title description 2
- 239000006193 liquid solution Substances 0.000 title description 2
- 239000011575 calcium Substances 0.000 claims abstract description 87
- 229910052717 sulfur Inorganic materials 0.000 claims abstract description 81
- 229910052791 calcium Inorganic materials 0.000 claims abstract description 80
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 claims abstract description 76
- 229920001021 polysulfide Polymers 0.000 claims abstract description 43
- 239000005077 polysulfide Substances 0.000 claims abstract description 43
- 150000008117 polysulfides Polymers 0.000 claims abstract description 43
- 238000004519 manufacturing process Methods 0.000 claims abstract description 22
- 239000007788 liquid Substances 0.000 claims abstract description 20
- 229910001861 calcium hydroxide Inorganic materials 0.000 claims description 84
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 claims description 83
- 239000000920 calcium hydroxide Substances 0.000 claims description 83
- 239000002002 slurry Substances 0.000 claims description 60
- JNVCSEDACVAATK-UHFFFAOYSA-L [Ca+2].[S-]SSS[S-] Chemical compound [Ca+2].[S-]SSS[S-] JNVCSEDACVAATK-UHFFFAOYSA-L 0.000 claims description 57
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 36
- 239000007789 gas Substances 0.000 claims description 35
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 claims description 20
- 239000011541 reaction mixture Substances 0.000 claims description 20
- 239000000292 calcium oxide Substances 0.000 claims description 13
- 238000001914 filtration Methods 0.000 claims description 11
- 238000001816 cooling Methods 0.000 claims description 7
- 239000000706 filtrate Substances 0.000 claims description 4
- 239000007921 spray Substances 0.000 claims description 4
- 230000003068 static effect Effects 0.000 claims description 4
- 239000002912 waste gas Substances 0.000 claims description 4
- 238000006243 chemical reaction Methods 0.000 abstract description 59
- 239000007787 solid Substances 0.000 abstract description 47
- 239000006227 byproduct Substances 0.000 abstract description 27
- 239000000047 product Substances 0.000 abstract description 22
- 239000000839 emulsion Substances 0.000 abstract description 4
- 230000002829 reductive effect Effects 0.000 abstract description 3
- 238000011437 continuous method Methods 0.000 abstract 1
- 239000000243 solution Substances 0.000 description 62
- 229940044609 sulfur dioxide Drugs 0.000 description 51
- 235000010269 sulphur dioxide Nutrition 0.000 description 51
- 235000011116 calcium hydroxide Nutrition 0.000 description 27
- 239000000203 mixture Substances 0.000 description 22
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 12
- 241000282326 Felis catus Species 0.000 description 12
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 12
- 229910000037 hydrogen sulfide Inorganic materials 0.000 description 12
- 238000011084 recovery Methods 0.000 description 12
- 239000002994 raw material Substances 0.000 description 11
- DHCDFWKWKRSZHF-UHFFFAOYSA-L thiosulfate(2-) Chemical compound [O-]S([S-])(=O)=O DHCDFWKWKRSZHF-UHFFFAOYSA-L 0.000 description 11
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 description 10
- 238000002474 experimental method Methods 0.000 description 10
- 150000004764 thiosulfuric acid derivatives Chemical class 0.000 description 10
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 8
- 239000012467 final product Substances 0.000 description 8
- 241000196324 Embryophyta Species 0.000 description 7
- 238000009835 boiling Methods 0.000 description 7
- 229910052751 metal Inorganic materials 0.000 description 7
- 239000002184 metal Substances 0.000 description 7
- 239000007858 starting material Substances 0.000 description 7
- 238000012360 testing method Methods 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 6
- 229940095672 calcium sulfate Drugs 0.000 description 6
- 238000002485 combustion reaction Methods 0.000 description 6
- 239000012535 impurity Substances 0.000 description 6
- IAZDPXIOMUYVGZ-UHFFFAOYSA-N Dimethylsulphoxide Chemical compound CS(C)=O IAZDPXIOMUYVGZ-UHFFFAOYSA-N 0.000 description 5
- LSNNMFCWUKXFEE-UHFFFAOYSA-N Sulfurous acid Chemical compound OS(O)=O LSNNMFCWUKXFEE-UHFFFAOYSA-N 0.000 description 5
- 238000010521 absorption reaction Methods 0.000 description 5
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 5
- 238000001704 evaporation Methods 0.000 description 5
- 230000008020 evaporation Effects 0.000 description 5
- 239000003546 flue gas Substances 0.000 description 5
- 229940062135 magnesium thiosulfate Drugs 0.000 description 5
- TZKHCTCLSRVZEY-UHFFFAOYSA-L magnesium;dioxido-oxo-sulfanylidene-$l^{6}-sulfane Chemical compound [Mg+2].[O-]S([O-])(=O)=S TZKHCTCLSRVZEY-UHFFFAOYSA-L 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 230000003647 oxidation Effects 0.000 description 5
- 238000007254 oxidation reaction Methods 0.000 description 5
- 239000001301 oxygen Substances 0.000 description 5
- 229910052760 oxygen Inorganic materials 0.000 description 5
- 239000010970 precious metal Substances 0.000 description 5
- 230000035484 reaction time Effects 0.000 description 5
- 238000005201 scrubbing Methods 0.000 description 5
- 229940048910 thiosulfate Drugs 0.000 description 5
- QGZKDVFQNNGYKY-UHFFFAOYSA-O Ammonium Chemical compound [NH4+] QGZKDVFQNNGYKY-UHFFFAOYSA-O 0.000 description 4
- LSNNMFCWUKXFEE-UHFFFAOYSA-M Bisulfite Chemical compound OS([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-M 0.000 description 4
- VTYYLEPIZMXCLO-UHFFFAOYSA-L Calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 description 4
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 4
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 4
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 4
- 229910021529 ammonia Inorganic materials 0.000 description 4
- 238000013459 approach Methods 0.000 description 4
- 238000010924 continuous production Methods 0.000 description 4
- 235000015097 nutrients Nutrition 0.000 description 4
- 235000011121 sodium hydroxide Nutrition 0.000 description 4
- 239000000126 substance Substances 0.000 description 4
- 125000004434 sulfur atom Chemical group 0.000 description 4
- 238000004448 titration Methods 0.000 description 4
- 238000003828 vacuum filtration Methods 0.000 description 4
- KCXVZYZYPLLWCC-UHFFFAOYSA-N EDTA Chemical compound OC(=O)CN(CC(O)=O)CCN(CC(O)=O)CC(O)=O KCXVZYZYPLLWCC-UHFFFAOYSA-N 0.000 description 3
- XYXNTHIYBIDHGM-UHFFFAOYSA-N ammonium thiosulfate Chemical compound [NH4+].[NH4+].[O-]S([O-])(=O)=S XYXNTHIYBIDHGM-UHFFFAOYSA-N 0.000 description 3
- 239000001110 calcium chloride Substances 0.000 description 3
- 229910001628 calcium chloride Inorganic materials 0.000 description 3
- 238000004364 calculation method Methods 0.000 description 3
- 238000000354 decomposition reaction Methods 0.000 description 3
- 230000003247 decreasing effect Effects 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 239000003337 fertilizer Substances 0.000 description 3
- 229910052602 gypsum Inorganic materials 0.000 description 3
- 239000010440 gypsum Substances 0.000 description 3
- 150000002739 metals Chemical class 0.000 description 3
- 238000005065 mining Methods 0.000 description 3
- 238000012544 monitoring process Methods 0.000 description 3
- 238000005457 optimization Methods 0.000 description 3
- AKHNMLFCWUSKQB-UHFFFAOYSA-L sodium thiosulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=S AKHNMLFCWUSKQB-UHFFFAOYSA-L 0.000 description 3
- 235000019345 sodium thiosulphate Nutrition 0.000 description 3
- LSNNMFCWUKXFEE-UHFFFAOYSA-L sulfite Chemical class [O-]S([O-])=O LSNNMFCWUKXFEE-UHFFFAOYSA-L 0.000 description 3
- 150000003467 sulfuric acid derivatives Chemical class 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 206010006956 Calcium deficiency Diseases 0.000 description 2
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 description 2
- 238000005033 Fourier transform infrared spectroscopy Methods 0.000 description 2
- MHAJPDPJQMAIIY-UHFFFAOYSA-N Hydrogen peroxide Chemical compound OO MHAJPDPJQMAIIY-UHFFFAOYSA-N 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 2
- 241000227653 Lycopersicon Species 0.000 description 2
- 235000007688 Lycopersicon esculentum Nutrition 0.000 description 2
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 230000002378 acidificating effect Effects 0.000 description 2
- 238000007605 air drying Methods 0.000 description 2
- 239000000809 air pollutant Substances 0.000 description 2
- 231100001243 air pollutant Toxicity 0.000 description 2
- 229910052783 alkali metal Inorganic materials 0.000 description 2
- 150000001340 alkali metals Chemical class 0.000 description 2
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 2
- 150000001341 alkaline earth metal compounds Chemical class 0.000 description 2
- 239000012670 alkaline solution Substances 0.000 description 2
- 229910052925 anhydrite Inorganic materials 0.000 description 2
- 229910000019 calcium carbonate Inorganic materials 0.000 description 2
- ZCCIPPOKBCJFDN-UHFFFAOYSA-N calcium nitrate Chemical compound [Ca+2].[O-][N+]([O-])=O.[O-][N+]([O-])=O ZCCIPPOKBCJFDN-UHFFFAOYSA-N 0.000 description 2
- GBAOBIBJACZTNA-UHFFFAOYSA-L calcium sulfite Chemical compound [Ca+2].[O-]S([O-])=O GBAOBIBJACZTNA-UHFFFAOYSA-L 0.000 description 2
- 235000010261 calcium sulphite Nutrition 0.000 description 2
- 239000000571 coke Substances 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000000446 fuel Substances 0.000 description 2
- 231100001261 hazardous Toxicity 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 230000000670 limiting effect Effects 0.000 description 2
- VTHJTEIRLNZDEV-UHFFFAOYSA-L magnesium dihydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 description 2
- 239000000347 magnesium hydroxide Substances 0.000 description 2
- 229910001862 magnesium hydroxide Inorganic materials 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 229910052976 metal sulfide Inorganic materials 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 229910052700 potassium Inorganic materials 0.000 description 2
- 239000011591 potassium Substances 0.000 description 2
- BWHMMNNQKKPAPP-UHFFFAOYSA-L potassium carbonate Chemical compound [K+].[K+].[O-]C([O-])=O BWHMMNNQKKPAPP-UHFFFAOYSA-L 0.000 description 2
- 238000010248 power generation Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000001603 reducing effect Effects 0.000 description 2
- 150000003839 salts Chemical group 0.000 description 2
- CDBYLPFSWZWCQE-UHFFFAOYSA-L sodium carbonate Substances [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 2
- 239000011780 sodium chloride Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- 239000002699 waste material Substances 0.000 description 2
- 238000005303 weighing Methods 0.000 description 2
- NWUYHJFMYQTDRP-UHFFFAOYSA-N 1,2-bis(ethenyl)benzene;1-ethenyl-2-ethylbenzene;styrene Chemical compound C=CC1=CC=CC=C1.CCC1=CC=CC=C1C=C.C=CC1=CC=CC=C1C=C NWUYHJFMYQTDRP-UHFFFAOYSA-N 0.000 description 1
- ZCYVEMRRCGMTRW-UHFFFAOYSA-N 7553-56-2 Chemical compound [I] ZCYVEMRRCGMTRW-UHFFFAOYSA-N 0.000 description 1
- 0 CS(=O)([O-])=S.Cs(o)([O-])s Chemical compound CS(=O)([O-])=S.Cs(o)([O-])s 0.000 description 1
- XFXPMWWXUTWYJX-UHFFFAOYSA-N Cyanide Chemical compound N#[C-] XFXPMWWXUTWYJX-UHFFFAOYSA-N 0.000 description 1
- 244000000626 Daucus carota Species 0.000 description 1
- 235000002767 Daucus carota Nutrition 0.000 description 1
- 241000223221 Fusarium oxysporum Species 0.000 description 1
- 240000008415 Lactuca sativa Species 0.000 description 1
- 235000003228 Lactuca sativa Nutrition 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 240000004658 Medicago sativa Species 0.000 description 1
- 235000017587 Medicago sativa ssp. sativa Nutrition 0.000 description 1
- 229910002651 NO3 Inorganic materials 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- CBENFWSGALASAD-UHFFFAOYSA-N Ozone Chemical compound [O-][O+]=O CBENFWSGALASAD-UHFFFAOYSA-N 0.000 description 1
- 238000003723 Smelting Methods 0.000 description 1
- PMZURENOXWZQFD-UHFFFAOYSA-L Sodium Sulfate Chemical compound [Na+].[Na+].[O-]S([O-])(=O)=O PMZURENOXWZQFD-UHFFFAOYSA-L 0.000 description 1
- 240000003768 Solanum lycopersicum Species 0.000 description 1
- 244000061456 Solanum tuberosum Species 0.000 description 1
- 235000002595 Solanum tuberosum Nutrition 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- 238000009825 accumulation Methods 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 238000013019 agitation Methods 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- BFNBIHQBYMNNAN-UHFFFAOYSA-N ammonium sulfate Chemical compound N.N.OS(O)(=O)=O BFNBIHQBYMNNAN-UHFFFAOYSA-N 0.000 description 1
- 229910052921 ammonium sulfate Inorganic materials 0.000 description 1
- 235000011130 ammonium sulphate Nutrition 0.000 description 1
- 238000004458 analytical method Methods 0.000 description 1
- 239000012736 aqueous medium Substances 0.000 description 1
- 238000003556 assay Methods 0.000 description 1
- NGLMYMJASOJOJY-UHFFFAOYSA-O azanium;calcium;nitrate Chemical compound [NH4+].[Ca].[O-][N+]([O-])=O NGLMYMJASOJOJY-UHFFFAOYSA-O 0.000 description 1
- 238000010923 batch production Methods 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- LVGQIQHJMRUCRM-UHFFFAOYSA-L calcium bisulfite Chemical compound [Ca+2].OS([O-])=O.OS([O-])=O LVGQIQHJMRUCRM-UHFFFAOYSA-L 0.000 description 1
- 235000010260 calcium hydrogen sulphite Nutrition 0.000 description 1
- 159000000007 calcium salts Chemical class 0.000 description 1
- 239000004202 carbamide Substances 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 150000005323 carbonate salts Chemical class 0.000 description 1
- 239000003729 cation exchange resin Substances 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 239000003518 caustics Substances 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000006388 chemical passivation reaction Methods 0.000 description 1
- 238000012993 chemical processing Methods 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000010960 commercial process Methods 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 230000000536 complexating effect Effects 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 238000006298 dechlorination reaction Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 238000006477 desulfuration reaction Methods 0.000 description 1
- 230000023556 desulfurization Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000035558 fertility Effects 0.000 description 1
- 150000004675 formic acid derivatives Chemical class 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000002803 fossil fuel Substances 0.000 description 1
- 235000012055 fruits and vegetables Nutrition 0.000 description 1
- 244000053095 fungal pathogen Species 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- RWSOTUBLDIXVET-UHFFFAOYSA-M hydrosulfide Chemical compound [SH-] RWSOTUBLDIXVET-UHFFFAOYSA-M 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-M hydroxide Chemical compound [OH-] XLYOFNOQVPJJNP-UHFFFAOYSA-M 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 208000015181 infectious disease Diseases 0.000 description 1
- 229910052740 iodine Inorganic materials 0.000 description 1
- 239000011630 iodine Substances 0.000 description 1
- 238000005342 ion exchange Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 238000002386 leaching Methods 0.000 description 1
- 239000010985 leather Substances 0.000 description 1
- 229910052808 lithium carbonate Inorganic materials 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- JESHZQPNPCJVNG-UHFFFAOYSA-L magnesium;sulfite Chemical compound [Mg+2].[O-]S([O-])=O JESHZQPNPCJVNG-UHFFFAOYSA-L 0.000 description 1
- 239000002609 medium Substances 0.000 description 1
- -1 metals carbonate salts Chemical class 0.000 description 1
- 238000005649 metathesis reaction Methods 0.000 description 1
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- 230000007935 neutral effect Effects 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000000618 nitrogen fertilizer Substances 0.000 description 1
- 230000009965 odorless effect Effects 0.000 description 1
- 238000005580 one pot reaction Methods 0.000 description 1
- 239000002420 orchard Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 125000004430 oxygen atom Chemical group O* 0.000 description 1
- 230000036961 partial effect Effects 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000011236 particulate material Substances 0.000 description 1
- 230000001863 plant nutrition Effects 0.000 description 1
- 229910000027 potassium carbonate Inorganic materials 0.000 description 1
- OQZCJRJRGMMSGK-UHFFFAOYSA-M potassium metaphosphate Chemical compound [K+].[O-]P(=O)=O OQZCJRJRGMMSGK-UHFFFAOYSA-M 0.000 description 1
- 235000019828 potassium polyphosphate Nutrition 0.000 description 1
- 229940016373 potassium polysulfide Drugs 0.000 description 1
- 230000003449 preventive effect Effects 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 238000006479 redox reaction Methods 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000006722 reduction reaction Methods 0.000 description 1
- 230000003252 repetitive effect Effects 0.000 description 1
- 239000000523 sample Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 239000010802 sludge Substances 0.000 description 1
- 239000011734 sodium Chemical class 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 229910000029 sodium carbonate Inorganic materials 0.000 description 1
- 229910052938 sodium sulfate Inorganic materials 0.000 description 1
- 235000011152 sodium sulphate Nutrition 0.000 description 1
- 239000002689 soil Substances 0.000 description 1
- 239000002364 soil amendment Substances 0.000 description 1
- 239000003381 stabilizer Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 235000001508 sulfur Nutrition 0.000 description 1
- 230000009897 systematic effect Effects 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- 229940006280 thiosulfate ion Drugs 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 230000007704 transition Effects 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
- C01B17/00—Sulfur; Compounds thereof
- C01B17/64—Thiosulfates; Dithionites; Polythionates
-
- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/10—Solid density
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01P—INDEXING SCHEME RELATING TO STRUCTURAL AND PHYSICAL ASPECTS OF SOLID INORGANIC COMPOUNDS
- C01P2006/00—Physical properties of inorganic compounds
- C01P2006/60—Optical properties, e.g. expressed in CIELAB-values
Definitions
- the present invention is directed to a process for the preparation of calcium thiosulfate, a plant nutrient solution. Another aspect of the present invention is the removal of air pollutant sulfur dioxide from industrial plants producing it, to convert the sulfur dioxide to calcium thio sulfate.
- the thiosulfate ion, S 2 O 3 2 ⁇ is a structural analogue of the SO 4 2 ⁇ ion in which one oxygen atom is replaced by one S atom.
- the two sulfur atoms in S 2 O 3 ⁇ 2 are not equivalent.
- One of the S atoms is a sulfide-like sulfur atom that gives the thiosulfate its reducing properties and complexing abilities.
- Thiosulfates are used in leather tanning, paper and textile manufacturing, flue-gas desulfurization, cement additives, dechlorination, ozone and hydrogen peroxide quenching, coating stabilizers and so on.
- thiosulfate compounds Due to these complex-forming abilities with metals, thiosulfate compounds have been used in commercial applications such as photography, waste treatment and water treatment applications.
- thiosulfates are used as fertilizers in combinations with cations such as ammonium, potassium, magnesium and calcium.
- the ammonium, alkali metal and alkaline earth thiosulfates are soluble in water. Water solubilities of thiosulfates decrease from ammonium to alkali metals to alkaline earth thiosulfates, i.e. ammonium thiosulfate has the highest relative water solubility and alkaline earth thiosulfates have relatively the lowest.
- Calcium is an essential plant nutrient. Calcium availability is essential in the biochemistry of plants and, as recently discovered, improves the nitrogen fertilizer efficiency of surface-applied urea. This is not to be confused with the role of important soil amendments such as lime or gypsum with the need of soluble calcium by high-value crops. Both are extremely important in soil fertility and plant nutrition and complement each other.
- Calcium has been applied as a foliar agent in apple orchards as a preventive to a physiological problem known as “bitter pit” which is caused by calcium deficiency. Calcium is also important to potato, tomato, lettuce, carrot, alfalfa and other fruit and vegetable production. Tomato plants with calcium deficiency show severe infection with Fusarium oxysporum , the fungal pathogen that causes wilt and crown rot in tomatoes.
- CaTs Calcium thiosulfate
- Li-sulfur is a commonly used term for a calcium thiosulfate and calcium polysulfide mixture resulting from reaction of lime and sulfur. Preparation of “lime-sulfur” via boiling of sulfur sludge from sulfuric acid plant and lime is described by P. Sivaprasad (India Pat. No. 163510, May 1987).
- U.S. Pat. No. 4,976,937 (Lee) describes a method for sulfur dioxide removal from flue gases with sulfite oxidation inhibition.
- the presence of a small amount of thiosulfate, 0.008-0.3 wt %, in the wet scrubber inhibits the oxidation of sulfur dioxide to sulfates and therefore provides a scrubbing system that is non-scaling for gypsum, i.e., that does not result in the buildup of gypsum scale.
- the '937 patent describes that a calcium thiosulfate and calcium polysulfide mixture results from the reaction of lime and emulsified sulfur in the lime-slaking tank.
- Calcium thiosulfate forms from the reaction of polysulfide, sulfites, and bisulfites at 82° C.-88° C. (180° F.-190° F.) during 5-25 minute intervals.
- concentration of calcium thiosulfate is only 0.3 wt %.
- U.S. Pat. No. 3,644,087 discloses a process for the removal of sulfur dioxide (SO 2 ) from gas streams containing SO 2 and oxygen (O 2 ) by converting SO 2 to the corresponding thiosulfate, whilst preventing the buildup of undesirable byproducts, e.g. sulfates, which otherwise occurs due to the reaction of oxygen from the input gas stream with the water-soluble sulfite that is formed when the SO 2 is absorbed in the scrubbing solution.
- SO 2 sulfur dioxide
- O 2 oxygen
- Urban's process involves adding a reducing agent such as hydrogen sulfide, finely divided sulfur or an alkaline earth polysulfide into the gas scrubbing zone, wherein the scrubbing solution can be a water-soluble alkaline earth hydroxide.
- a reducing agent such as hydrogen sulfide, finely divided sulfur or an alkaline earth polysulfide
- the scrubbing solution can be a water-soluble alkaline earth hydroxide.
- Calcium hydroxide which is only slightly water-soluble, is not listed as an example for the scrubbing solution. This patent does not relate to the production of calcium thio sulfate.
- EPO 043869A1 discloses a process for removing SO 2 from flue gases using an aqueous slurry of alkaline earth metal compounds, wherein thiosulfates are produced and recycled for use in the process to inhibit the oxidation of sulfites (which forms undesirable byproducts that cause buildup).
- Lee discusses that lime and emulsified sulfur are reacted to produce calcium thiosulfate and calcium polysulfide.
- One of Lee's preferred slurries of the alkaline earth metal compounds is formed from a mixture of calcium hydroxide and magnesium hydroxide.
- Lee is not concerned with producing calcium thiosulfate for recovery as a product.
- Japan Patent No. 6,039 issued in 1973 describes preparation of calcium and magnesium thiosulfate by treating sulfur and the corresponding sulfite in an alkaline solution. High yields only are obtained only with magnesium thiosulfate. This patent also described the formation of calcium thiosulfate from salt exchange process between magnesium thiosulfate and calcium hydroxide.
- Japan Patent No. 48,006,039 discloses a process for the manufacturing of calcium and magnesium thiosulfate by reacting calcium and/or magnesium sulfite with sulfur in alkaline solution. High yield is only obtained in the preparation of magnesium thiosulfate, and the preparation of calcium thiosulfate requires a difficult filtration of a slurry containing magnesium hydroxide.
- Spain Patent No. 245,171 discloses the use of the salt-exchange process with sodium thiosulfate and calcium chloride.
- the byproduct of this approach is a large amount of sodium chloride that also contaminates the resulting calcium thiosulfate.
- Russia Patent No. 1,773,866 discloses an ion-exchange technology for preparation of calcium thiosulfate involving contacting calcium chloride solution with a strong acidic cation-exchange resin in H + form, and unloading the adsorbed calcium with sodium thiosulfate solution.
- the calcium thiosulfate product formed in this way is contaminated with sodium chloride, calcium chloride and sodium thiosulfate.
- U.S. Pat. No. 7,572,317 (Choi) describes a method for leaching gold and other precious metals using elemental sulfur to convert the precious metals to their sulfidic metal bearing material, and oxidizing this at high pressure and temperature to form thiosulfate salts of the metals.
- Calcium thiosulfate of the precious metals was formed by addition of lime. The thiosulfate of precious metal is then converted to precious metal cyanide and the metal is leached.
- U.S. Pat. No. 6,984,368 (Hojjatie) describes the production of calcium thiosulfate in high yield and with low solid byproducts from oxidation of calcium polysulfide at elevated temperature.
- the '368 patent does not utilize sulfur dioxide.
- Sulfur dioxide is a common air pollutant which forms due to combustion processes and burning of fossil fuels containing sulfur.
- Many industries contribute to the emission of sulfur dioxide in the atmosphere in the United States. Chief among these industries are: electric power plants (42%), coal (4%), oil (17%), refinery operations (5%), smelting of ores (12%), coke processing (2%), and sulfuric acid manufacture (2%).
- the maximum allowable concentration of sulfur dioxide (SO 2 ) in the air is about 5 ppm.
- sulfur dioxide may be toxic to vegetation in concentrations of about 2 to 3 ppm and corrosive to materials made of metal.
- the principle methods used to limit sulfur dioxide emissions are (a) use of low-sulfur fuels, (b) removal of sulfur from fuel before combustion, (c) removal of sulfur dioxide after chemical combustion processes, and (d) modification of chemical combustion processes.
- the present invention relates to processes for the production of calcium thiosulfate by (1) reacting sulfur dioxide (SO 2 ) with sulfur (S) and hydrated lime [i.e., calcium hydroxide, Ca(OH) 2 ], or (2) by reacting SO 2 with lime-sulfur or calcium polysulfide.
- SO 2 sulfur dioxide
- S sulfur
- hydrated lime i.e., calcium hydroxide, Ca(OH) 2
- the invention further relates to the foregoing reactions being conducted under certain conditions, to produce a solution of calcium thiosulfate having a high concentration and with low byproduct formation.
- Liquid solutions containing high concentrations of calcium thiosulfate can be prepared in accordance with the present invention, having only minimal quantities of solid byproducts and unreacted sulfur in the manner of batch reaction, or via a semi-continuous reaction process.
- the invention involves the use of specific conditions for the reaction, for example the use of certain molar ratios of the raw materials, reaction time and temperature, which reduces the formation of undesirable calcium sulfate byproduct and produces CaTs at a high concentration and high purity level.
- calcium hydroxide slurry is introduced to the process reactor, elemental sulfur is added to this slurry, and the mixture is heated while agitating. The mixture is brought to a temperature suitable for reaction with sulfur dioxide gas under conditions sufficient to produce calcium thiosulfate.
- a contactor/reactor apparatus for reacting sulfur dioxide with a slurry, wherein the slurry is a CaO slurry, a Ca(OH) 2 slurry, or a lime-sulfur slurry, to prepare a calcium thiosulfate solution. If the aforementioned slurry is a CaO or a Ca(OH) 2 slurry, then sulfur is added to the slurry.
- the apparatus comprises (i) a bubble column for providing contact between sulfur dioxide gas bubbles and liquid/slurry; (ii) a mechanical agitator for dispersing the gas bubbles within the bubble column; (iii) a venturi, having an ejector/eductor for ejecting accumulated gas at the top portion of the bubble column and educting the gas through a venturi, wherein the venturi contacts the gas with a recirculated portion of the liquid/slurry; and (iv) a pipe/tube contactor in contact with the venturi for contacting the gas and a recirculated portion of the liquid/slurry mixture and returning the mixture to the bottom portion of the bubble column.
- the present invention may use sulfur dioxide that is obtained as a byproduct of industrial operations such as mining, coke processing, oil and gas refineries and power generation plants.
- the sulfur dioxide used in the present invention may be obtained via recovery from incineration of sulfur-bearing gases from oil refineries.
- a semi-continuous approach is designed for the removal of sulfur dioxide tail gas from chemical processing units, power generation industries and mining industries, and using that sulfur dioxide in a process for producing high concentration liquid calcium thiosulfate product.
- the sulfur dioxide is continuously removed and immediately used in a process as described herein, to produce the calcium thiosulfate product.
- FIG. 1 is a graphical illustration of the process kinetics for calcium thiosulfate preparation from a calcium polysulfide slurry and sulfur dioxide as a function of pH versus time.
- FIG. 2 is a graphical illustration of the process control of calcium thiosulfate solution preparation.
- FIG. 3 is a graphical illustration of the process flow diagram for calcium thiosulfate preparation.
- FIG. 4 is a process flow diagram, including a schematic illustration of a contactor/reactor, in accordance with a preferred embodiment of the present invention.
- the present invention relates to a process for preparing calcium thiosulfate by reacting sulfur dioxide with a slurry of calcium hydroxide, lime-sulfur or calcium polysulfide. More specifically, the invention relates to a process for preparing calcium thiosulfate utilizing particular reactants and reaction parameters and conditions.
- the present invention provides a process for the preparation of high purity, concentrated calcium thiosulfate.
- the calcium thiosulfate produced according to this invention does not require further concentration by evaporation or other means, and is useful as an agricultural nutrient.
- the production of calcium thiosulfate according to the invention is conducted in a single reaction vessel or, alternatively, in a series of reaction vessels and holding tanks to facilitate a semi-continuous reaction.
- the process of the invention includes a series of process steps, which can be implemented in equipment designed to provide the desired process conditions.
- the process steps can be accommodated in a single reaction vessel with the appropriate auxiliary equipment (pumps, piping, valves, heat exchangers, filters, controls, etc.) to produce one single batch at a time.
- the process steps can be carried out in a series of reaction vessels and holding tanks to facilitate a semi-continuous production arrangement.
- calcium thiosulfate can be prepared from inexpensive raw materials, such as lime (calcium oxide, CaO) and sulfur.
- a further advantage is that the invention provides a way to utilize sulfur dioxide recovered from flue gas (tail or waste gas) from power plants, the mining industry or other industries, to make the non-hazardous plant nutrient calcium thiosulfate.
- lime-sulfur mixture of calcium polysulfides, CaS x , and calcium thiosulfate, CaS 2 O 3 .
- CaS x calcium polysulfide
- the process of the invention may be carried out according to the following preferred reaction conditions and parameters.
- lime (CaO) or hydrated lime [Ca(OH) 2 ] is used as the calcium source, a slurry of the lime or hydrated lime in water is first provided, and then sulfur is added to the slurry.
- Lime must be converted to hydrated lime by slaking, i.e. by mixing with water. Either a pre-existing slurry of hydrated lime is used, or a slurry is formed by mixing lime with water to form hydrated lime.
- the lime is about 96% to about 99% pure.
- the mixture of sulfur and the slurry is heated. In a preferred embodiment, it is heated to at least about 70° C. (about 158° F.). More preferably, it is heated to a temperature in the range of about 85° C. to about 99° C. (about 185° F.-210° F.). Even more preferably, it is heated to a temperature in the range of about 90° C. to about 92° C. (about 195° F.-198° F.).
- the sulfur is preferably combined with the calcium hydroxide at a sulfur to calcium hydroxide mole ratio of about 1:1 to about 6:1. More preferably, the mole ratio is about 3.5:1 to about 6:1. Still more preferably, the mole ratio is about 3.4:1 to about 3.8:1. Even more preferably, the ratio is about 3.6:1.
- the mole ratio of sulfur to calcium hydroxide to water is at least about 2:6:30.
- the mole ratio of sulfur to calcium hydroxide to water is about 3.6 to about 4.9:1:25.5.
- the mole ratio of sulfur to calcium hydroxide to water is about 3.6:1:25.5.
- Sulfur dioxide is then added to the slurry, which now contains calcium polysulfides as the result of the reaction of calcium hydroxide and sulfur.
- the calcium polysulfide reaction mixture slurry Prior to the addition of sulfur dioxide, the calcium polysulfide reaction mixture slurry typically will require cooling. Cooling may be by external cooling or other means known to one of skill in the art. Cooling is used to avoid decomposition of the calcium thiosulfate that has formed and to avoid loss of sulfur dioxide due to evaporation or boiling off.
- the calcium polysulfide reaction mixture is cooled to a temperature of about 55° C. to about 75° C. (about 131° C.-167° C.) before the addition of sulfur dioxide.
- the reaction mixture may optionally be subjected to further cooling during and/or after addition of the sulfur dioxide to maintain the temperature of the reaction mixture below a certain temperature, to avoid decomposition of the calcium thiosulfate formed and to avoid loss of sulfur dioxide by boiling off.
- the sulfur dioxide when added, it is preferable to maintain the temperature of the reaction mixture at about 82° C. to about 95° C. (about 180° F.-203° F.). Still more preferably, the reaction mixture is maintained at about 85° C. to about 88° C. (about 185° F.-190° F.).
- the pH is adjusted to about 3-6, or still more, preferably to about 3.5-4.
- Residual reaction byproducts, raw material impurities, and unreacted raw materials in the calcium thiosulfate solution can form solid particulate byproduct matter, which preferably is filtered out in order to provide a clear, solid-free calcium thiosulfate product solution.
- Particulate materials such as calcium sulfate, calcium sulfite, calcium carbonate, metal sulfides, elemental sulfur, and silicate impurities can be filtered more efficiently by adjusting pH and by choosing an appropriate flocculent.
- the invention includes a series of process steps, which can be implemented in equipment designed to provide the desired process conditions.
- the process steps can be accommodated in a single reaction vessel with the appropriate auxiliary equipment (pumps, piping, valves, heat exchangers, filters, controls, etc.) to produce one single batch at a time.
- the process steps alternatively can be carried out in a series of continuously stirred reaction tanks (CSRT) with appropriate auxiliary equipment to facilitate a continuous production arrangement.
- CSRT continuously stirred reaction tanks
- the process steps for the batch production could be subdivided into three sections: lime slaking, reaction, and filtration.
- the process steps for semi-continuous production consist of repeatable cycles. Each cycle preferably consists of two steps as described herein.
- the present invention utilizes a series of reactions between lime or slaked lime, sulfur, and sulfur dioxide (or between lime-sulfur or calcium polysulfide and sulfur dioxide) using reaction conditions as described herein, such as raw material, molar ratios, temperature, pH control, reaction time, and equipment configuration, to produce high purity and concentrated calcium thio sulfate without further need for concentration by evaporation.
- reaction conditions such as raw material, molar ratios, temperature, pH control, reaction time, and equipment configuration
- calcium thiosulfate can be prepared according to the invention from inexpensive raw materials, such as lime and sulfur, as well as sulfur dioxide, an environmentally hazardous gas that is often present in industrial flue gases.
- color changes in the reaction mixture are used to observe the progress of the reaction.
- lime-sulfur and polysulfide are typically intensely red colored, and as they react with sulfur dioxide, the reaction mixture turns to a yellowish color, and then to a grey-green color.
- the grey-green color indicates that the calcium thiosulfate product in high concentration has been achieved.
- Reaction (i) describes a way of making calcium polysulfide with a relatively low content of calcium thiosulfate.
- the addition of reaction (ii) provides one of the processes according to the invention, for making calcium thiosulfate from sulfur dioxide and lime-sulfur (lime-sulfur being a mixture of calcium polysulfide and calcium thiosulfate).
- the following is an example illustrating the production of CaTs according to the aforementioned process.
- Laboratory experiments were conducted in three- or four-neck flasks (the volume varied from 500 mL to 3 L), equipped with a mechanical agitator, pH probe, and thermometer.
- the flask was fitted with a KOH or caustic soda (NaOH) trap as a scrubber to capture vent gases. Heating was provided by a heating mantle.
- the SO 2 source was compressed, liquefied 100% SO 2 .
- Yet another embodiment involves preparation of calcium thiosulfate also using hydrated lime, but via the following direct one-step reaction:
- the molar ratio of Ca(OH) 2 :S should be 1:1.
- SO 2 sparging was started as soon as the temperature of Ca(OH) 2 slurry, mixed with sulfur, reached 180-190° F. Four hours of SO 2 sparging was required to bring the pH of the slurry down to 5.8 from pH 11.5.
- the inventors determined that the formation of CaSO 3 resulted from the reaction between Ca(OH) 2 and SO 2 . Therefore, preferably, if there is any unreacted Ca(OH) 2 by the end of the lime-sulfur preparation, all solids should be removed from the reaction zone before reacting the lime-sulfur solution with sulfur dioxide, to avoid the production of CaSO 3 . Otherwise, the amount of final solids will be increased by CaSO 3 byproduct (i.e., the purity of the CaTs will be lower, due to the presence of CaSO 3 ).
- Yet another embodiment of the invention involves preparation of calcium thiosulfate by reacting calcium polysulfide with sulfur dioxide, as shown in the following reaction:
- the product contained about 25 wt % calcium thiosulfate but yield was about 25%.
- the calcium polysulfide was diluted to contain about 7 wt % Ca.
- the product contained 28 wt % calcium thiosulfate and the yield was 34%.
- full strength calcium polysulfide (9.66 wt % Ca) was used but some calcium thiosulfate (about 5 wt %) was added with the hope that presence of calcium thiosulfate would accelerate the process.
- the product contained 25 wt % calcium thiosulfate and the yield was 49%.
- FIG. 1 The kinetics of these three experiments as a function of pH vs. reaction time is shown in FIG. 1 .
- These plots consist of two portions, straight line and steep drop of pH. The transition from straight line to pH drop corresponds to pH values of 7.5-8.0. The pH appeared to be the most objective monitoring factor and was used as the control parameter for the endpoint of the process.
- An example of a preferred embodiment of the invention involves preparation of calcium thiosulfate from lime-sulfur solution.
- the kinetic curves, pH versus time, are shown in FIG. 1 . This shows that during the step (i), pH of the slurry was gradually decreased to 9.7.
- the step (ii) corresponded to a wide straight line preceding a rapid drop of pH which occurred in less than 10 minutes.
- step (i) the color of the reaction mixture changed from the initial whitish to pale yellow, then to an intensive yellow, and finally to brownish-yellow. This was interpreted as accumulation of calcium polysulfide.
- step (ii) the brownish-yellow color was converted back to yellow and remained nearly unchanged, along with stabilized pH. The sudden drop of pH was accompanied with rapid change of color; the intensity of yellow gradually disappeared and finally the solution became whitish-gray.
- the maximum concentration of calcium (C Ca ) in the lime-sulfur solution by the end of step (i) was 4.82 wt %.
- Calcium thiosulfate concentration (C CaTs ) in the final solution was 21.8-25.4 wt % and calcium polysulfide concentration (C Ca p s , as CaS 2 ) was less than 3.7 wt % (later SO 2 sparging was prolonged to lower the pH to 3.8-4.0).
- SG ⁇ 1.38, pH 10-11. Solids amounted to 14 wt %. Solids contained about 17 wt % calcium thio sulfate.
- Kinetic data of the (i) step are shown in Table 1.
- pH is one of the factors in monitoring the reaction. It was found that if pH would be allowed to drop as low as possible, but still was above the critical value (the critical pH is approximately 4, or more precisely at pH 3.8-4, below which calcium thiosulfate decomposes), partial dissolving of CaSO 3 (CaS and CaSO 4 if any) could be obtained, and as a result a further reduction of the amount of solids could be obtained.
- the inventors determined that sulfur dioxide should be purged into the solution until the pH drops to about 3.8 to about 4.0.
- the inventors also determined that the purity of lime is also another factor in reducing the amount of solid byproducts. They determined that the use of higher purity lime resulted in a reduced amount of byproduct solids. Preferably, the lime is about 96% to about 99% pure. The amount of byproduct solids was decreased to 6 wt % of the total product with higher purity lime. The reaction time also decreased when higher purity lime was used.
- the inventors also determined what pH is needed to prevent calcium thiosulfate decomposition in the acidic medium according to equation:
- FTIR Fourier Transform Infrared Spectroscopy
- Calcium thiosulfate solution can be distinguished from Ca(HSO 3 ) 2 solution visually, as well. Calcium thiosulfate is a colorless, sometimes cloudy and practically odorless solution. Ca(HSO 3 ) 2 is yellow with the strong SO 2 smell typical of bisulfite solutions.
- S:Ca(OH) 2 molar ratio The inventors determined preferred S:Ca(OH) 2 molar ratios for the process, in correlation with the duration of the process and amount of solids produced, as follows:
- Solids analysis showed that when the molar ratio was less than 3.6 to 3.8:1, solids contained unreacted lime. The smaller the molar ratio, the larger was the percentage of unreacted lime.
- Table 3 shows the results of three different experiments in attempts to optimize the yield and minimize the amount of solid byproducts:
- the inventors determined that the higher the C Ca was in the lime-sulfur parent solution, the higher the C Ca was in the calcium thiosulfate solution. This was true if C CaTs was less than about 27 wt %. The further increase of C Ca in the lime-sulfur solution did not influence C CaTs , but resulted in the growth of the amount of solid.
- the preferred temperature during the step (i) in which lime-sulfur is produced by reacting calcium hydroxide and sulfur is about 93° C. to about 99° C. (200° F.-210° F.) as described in U.S. Pat. No. 6,984,368.
- the inventors determined that the duration of the step (i) appears to be dependent on molar ratio only (since temperature is not variable).
- the lime purities were Source 1: >99 wt % Ca(OH) 2 ; Source 2: 97.40 wt % Ca(OH) 2 ; Source 3: 94.20 wt % Ca(OH) 2 ; and Source 4: 95.80 wt % Ca(OH) 2 .
- the comparison was made in the following series of tests using pure sulfur (start-up operation):
- SO 2 was produced by burning sulfur in air with a resulting gas mixture consisting of 14% SO 2 , 3% O 2 , and 83% N 2 .
- the test was performed to record the effects of substitution of 100% SO 2 with dilute SO 2 such as:
- the reaction between sulfur dioxide and lime-sulfur can be performed in a batch manner in the same equipment where the lime-sulfur is produced, or it can be performed in separate dedicated equipment.
- the lime-sulfur or calcium polysulfide slurry is cooled to the preferred temperature for reaction with sulfur dioxide.
- the reaction mixture is maintained in the range of about 55° C.-75° C. during the step of reacting the slurry with the sulfur dioxide.
- Reaction temperatures above 75° C. (167° F.) should be avoided during conversion of lime-sulfur (or calcium polysulfide) to calcium thiosulfate because of possible losses due to thermal decomposition.
- the reaction of sulfur dioxide with calcium polysulfide is exothermic and excess heat generated during SO 2 addition is removed to maintain the desired temperature.
- An important consideration in maintaining a good reaction rate and complete conversion of the lime-sulfur (or calcium polysulfide) intermediate to calcium thiosulfate is to provide adequate gas/liquid contacting area and time for the sulfur dioxide gas and the liquid lime-sulfur (or calcium polysulfide) slurry to react.
- Contact area is important because the reaction primarily takes place at the SO 2 gas/liquid slurry interface. If this interface area is not adequate, the reaction will be slow, leading to larger amounts of undesirable byproducts.
- gas/liquid contacting process equipment can be utilized for contacting and reacting the gas and liquid. These include, but are not limited to bubble columns, packed columns, tray columns, spray columns, mechanically agitated tanks, jet loops, venturi ejector/eductor, pipes/tubes and static mixers.
- a special contactor was developed which utilizes elements of common types of contacting equipment combined into a single contactor-reactor design.
- the elements of this arrangement work to maximize contact time, area, and overall mass-transfer coefficient of reacting the lime-sulfur slurry (or calcium polysulfide slurry) and sulfur dioxide gas with recycled liquid/gas.
- This arrangement was described in U.S. Pat. No. 6,984,386, the entire disclosure of which is incorporated herein by reference, and is shown in FIG.
- a contactor/reactor 60 in accordance with an embodiment of the invention, comprises (i) a bubble column 61 , in which gas bubbles up through the liquid; (ii) a mechanical agitator 58 , which further disperses bubbles within the column 61 to provide additional contact area time and mass-transfer; (iii) a venturi ejector/eductor, where accumulated gas at the top portion 61 a of the column is ejected via a line 11 and educed through a venturi 64 , where it is contacted with recirculated liquid/slurry 10 ; and (iv) a pipe/tube contactor where the gas/liquid mixture exiting the venturi 64 is further contacted as it is conducted inside a draft tube, back to the bottom portion 61 b of the bubble column 61 , where it is recombined with the liquid/slurry.
- the loss of material was 619.5 g (9.3%). Most of the loss occurred during step (i) due to water evaporation and vacuum filtration.
- a further embodiment of the invention is one for the semi-continuous process of CaTs preparation, consisting of repetitive cycle. Each cycle involves two steps, described by the following equations:
- Step (i) is the preparation of lime-sulfur from lime, sulfur, and water in the reactor R- 1 .
- the lime-sulfur product is transferred to filtering unit F- 1 (this step is not shown in FIG. 3 ). Solids are separated. The filtrate is transferred to the reactor R- 2 and reacted with sulfur dioxide [step (ii)]. The required SO 2 is provided from sulfur burner B- 1 .
- the final product prepared in reactor R- 2 is filtered in the filtering unit F- 2 (not shown) and is transferred to the storage tank.
- the solids from filtering units F- 1 , and F- 2 are combined and analyzed for their sulfur and lime content and transferred back to R- 1 . This unreacted sulfur that is transferred back to R- 1 is referred to herein as “recycled sulfur”. The deficient amount of sulfur and/or lime is added and the cycle continues.
- H 2 S, generated during the step (ii) in the reactor R- 2 is vented to a scrubber containing caustic soda or can be recycled to the sulfur burner along with unreacted SO 2 , if any.
- pure sulfur and recycled sulfur are preferably used separately because it is desirable for the user of the process to be able to predict with some certainty what will be the concentration of calcium in the lime-sulfur solution and what will be the concentration of calcium in the unreacted solids at the end of step (i).
- Using pure sulfur permits one to predict with greater certainty what the concentration of calcium will be.
- recycled sulfur it is difficult to predict with certainty how concentrated the aforementioned calcium levels will be, because with recycled sulfur it is more difficult to predict how high the level of S is in the recycled sulfur, and it is also difficult to predict how pure and how wet (i.e., how much water it contains) the recycled sulfur is.
- the total incoming amount 4284.26 g.
- the calcium thiosulfate produced according to the invention is an emulsion of liquid calcium thiosulfate and solid byproducts.
- This emulsion is preferably further treated to produce a solution that may be readily filtered.
- the emulsion may be treated with a flocculent and acidified to a near neutral pH, to produce a colloidal solution that filters with ease.
- the resulting calcium thiosulfate is a clear liquid with a concentration of up to about 29% by weight.
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Abstract
Description
- The present invention is directed to a process for the preparation of calcium thiosulfate, a plant nutrient solution. Another aspect of the present invention is the removal of air pollutant sulfur dioxide from industrial plants producing it, to convert the sulfur dioxide to calcium thio sulfate.
- The thiosulfate ion, S2O3 2−, is a structural analogue of the SO4 2− ion in which one oxygen atom is replaced by one S atom. However, the two sulfur atoms in S2O3 −2 are not equivalent. One of the S atoms is a sulfide-like sulfur atom that gives the thiosulfate its reducing properties and complexing abilities.
- Thiosulfates are used in leather tanning, paper and textile manufacturing, flue-gas desulfurization, cement additives, dechlorination, ozone and hydrogen peroxide quenching, coating stabilizers and so on.
- Due to these complex-forming abilities with metals, thiosulfate compounds have been used in commercial applications such as photography, waste treatment and water treatment applications.
- Thiosulfates readily oxidize to tetrathionates and sulfates:
- Due to this transformation, thiosulfates are used as fertilizers in combinations with cations such as ammonium, potassium, magnesium and calcium. The ammonium, alkali metal and alkaline earth thiosulfates are soluble in water. Water solubilities of thiosulfates decrease from ammonium to alkali metals to alkaline earth thiosulfates, i.e. ammonium thiosulfate has the highest relative water solubility and alkaline earth thiosulfates have relatively the lowest.
- Calcium is an essential plant nutrient. Calcium availability is essential in the biochemistry of plants and, as recently discovered, improves the nitrogen fertilizer efficiency of surface-applied urea. This is not to be confused with the role of important soil amendments such as lime or gypsum with the need of soluble calcium by high-value crops. Both are extremely important in soil fertility and plant nutrition and complement each other.
- Calcium has been applied as a foliar agent in apple orchards as a preventive to a physiological problem known as “bitter pit” which is caused by calcium deficiency. Calcium is also important to potato, tomato, lettuce, carrot, alfalfa and other fruit and vegetable production. Tomato plants with calcium deficiency show severe infection with Fusarium oxysporum, the fungal pathogen that causes wilt and crown rot in tomatoes.
- Although soluble calcium could be attained from calcium nitrate, calcium chloride and calcium ammonium nitrate, due to the NO3 −, or Cl− anion presence, a more environmentally-friendly counter ion such as thiosulfate (S2O3 −2) is desirable in the application of calcium fertilizer products. Calcium thiosulfate is referred to herein as “CaTs”. CaTs is a registered trademark of Tessenderlo Kerley, Inc.
- Although calcium thiosulfate has been known for many years and has many references in the literature, there are not many known commercial methods that employ inexpensive raw materials to produce high purity calcium thiosulfate with a low amount of byproducts and with solid residue of insoluble calcium salts which permit easy separation from the calcium thiosulfate product.
- “Lime-sulfur” is a commonly used term for a calcium thiosulfate and calcium polysulfide mixture resulting from reaction of lime and sulfur. Preparation of “lime-sulfur” via boiling of sulfur sludge from sulfuric acid plant and lime is described by P. Sivaprasad (India Pat. No. 163510, May 1987).
- U.S. Pat. No. 4,976,937 (Lee) describes a method for sulfur dioxide removal from flue gases with sulfite oxidation inhibition. The presence of a small amount of thiosulfate, 0.008-0.3 wt %, in the wet scrubber inhibits the oxidation of sulfur dioxide to sulfates and therefore provides a scrubbing system that is non-scaling for gypsum, i.e., that does not result in the buildup of gypsum scale. The '937 patent describes that a calcium thiosulfate and calcium polysulfide mixture results from the reaction of lime and emulsified sulfur in the lime-slaking tank. It is mixed with sulfites and bisulfites that originally formed in the wet scrubber in the recycling tank. Calcium thiosulfate forms from the reaction of polysulfide, sulfites, and bisulfites at 82° C.-88° C. (180° F.-190° F.) during 5-25 minute intervals. However, the concentration of calcium thiosulfate is only 0.3 wt %.
- U.S. Pat. No. 3,644,087 (Urban) discloses a process for the removal of sulfur dioxide (SO2) from gas streams containing SO2 and oxygen (O2) by converting SO2 to the corresponding thiosulfate, whilst preventing the buildup of undesirable byproducts, e.g. sulfates, which otherwise occurs due to the reaction of oxygen from the input gas stream with the water-soluble sulfite that is formed when the SO2 is absorbed in the scrubbing solution. Urban's process involves adding a reducing agent such as hydrogen sulfide, finely divided sulfur or an alkaline earth polysulfide into the gas scrubbing zone, wherein the scrubbing solution can be a water-soluble alkaline earth hydroxide. Calcium hydroxide, which is only slightly water-soluble, is not listed as an example for the scrubbing solution. This patent does not relate to the production of calcium thio sulfate.
- EPO 043869A1 (Lee) discloses a process for removing SO2 from flue gases using an aqueous slurry of alkaline earth metal compounds, wherein thiosulfates are produced and recycled for use in the process to inhibit the oxidation of sulfites (which forms undesirable byproducts that cause buildup). Lee discusses that lime and emulsified sulfur are reacted to produce calcium thiosulfate and calcium polysulfide. One of Lee's preferred slurries of the alkaline earth metal compounds is formed from a mixture of calcium hydroxide and magnesium hydroxide. Lee is not concerned with producing calcium thiosulfate for recovery as a product.
- U.S. Pat. No. 4,105,754 (Swaine, Jr.) describes the production of calcium thiosulfate by a metathesis reaction of ammonium thiosulfate and calcium hydroxide or calcium oxide. This approach requires constant removal of ammonia by air stripping at below the boiling point of the mixture and capturing the gas. Further, not all the ammonia can be removed by this process, and as a result, the resulting calcium thiosulfate tends to have a lingering ammonia odor and/or contamination with ammonia or ammonium thiosulfate.
- Japan Patent No. 6,039 issued in 1973 describes preparation of calcium and magnesium thiosulfate by treating sulfur and the corresponding sulfite in an alkaline solution. High yields only are obtained only with magnesium thiosulfate. This patent also described the formation of calcium thiosulfate from salt exchange process between magnesium thiosulfate and calcium hydroxide.
- U.S. Pat. No. 4,156,656 (Dannenberg) describes the reaction of oxides or hydroxides of alkali and alkaline-earth metals with sulfur in aqueous media at elevated temperature (200° C.-250° C.) and pressure (210-560 psig) to produce a hydrosulfide solution.
- Japan Patent No. 48,006,039 discloses a process for the manufacturing of calcium and magnesium thiosulfate by reacting calcium and/or magnesium sulfite with sulfur in alkaline solution. High yield is only obtained in the preparation of magnesium thiosulfate, and the preparation of calcium thiosulfate requires a difficult filtration of a slurry containing magnesium hydroxide.
- Spain Patent No. 245,171 discloses the use of the salt-exchange process with sodium thiosulfate and calcium chloride. The byproduct of this approach is a large amount of sodium chloride that also contaminates the resulting calcium thiosulfate.
- Russia Patent No. 1,773,866 discloses an ion-exchange technology for preparation of calcium thiosulfate involving contacting calcium chloride solution with a strong acidic cation-exchange resin in H+ form, and unloading the adsorbed calcium with sodium thiosulfate solution. The calcium thiosulfate product formed in this way is contaminated with sodium chloride, calcium chloride and sodium thiosulfate.
- U.S. Pat. No. 7,572,317 (Choi) describes a method for leaching gold and other precious metals using elemental sulfur to convert the precious metals to their sulfidic metal bearing material, and oxidizing this at high pressure and temperature to form thiosulfate salts of the metals. Calcium thiosulfate of the precious metals was formed by addition of lime. The thiosulfate of precious metal is then converted to precious metal cyanide and the metal is leached.
- U.S. Pat. No. 6,984,368 (Hojjatie) describes the production of calcium thiosulfate in high yield and with low solid byproducts from oxidation of calcium polysulfide at elevated temperature. However, the '368 patent does not utilize sulfur dioxide.
- Sulfur dioxide is a common air pollutant which forms due to combustion processes and burning of fossil fuels containing sulfur. Many industries contribute to the emission of sulfur dioxide in the atmosphere in the United States. Chief among these industries are: electric power plants (42%), coal (4%), oil (17%), refinery operations (5%), smelting of ores (12%), coke processing (2%), and sulfuric acid manufacture (2%). The maximum allowable concentration of sulfur dioxide (SO2) in the air is about 5 ppm. However, sulfur dioxide may be toxic to vegetation in concentrations of about 2 to 3 ppm and corrosive to materials made of metal.
- The principle methods used to limit sulfur dioxide emissions are (a) use of low-sulfur fuels, (b) removal of sulfur from fuel before combustion, (c) removal of sulfur dioxide after chemical combustion processes, and (d) modification of chemical combustion processes.
- Numerous methods have been developed to remove sulfur dioxide for chemical combustion processes involving sulfur dioxide. The following are examples of such methods: Absorption into dimethyl sulfoxide (DMSO, U.S. Pat. No. 3,538,681), absorption in molten alkaline metals carbonate salts such as lithium, sodium, and potassium carbonate at 1500° F.-2000° F. (U.S. Pat. No. 3,671,185) and recovery as hydrogen sulfide, absorption into potassium polyphosphate solution to form potassium polysulfide (U.S. Pat. No. 3,630,672), absorption into soda caustic or hydrated lime to form waste sodium sulfate or calcium sulfate (U.S. Pat. No. 3,640,053), absorption into salts such as formate salts of ammonium, sodium, and potassium at 457° F. to form hydrogen sulfide, carbon dioxide, and carbonate salts of these metals (U.S. Pat. No. 3,687,615), and recovery as ammonium sulfate fertilizer (U.S. Pat. No. 3,615,165).
- The present invention relates to processes for the production of calcium thiosulfate by (1) reacting sulfur dioxide (SO2) with sulfur (S) and hydrated lime [i.e., calcium hydroxide, Ca(OH)2], or (2) by reacting SO2 with lime-sulfur or calcium polysulfide. The invention further relates to the foregoing reactions being conducted under certain conditions, to produce a solution of calcium thiosulfate having a high concentration and with low byproduct formation.
- Liquid solutions containing high concentrations of calcium thiosulfate can be prepared in accordance with the present invention, having only minimal quantities of solid byproducts and unreacted sulfur in the manner of batch reaction, or via a semi-continuous reaction process. The invention involves the use of specific conditions for the reaction, for example the use of certain molar ratios of the raw materials, reaction time and temperature, which reduces the formation of undesirable calcium sulfate byproduct and produces CaTs at a high concentration and high purity level.
- In one embodiment of the invention, calcium hydroxide slurry is introduced to the process reactor, elemental sulfur is added to this slurry, and the mixture is heated while agitating. The mixture is brought to a temperature suitable for reaction with sulfur dioxide gas under conditions sufficient to produce calcium thiosulfate.
- In another embodiment of the invention, a contactor/reactor apparatus is provided for reacting sulfur dioxide with a slurry, wherein the slurry is a CaO slurry, a Ca(OH)2 slurry, or a lime-sulfur slurry, to prepare a calcium thiosulfate solution. If the aforementioned slurry is a CaO or a Ca(OH)2 slurry, then sulfur is added to the slurry. The apparatus comprises (i) a bubble column for providing contact between sulfur dioxide gas bubbles and liquid/slurry; (ii) a mechanical agitator for dispersing the gas bubbles within the bubble column; (iii) a venturi, having an ejector/eductor for ejecting accumulated gas at the top portion of the bubble column and educting the gas through a venturi, wherein the venturi contacts the gas with a recirculated portion of the liquid/slurry; and (iv) a pipe/tube contactor in contact with the venturi for contacting the gas and a recirculated portion of the liquid/slurry mixture and returning the mixture to the bottom portion of the bubble column.
- The present invention may use sulfur dioxide that is obtained as a byproduct of industrial operations such as mining, coke processing, oil and gas refineries and power generation plants. For example, the sulfur dioxide used in the present invention may be obtained via recovery from incineration of sulfur-bearing gases from oil refineries.
- In yet another aspect of the invention, a semi-continuous approach is designed for the removal of sulfur dioxide tail gas from chemical processing units, power generation industries and mining industries, and using that sulfur dioxide in a process for producing high concentration liquid calcium thiosulfate product. In a specific embodiment, the sulfur dioxide is continuously removed and immediately used in a process as described herein, to produce the calcium thiosulfate product.
- The present invention will now be described in more detail with reference to preferred embodiments of the invention, given by way of examples, and illustrated in the accompanying drawings in which:
-
FIG. 1 is a graphical illustration of the process kinetics for calcium thiosulfate preparation from a calcium polysulfide slurry and sulfur dioxide as a function of pH versus time. -
FIG. 2 is a graphical illustration of the process control of calcium thiosulfate solution preparation. -
FIG. 3 is a graphical illustration of the process flow diagram for calcium thiosulfate preparation. -
FIG. 4 is a process flow diagram, including a schematic illustration of a contactor/reactor, in accordance with a preferred embodiment of the present invention. - The present invention relates to a process for preparing calcium thiosulfate by reacting sulfur dioxide with a slurry of calcium hydroxide, lime-sulfur or calcium polysulfide. More specifically, the invention relates to a process for preparing calcium thiosulfate utilizing particular reactants and reaction parameters and conditions. The present invention provides a process for the preparation of high purity, concentrated calcium thiosulfate. The calcium thiosulfate produced according to this invention does not require further concentration by evaporation or other means, and is useful as an agricultural nutrient.
- The production of calcium thiosulfate according to the invention is conducted in a single reaction vessel or, alternatively, in a series of reaction vessels and holding tanks to facilitate a semi-continuous reaction. The process of the invention includes a series of process steps, which can be implemented in equipment designed to provide the desired process conditions.
- The process steps can be accommodated in a single reaction vessel with the appropriate auxiliary equipment (pumps, piping, valves, heat exchangers, filters, controls, etc.) to produce one single batch at a time. Alternatively, the process steps can be carried out in a series of reaction vessels and holding tanks to facilitate a semi-continuous production arrangement.
- Advantageously, described herein is a process by which calcium thiosulfate can be prepared from inexpensive raw materials, such as lime (calcium oxide, CaO) and sulfur. A further advantage is that the invention provides a way to utilize sulfur dioxide recovered from flue gas (tail or waste gas) from power plants, the mining industry or other industries, to make the non-hazardous plant nutrient calcium thiosulfate.
- The following equations illustrate alternative processes for making CaTs according to the invention.
- Using lime (calcium oxide, CaO) as calcium source:
-
CaO+S+SO2→CaS2O3 - Using hydrated lime (calcium hydroxide, Ca(OH)2) as calcium source:
-
Ca(OH)2+S+SO2→CaS2O3+H2O - Using lime-sulfur (mixture of calcium polysulfides, CaSx, and calcium thiosulfate, CaS2O3) as calcium source:
-
CaSx+CaS2O3+SO2+H2O→2CaS2O3+H2S+(x−2)S - Using calcium polysulfide (CaSx) as calcium source:
-
CaSx+SO2+H2O→CaS2O3+H2S+(x−2)S - The process of the invention may be carried out according to the following preferred reaction conditions and parameters.
- If either lime (CaO) or hydrated lime [Ca(OH)2] is used as the calcium source, a slurry of the lime or hydrated lime in water is first provided, and then sulfur is added to the slurry. Lime must be converted to hydrated lime by slaking, i.e. by mixing with water. Either a pre-existing slurry of hydrated lime is used, or a slurry is formed by mixing lime with water to form hydrated lime. In a preferred embodiment, the lime is about 96% to about 99% pure.
- Preferably, the mixture of sulfur and the slurry is heated. In a preferred embodiment, it is heated to at least about 70° C. (about 158° F.). More preferably, it is heated to a temperature in the range of about 85° C. to about 99° C. (about 185° F.-210° F.). Even more preferably, it is heated to a temperature in the range of about 90° C. to about 92° C. (about 195° F.-198° F.).
- The sulfur is preferably combined with the calcium hydroxide at a sulfur to calcium hydroxide mole ratio of about 1:1 to about 6:1. More preferably, the mole ratio is about 3.5:1 to about 6:1. Still more preferably, the mole ratio is about 3.4:1 to about 3.8:1. Even more preferably, the ratio is about 3.6:1.
- In a preferred embodiment, the mole ratio of sulfur to calcium hydroxide to water is at least about 2:6:30.
- In another preferred embodiment, the mole ratio of sulfur to calcium hydroxide to water is about 3.6 to about 4.9:1:25.5.
- In still yet another preferred embodiment, the mole ratio of sulfur to calcium hydroxide to water is about 3.6:1:25.5.
- If the sulfur to calcium hydroxide to water ratio used is about 3.6:1:25.5, then the reaction takes about 2-6 hours to complete.
- Sulfur dioxide is then added to the slurry, which now contains calcium polysulfides as the result of the reaction of calcium hydroxide and sulfur. Prior to the addition of sulfur dioxide, the calcium polysulfide reaction mixture slurry typically will require cooling. Cooling may be by external cooling or other means known to one of skill in the art. Cooling is used to avoid decomposition of the calcium thiosulfate that has formed and to avoid loss of sulfur dioxide due to evaporation or boiling off. In a preferred embodiment, the calcium polysulfide reaction mixture is cooled to a temperature of about 55° C. to about 75° C. (about 131° C.-167° C.) before the addition of sulfur dioxide.
- The reaction mixture may optionally be subjected to further cooling during and/or after addition of the sulfur dioxide to maintain the temperature of the reaction mixture below a certain temperature, to avoid decomposition of the calcium thiosulfate formed and to avoid loss of sulfur dioxide by boiling off. For example, when the sulfur dioxide is added, it is preferable to maintain the temperature of the reaction mixture at about 82° C. to about 95° C. (about 180° F.-203° F.). Still more preferably, the reaction mixture is maintained at about 85° C. to about 88° C. (about 185° F.-190° F.).
- Preferably, when the sulfur dioxide is added, the pH is adjusted to about 3-6, or still more, preferably to about 3.5-4.
- In the preferred practice of the invention, only minor quantities of byproducts are formed. These residual byproducts generated during lime-sulfur production and subsequent reaction with sulfur dioxide typically contain calcium sulfite, calcium sulfate, and elemental sulfur. If metal oxides are present in the lime (calcium oxide) raw material, some metal sulfides could be present as well after the reaction is complete. Higher purity calcium oxide typically contains lower amounts of metal oxides. Calcium carbonate and silica impurities may accompany commercial grade calcium oxide. These impurities usually amount to less than 2% by weight of the final calcium thiosulfate solution when a high grade of calcium oxide is utilized and the formulation and reaction conditions are adequately controlled. Therefore, a preferred embodiment of the invention uses a high grade lime as a starting material.
- Residual reaction byproducts, raw material impurities, and unreacted raw materials in the calcium thiosulfate solution can form solid particulate byproduct matter, which preferably is filtered out in order to provide a clear, solid-free calcium thiosulfate product solution. Particulate materials, such as calcium sulfate, calcium sulfite, calcium carbonate, metal sulfides, elemental sulfur, and silicate impurities can be filtered more efficiently by adjusting pH and by choosing an appropriate flocculent.
- The invention includes a series of process steps, which can be implemented in equipment designed to provide the desired process conditions. The process steps can be accommodated in a single reaction vessel with the appropriate auxiliary equipment (pumps, piping, valves, heat exchangers, filters, controls, etc.) to produce one single batch at a time. The process steps alternatively can be carried out in a series of continuously stirred reaction tanks (CSRT) with appropriate auxiliary equipment to facilitate a continuous production arrangement.
- The process steps for the batch production could be subdivided into three sections: lime slaking, reaction, and filtration.
- The process steps for semi-continuous production consist of repeatable cycles. Each cycle preferably consists of two steps as described herein.
- As described herein, the present invention utilizes a series of reactions between lime or slaked lime, sulfur, and sulfur dioxide (or between lime-sulfur or calcium polysulfide and sulfur dioxide) using reaction conditions as described herein, such as raw material, molar ratios, temperature, pH control, reaction time, and equipment configuration, to produce high purity and concentrated calcium thio sulfate without further need for concentration by evaporation. Advantageously, calcium thiosulfate can be prepared according to the invention from inexpensive raw materials, such as lime and sulfur, as well as sulfur dioxide, an environmentally hazardous gas that is often present in industrial flue gases.
- In an embodiment of the invention, color changes in the reaction mixture are used to observe the progress of the reaction. For example, lime-sulfur and polysulfide are typically intensely red colored, and as they react with sulfur dioxide, the reaction mixture turns to a yellowish color, and then to a grey-green color. The grey-green color indicates that the calcium thiosulfate product in high concentration has been achieved.
- The following describes the preparation of calcium thiosulfate according to one embodiment of the invention, wherein hydrated lime is used as the calcium source.
-
3Ca(OH)2+2(x+1)S→2CaSx+CaS2O3+3H2O (i) -
- (for example, if x=4: 3Ca(OH)2+10S→2CaS4+CaS2O3+3H2O)
- (molar ratio S:Ca(OH)2˜3.3:1)
-
CaSx+CaS2O3+SO2+H2O→2CaS2O3+H2S+(x−2)S - Reaction (i) describes a way of making calcium polysulfide with a relatively low content of calcium thiosulfate. The addition of reaction (ii) provides one of the processes according to the invention, for making calcium thiosulfate from sulfur dioxide and lime-sulfur (lime-sulfur being a mixture of calcium polysulfide and calcium thiosulfate).
- The following is an example illustrating the production of CaTs according to the aforementioned process. Laboratory experiments were conducted in three- or four-neck flasks (the volume varied from 500 mL to 3 L), equipped with a mechanical agitator, pH probe, and thermometer. The flask was fitted with a KOH or caustic soda (NaOH) trap as a scrubber to capture vent gases. Heating was provided by a heating mantle. The SO2 source was compressed, liquefied 100% SO2.
- Raw materials: 41.7 g Ca(OH)2, 36.1 g S (S:Ca(OH)2 molar ratio=2:1), and 200 g H2O.
- Step (i): the maximum expected concentration of Ca=8.1 wt %; reaction duration=120 min, temperature=80° C.-90° C. (176° F.-194° F.). The observed drop of pH was from 12.6 to 9.0.
- Intermediate results: 3.96 wt % Ca, pH 11.5, SG −1.24, —all referred to the lime-sulfur solution.
- Step (ii): duration=90 minutes, temperature range=30° C.-40° C. (86° F.-104° F.) (SO2 sparging was started when the solution cooled down to 104° F.). The final product was amber yellow solution, specific gravity=1.32, pH=11.0, CCa by EDTA titration=7.0 wt %, CCaTs by iodine titration=21.8 wt % (recalculated CCa=5.7 wt %; the rest of calcium was in the calcium polysulfide form). Solids were greenish-gray and comprised 22 wt % of the total weight of the final product. Solids contained 18 wt % of CaTs.
- Yet another embodiment involves preparation of calcium thiosulfate also using hydrated lime, but via the following direct one-step reaction:
-
Ca(OH)2+S+SO2→CaS2O3+H2O (iii) - As follows from the preceding equation, the molar ratio of Ca(OH)2:S should be 1:1. SO2 sparging was started as soon as the temperature of Ca(OH)2 slurry, mixed with sulfur, reached 180-190° F. Four hours of SO2 sparging was required to bring the pH of the slurry down to 5.8 from pH 11.5.
- The final product: assay=12.25 wt % CaTs by the EDTA titration, SG=1.12, pH=8.6. The solids, resulting from the vacuum filtration, comprised 31.4% of the total weight of the final product, which appeared to be unusually high. The inventors determined that the formation of CaSO3 resulted from the reaction between Ca(OH)2 and SO2. Therefore, preferably, if there is any unreacted Ca(OH)2 by the end of the lime-sulfur preparation, all solids should be removed from the reaction zone before reacting the lime-sulfur solution with sulfur dioxide, to avoid the production of CaSO3. Otherwise, the amount of final solids will be increased by CaSO3 byproduct (i.e., the purity of the CaTs will be lower, due to the presence of CaSO3).
- Yet another embodiment of the invention involves preparation of calcium thiosulfate by reacting calcium polysulfide with sulfur dioxide, as shown in the following reaction:
-
CaSx+SO2+H2O→CaS2O3+H2S+(x−2)S (iv) - The chemical description of this approach is identical to reaction (ii). The difference is in the source of CaSx and in its composition. As shown above, the process of calcium thiosulfate preparation from lime-sulfur solution consists of two steps (i) and (ii). If relatively pure calcium polysulfide (CaSx) is used as a starting material as is proposed in reaction (iv) above, rather than lime-sulfur, the tendency to form byproducts is significantly reduced.
- Three variations of that process were performed. The starting material CaS4.5 (CCa=9.66 wt %, SG=1.48) was used as a starting material. The product contained about 25 wt % calcium thiosulfate but yield was about 25%. In the next experiment the calcium polysulfide was diluted to contain about 7 wt % Ca. The product contained 28 wt % calcium thiosulfate and the yield was 34%. In the third experiment full strength calcium polysulfide (9.66 wt % Ca) was used but some calcium thiosulfate (about 5 wt %) was added with the hope that presence of calcium thiosulfate would accelerate the process. The product contained 25 wt % calcium thiosulfate and the yield was 49%.
- The kinetics of these three experiments as a function of pH vs. reaction time is shown in
FIG. 1 . These plots consist of two portions, straight line and steep drop of pH. The transition from straight line to pH drop corresponds to pH values of 7.5-8.0. The pH appeared to be the most objective monitoring factor and was used as the control parameter for the endpoint of the process. - An example of a preferred embodiment of the invention involves preparation of calcium thiosulfate from lime-sulfur solution.
- Listed below are the general characteristics of the calcium thiosulfate preparation process from a lime-sulfur solution, by reacting the lime-sulfur solution with sulfur-dioxide, as shown in the following reaction:
-
CaSx+CaS2O3+SO2+H2O→2CaS2O3+H2S+(x−2)S -
- 1. The calculated concentration of calcium from Ca(OH)2 at the beginning of the (i) step was 8.1 wt %.
- 2. S:Ca(OH)2 molar ratio was 2:1.
- 3. The reaction temperature during the (i) step was approximately (about) 80° C. (176° F.)+/−2° C.
- 4. The reaction duration of the (i) step was variable (for example, 120 and 153 min), 2.5 hr on the average, but the longer the (i) step, the higher is CCa in the lime-sulfur solution (Table 1, below). The average duration of the whole process was 3.5-4.0 hr.
- 5. pH was a control parameter of the process.
- The kinetic curves, pH versus time, are shown in
FIG. 1 . This shows that during the step (i), pH of the slurry was gradually decreased to 9.7. The step (ii) corresponded to a wide straight line preceding a rapid drop of pH which occurred in less than 10 minutes. -
- 6. pH was also a monitoring factor to determine the endpoint of SO2 sparging. Sparging was stopped when pH of the slurry reached 3.8-4.0.
- 7. In addition to pH, the color of the slurry was another control parameter of the process.
- During step (i), the color of the reaction mixture changed from the initial whitish to pale yellow, then to an intensive yellow, and finally to brownish-yellow. This was interpreted as accumulation of calcium polysulfide. During step (ii), the brownish-yellow color was converted back to yellow and remained nearly unchanged, along with stabilized pH. The sudden drop of pH was accompanied with rapid change of color; the intensity of yellow gradually disappeared and finally the solution became whitish-gray.
- The maximum concentration of calcium (CCa) in the lime-sulfur solution by the end of step (i) was 4.82 wt %. Calcium thiosulfate concentration (CCaTs) in the final solution was 21.8-25.4 wt % and calcium polysulfide concentration (CCaps, as CaS2) was less than 3.7 wt % (later SO2 sparging was prolonged to lower the pH to 3.8-4.0). SG<1.38, pH=10-11. Solids amounted to 14 wt %. Solids contained about 17 wt % calcium thio sulfate. Kinetic data of the (i) step are shown in Table 1.
-
TABLE 1 Kinetics of the process for lime-sulfur preparation Time, min 7 40 70 87 96 128 153 SG 1.08 1.08 1.08 1.11 1.14 1.22 1.26 CCa, Wt % 0.12 0.22 0.74 1.4 1.82 3.57 4.82 - As mentioned before, the inventors determined that pH is one of the factors in monitoring the reaction. It was found that if pH would be allowed to drop as low as possible, but still was above the critical value (the critical pH is approximately 4, or more precisely at pH 3.8-4, below which calcium thiosulfate decomposes), partial dissolving of CaSO3 (CaS and CaSO4 if any) could be obtained, and as a result a further reduction of the amount of solids could be obtained. The inventors determined that sulfur dioxide should be purged into the solution until the pH drops to about 3.8 to about 4.0.
- The inventors also determined that the purity of lime is also another factor in reducing the amount of solid byproducts. They determined that the use of higher purity lime resulted in a reduced amount of byproduct solids. Preferably, the lime is about 96% to about 99% pure. The amount of byproduct solids was decreased to 6 wt % of the total product with higher purity lime. The reaction time also decreased when higher purity lime was used.
- The inventors also determined what pH is needed to prevent calcium thiosulfate decomposition in the acidic medium according to equation:
-
S2O3 2−+H+→HSO3 −+So - Fourier Transform Infrared Spectroscopy (FTIR) studies proved that even at
pH 4 the product is still calcium thiosulfate and not calcium bisulfite. - Calcium thiosulfate solution can be distinguished from Ca(HSO3)2 solution visually, as well. Calcium thiosulfate is a colorless, sometimes cloudy and practically odorless solution. Ca(HSO3)2 is yellow with the strong SO2 smell typical of bisulfite solutions.
- Preferred process parameters according to the invention are as follows:
- S:Ca(OH)2 molar ratio. The inventors determined preferred S:Ca(OH)2 molar ratios for the process, in correlation with the duration of the process and amount of solids produced, as follows:
-
- The higher the molar ratio, the shorter the reaction time required (the endpoint attainment of CCa, approximately 6.5 wt % Ca, correlates to 24.7 wt % calcium thio sulfate);
- The molar ratio 5:1 resulted in the maximum concentration of calcium: CCa=6.94 wt % (recalculated equivalent calcium thiosulfate concentration=26.4 wt %);
- The molar ratio 4:1 resulted in the minimum amount of remaining solids and still satisfactory CCa=6.60 wt % (the predicted calcium thiosulfate concentration was 25.1 wt %).
- 99% lime purity was chosen for optimization of the S:Ca(OH)2 molar ratio to exclude formation of solids due to impurities associated with lower quality lime. The amounts of Ca(OH)2 and H2O were constant in all the experiments (42.56 g Ca(OH)2 and 263.34 g H2O). The amount of sulfur was variable. The conditions of the experiment were as follows:
-
- temperature: about 96° C.-99° C. (205° F.-210° F.) (near the boiling point);
- duration: 40 min after the temperature reached 200° F.;
- immediate vacuum filtration of the hot final product;
- weighing solids immediately after filtration, without air drying.
- The optimization of the molar ratio was judged by the following parameters:
-
- 1. Relative amount of solids (%) related to the total amount of the final lime-sulfur product (a sum of the weight of filtered lime-sulfur solution and solids). Loss was not included.
- 2. Concentration of calcium in the lime-sulfur solution (wt %).
- 3. Recovery of calcium (%) as the total amount of calcium in the lime-sulfur solution, related to the amount of calcium in the lime starting material. Calculation was based on 100% Ca(OH)2.
- Results are shown in Table 2.
-
TABLE 2 Optimization of the S:Ca(OH)2 Molar Ratio. Relative CCa in the S:Ca(OH)2 amount of lime-sulfur Recovery of # molar ratio solids, % solution, wt % Ca, % Loss, g 1 1.00 10.9 2.66 31.7 16.0 2 1.92 6.5 4.36 58.0 13.7 3 2.87 3.1 5.71 82.5 15.7 4 3.00 2.7 5.83 86.3 11.0 5 3.20 1.7 6.17 91.6 17.1 6 3.40 1.3 6.22 95.9 9.2 7 3.45 1.5 6.50 97.3 19.8 8 3.60 0.5 6.46 100.0 8.1 9 3.80 0 6.59 100.0 9.1 10 3.83 0.1 6.73 100.0 16.4 11 4.02 0.5 6.57 100.0 14.5 12 4.02 0.2 6.50 100.0 18.3 13 5.00 6.0 6.70 100.0 17.0 - The inventors determined that the preferred S:Ca(OH)2 molar ratio is 3.6 to 3.8:1 (Table 2). This resulted in the minimal amount of solids (0-0.5%), 100% recovery of calcium, and therefore, the maximum possible CCa was 6.46 wt %, which correlates to CCaTs=24.5 wt %.
- Solids analysis showed that when the molar ratio was less than 3.6 to 3.8:1, solids contained unreacted lime. The smaller the molar ratio, the larger was the percentage of unreacted lime.
- Starting with molar ratio of 4.0, there was a noticeable amount of unreacted sulfur.
- Table 3 shows the results of three different experiments in attempts to optimize the yield and minimize the amount of solid byproducts:
-
TABLE 3 Preparation of the Maximum Concentrated Lime-Sulfur Solution. CCa in the Relative Experiment Expected lime-sulfur amount of Recovery CcaTs, # Ca(OH)2, g S, g Cca, wt % * solution, wt % solids, % of Ca, % wt % ** 1 52.0 81.02 7.11 7.26 1.0 99.0 27.45 2 59.7 93.02 7.76 7.99 1.1 97.2 27.0 3 70.0 109.07 8.56 8.17 8.9 70.8 — * calculation is based on 100% recovery of Ca from lime in lime-sulfur solution ** real CcaTs in the final calcium thiosulfate solution, resulting from the corresponding lime-sulfur solution -
Experiment # 3 was not completed due to the low recovery of calcium in step (i). - The inventors determined that the higher the CCa was in the lime-sulfur parent solution, the higher the CCa was in the calcium thiosulfate solution. This was true if CCaTs was less than about 27 wt %. The further increase of CCa in the lime-sulfur solution did not influence CCaTs, but resulted in the growth of the amount of solid.
- The preferred temperature during the step (i) in which lime-sulfur is produced by reacting calcium hydroxide and sulfur is about 93° C. to about 99° C. (200° F.-210° F.) as described in U.S. Pat. No. 6,984,368.
- The inventors determined that the duration of the step (i) appears to be dependent on molar ratio only (since temperature is not variable).
- While using pure lime (99% or better) and pure sulfur with the optimal molar ratio of S:Ca(OH)2:H2O=(3.6-3.8):1:25.5, the endpoint of step (i) could be judged by the appearance of the solution. The endpoint is when the solution becomes dark reddish-brown and clear (no solid particles could be observed). Even while using a different kind of lime, when the reaction is completed, the color of the reacting mixture reaches a certain point and remains unchanged. While using recycled sulfur, it becomes more complicated to determine the endpoint by color, because impurities and contaminants in the sulfur tend to cause coloration of the solution, which makes determination of the endpoint more difficult.
- SO2 flow. Lime-sulfur solutions are absorbing SO2 completely even at the highest flow rate (no carry over of SO2 is monitored in the KOH or NaOH trap). Lab experiments utilized synthetic SO2 gas. Industrial gas composition will be dilute, approximately 4-14 vol % of SO2, with the balance consisting of nitrogen, oxygen, and other combustion products. SO2 flow rate is not a limiting factor in step (ii).
- Raw Materials
- Different lime purities from different sources were tested and their effects were compared on the overall process. The lime purities were Source 1: >99 wt % Ca(OH)2; Source 2: 97.40 wt % Ca(OH)2; Source 3: 94.20 wt % Ca(OH)2; and Source 4: 95.80 wt % Ca(OH)2. The comparison was made in the following series of tests using pure sulfur (start-up operation):
-
- pure sulfur: (67.0 g);
- molar ratio: S:Ca(OH)2:H2O=3.8:1:25.5;
- duration: 40 min after temperature reached 93.3° C. (200° F.);
- temperature: 95° C.-96° C. (203° F.-205° F.). Solution was boiling;
- immediate vacuum filtration of the hot final product;
- weighing solids immediately after filtration, without air drying.
- The following characteristics were chosen for comparison of applicability of different lime purities:
-
- 1. Relative amount of solids (%) as absolute amount of solids, related to the total amount of the final lime-sulfur product (a sum of the weight of the final solution and solids. Loss, mostly due to evaporation, was not included. The average loss was approximately 20 g in each experiment).
- 2. Concentration of calcium in the lime-sulfur solution determined by EDTA titration (wt %).
- 3. Recovery of calcium (%) as the total amount of calcium in the lime-sulfur solution, related to the total amount of calcium in the lime starting material. Calculation was based on assumption for 100% Ca(OH)2.
-
TABLE 4 Preparation of lime-sulfur solutions step (i) from different sources of lime and pure sulfur. Amount of Recovery of Source of lime solids, wt % CCa, wt % Ca, % Filtration Source 1 0.295* 6.65 100 fast Source 2 2.7 6.57 96.3 very slow Source 3 4.0 6.45 93.9 very slow Source 4 2.25 6.44 97.0 slow *A second set of tests was performed to verify reproducibility. The results shown are averages. The conclusion showed that higher purity lime reacted more quickly and had less solid byproducts formed during the reaction. - Real Gas Mixture
- In the commercial process SO2 was produced by burning sulfur in air with a resulting gas mixture consisting of 14% SO2, 3% O2, and 83% N2. The test was performed to record the effects of substitution of 100% SO2 with dilute SO2 such as:
-
- Carry-through of unreacted SO2 due to an increase in the flow rate to compensate for the dilute concentration of SO2;
- Possible oxidation of calcium thiosulfate resulting in CaSO3 and/or CaSO4 solid, due to the presence of oxygen and SO2 in the real gas mixture. Tests were performed to investigate these possibilities. SO2 was mixed with the excess amount of air and the mixture was used as a source of SO2. Due to the presence of air, the following oxidation-reduction reaction is possible:
-
2CaS2O3+O2→2CaSO4+2S - For the systematic study, compressed SO2/air gas mixture (14.56 vol % SO2) was used and N2 was intentionally substituted with air to replicate the commercial conditions. Observations from the test:
-
- 1. No considerable excess oxidation of calcium thiosulfate occurred due to presence of oxygen.
- 2. No significant SO2 carry-through was observed during the step (ii) of the process.
- The reaction between sulfur dioxide and lime-sulfur can be performed in a batch manner in the same equipment where the lime-sulfur is produced, or it can be performed in separate dedicated equipment. The lime-sulfur or calcium polysulfide slurry is cooled to the preferred temperature for reaction with sulfur dioxide. Preferably, the reaction mixture is maintained in the range of about 55° C.-75° C. during the step of reacting the slurry with the sulfur dioxide. Reaction temperatures above 75° C. (167° F.) should be avoided during conversion of lime-sulfur (or calcium polysulfide) to calcium thiosulfate because of possible losses due to thermal decomposition. The reaction of sulfur dioxide with calcium polysulfide is exothermic and excess heat generated during SO2 addition is removed to maintain the desired temperature.
- An important consideration in maintaining a good reaction rate and complete conversion of the lime-sulfur (or calcium polysulfide) intermediate to calcium thiosulfate is to provide adequate gas/liquid contacting area and time for the sulfur dioxide gas and the liquid lime-sulfur (or calcium polysulfide) slurry to react. Contact area is important because the reaction primarily takes place at the SO2 gas/liquid slurry interface. If this interface area is not adequate, the reaction will be slow, leading to larger amounts of undesirable byproducts.
- Many common types of gas/liquid contacting process equipment can be utilized for contacting and reacting the gas and liquid. These include, but are not limited to bubble columns, packed columns, tray columns, spray columns, mechanically agitated tanks, jet loops, venturi ejector/eductor, pipes/tubes and static mixers.
- A special contactor was developed which utilizes elements of common types of contacting equipment combined into a single contactor-reactor design. The elements of this arrangement work to maximize contact time, area, and overall mass-transfer coefficient of reacting the lime-sulfur slurry (or calcium polysulfide slurry) and sulfur dioxide gas with recycled liquid/gas. This arrangement was described in U.S. Pat. No. 6,984,386, the entire disclosure of which is incorporated herein by reference, and is shown in
FIG. 4 in which a contactor/reactor 60 in accordance with an embodiment of the invention, comprises (i) abubble column 61, in which gas bubbles up through the liquid; (ii) amechanical agitator 58, which further disperses bubbles within thecolumn 61 to provide additional contact area time and mass-transfer; (iii) a venturi ejector/eductor, where accumulated gas at thetop portion 61 a of the column is ejected via aline 11 and educed through aventuri 64, where it is contacted with recirculated liquid/slurry 10; and (iv) a pipe/tube contactor where the gas/liquid mixture exiting theventuri 64 is further contacted as it is conducted inside a draft tube, back to thebottom portion 61 b of thebubble column 61, where it is recombined with the liquid/slurry. - Mass Balance Check
- A series of tests were performed to calculate mass balance between raw materials and product/byproduct. Results of one test are shown in Table 5.
-
TABLE 5 Mass balance check. Description Incoming amount, g Final products, g Ca(OH)2 728.1 S 588.9 H2O 5039.5 SO2 313.4 CaTs solution 5589.7 Recycled sulfur 146.2 Solids 272.3 Material, accumulated in 42.2 the KOH trap Total 6669.9 6050.4 - The loss of material, as a difference between the total starting material and the final products, was 619.5 g (9.3%). Most of the loss occurred during step (i) due to water evaporation and vacuum filtration.
- A further embodiment of the invention is one for the semi-continuous process of CaTs preparation, consisting of repetitive cycle. Each cycle involves two steps, described by the following equations:
-
- (a) Preparation of the lime-sulfur solution (mixture of calcium polysulfide and calcium thio sulfate):
-
3Ca(OH)2+2(x+1)S→2CaSx+CaS2O3+3H2O (i) -
- (b) SO2 sparging, resulting in conversion of calcium polysulfide into calcium thio sulfate:
-
CaSx+CaS2O3+SO2+H2O→2CaS2O3+H2S+(x−2)S (ii) - The flow diagram of the said process is shown in
FIG. 3 . Step (i) is the preparation of lime-sulfur from lime, sulfur, and water in the reactor R-1. By the end of step (i) the lime-sulfur product is transferred to filtering unit F-1 (this step is not shown inFIG. 3 ). Solids are separated. The filtrate is transferred to the reactor R-2 and reacted with sulfur dioxide [step (ii)]. The required SO2 is provided from sulfur burner B-1. The final product prepared in reactor R-2 is filtered in the filtering unit F-2 (not shown) and is transferred to the storage tank. The solids from filtering units F-1, and F-2 are combined and analyzed for their sulfur and lime content and transferred back to R-1. This unreacted sulfur that is transferred back to R-1 is referred to herein as “recycled sulfur”. The deficient amount of sulfur and/or lime is added and the cycle continues. - H2S, generated during the step (ii) in the reactor R-2, is vented to a scrubber containing caustic soda or can be recycled to the sulfur burner along with unreacted SO2, if any.
- The process described above eliminates formation of CaSO3 (solid) during the step (ii) by limiting the potential reaction of unreacted Ca(OH)2, remaining after step (i), with SO2.
- A preferred embodiment of the process of the invention is as follows:
- Step (i):
-
- The molar ratio S:Ca(OH)2:H2O=3.6:1:25.5, when pure sulfur feed is used;
- The molar ratio S:Ca(OH)2:H2O=(3.6-4.9):1:25.5, when recycled sulfur is used;
- Pure feed sulfur and recycled sulfur should be used separately to attain predictable results by the end of step (i) (CCa in the lime-sulfur solution and relative amount of the unreacted solids);
- Duration: 30-35 min.
- When pure sulfur is used, the endpoint of the reaction can be monitored by color: dark reddish-brown and clear signifies a complete reaction;
-
- Temperature: 200° F.-210° F. (210° F. is near the boiling point).
- Immediate filtration of the lime-sulfur product by the end of step (i);
- To determine lime-sulfur concentration for 25 wt % calcium thiosulfate production, samples are taken and analyzed at the end of each step (i). In a case where the lime-sulfur solution contains lower than projected calcium thio sulfate concentration (CCa), the deficient amount of calcium and sulfur are added and additional step (i) performed.
- Step (ii):
-
- Sparging of the SO2/N2/O2 gas mixture into lime-sulfur until pH drops to approximately 4. The low pH guarantees the final calcium thiosulfate solution will be free from H2S, which is a side-product of the step (ii).
- Filtration of the final product. Solids, termed as “recycled sulfur”, consist mostly of sulfur. The solids are recycled to the reactor R-1 as a part of the sulfur feed material.
- pH of the final calcium thiosulfate solution is adjusted to 7.0-7.5 via addition of lime. Continuous agitation is necessary to have a steady state pH reading. Afterwards the CaTs solution is filtered again.
- The reason why pure sulfur and recycled sulfur are preferably used separately is because it is desirable for the user of the process to be able to predict with some certainty what will be the concentration of calcium in the lime-sulfur solution and what will be the concentration of calcium in the unreacted solids at the end of step (i). Using pure sulfur permits one to predict with greater certainty what the concentration of calcium will be. In contrast, when recycled sulfur is used, it is difficult to predict with certainty how concentrated the aforementioned calcium levels will be, because with recycled sulfur it is more difficult to predict how high the level of S is in the recycled sulfur, and it is also difficult to predict how pure and how wet (i.e., how much water it contains) the recycled sulfur is.
- Mass balance check for a semi-continuous seven cycle process is shown in Table 6.
-
TABLE 6 Mass Balance Check of the Seven-Cycle Process. Incoming amount, g Outgoing amount, g Cycle CaTs # Ca(OH)2, g S, g H2O, g SO2, g solution, g Loss, g H2S, g I 62.25 54.14 410 not avail. 394.7 12.97 0 II 62.25 27.07 400 III 0 17.96 199 (II + III) (II + III) (II + III) (II + III) cycles: 19.9 cycles: 607.1 cycles: 72.56 cycles: 0 IV 108.24 14.4 651 32.2 715.9 13.92 0 V 110.46 40.61 550 31.2 674.9 7.84 0 VI 0 69.98 689 43.6 816.8 27.04 0 VII 0 64.36 622 4.9+ 749.5 24.57 0 Total 343.2 288.26 3521 131.8 3958.9 158.9 0 - The total incoming amount: 4284.26 g.
- The total outgoing amount: 4117.8 g+20.53 g (solids from VII)+87.07 g=4225.4 g.
- Loss as a difference between the incoming and outgoing amounts: 58.86 g (1.4 wt %).
- Yield: 3958.9:4284.26=92.4%.
- The calcium thiosulfate produced according to the invention is an emulsion of liquid calcium thiosulfate and solid byproducts. This emulsion is preferably further treated to produce a solution that may be readily filtered. For example, the emulsion may be treated with a flocculent and acidified to a near neutral pH, to produce a colloidal solution that filters with ease. The resulting calcium thiosulfate is a clear liquid with a concentration of up to about 29% by weight.
Claims (47)
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US12/764,843 US8034318B1 (en) | 2010-04-21 | 2010-04-21 | Process for preparation of calcium thiosulfate liquid solution from lime, sulfur, and sulfur dioxide |
PE2011000927A PE20121740A1 (en) | 2010-04-21 | 2011-04-20 | PROCEDURE FOR THE PREPARATION OF LIQUID SOLUTION OF CALCIUM THOSULFATE FROM LIME, SULFUR AND SULFUR DIOXIDE |
ES201130638A ES2377388B2 (en) | 2010-04-21 | 2011-04-20 | PROCEDURE FOR THE PREPARATION OF LIQUID DISSOLUTION OF CALCIUM TIOSULFATE FROM LIME, SULFUR AND SULFUR DIOXIDE. |
AU2011201818A AU2011201818B2 (en) | 2010-04-21 | 2011-04-20 | Process for preparation of calcium thiosulfate liquid solution from lime, sulfur, and sulfur dioxide |
ARP110101379A AR085170A1 (en) | 2010-04-21 | 2011-04-20 | PROCEDURE FOR THE PREPARATION OF LIQUID DISSOLUTION OF CALCIUM TIOSULFATE FROM LIME, SULFUR AND Sulfur DIOXIDE |
CL2011000902A CL2011000902A1 (en) | 2010-04-21 | 2011-04-21 | Process for preparing calcium thiosulfate comprising reacting a suspension containing a calcium and sulfur compound with sulfur dioxide to form calcium thiosulfate and subsequently recovering it. |
US13/211,135 US8454929B2 (en) | 2010-04-21 | 2011-08-16 | Continuous process for preparation of calcium thiosulfate liquid solution |
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US20140054464A1 (en) * | 2012-08-20 | 2014-02-27 | Sabic Innovative Plastics Ip B.V. | Real-time online determination of caustic in process scrubbers using near infrared spectroscopy and chemometrics |
CN108473382A (en) * | 2015-12-30 | 2018-08-31 | 泰森德洛克利公司 | Method for oxidation for producing potassium thiosulfate |
CN111017883A (en) * | 2019-11-27 | 2020-04-17 | 郑州中科新兴产业技术研究院 | Method for recycling desulfurization byproducts of power plant |
CN114364632A (en) * | 2019-07-03 | 2022-04-15 | 泰森德洛集团公司 | From a compound containing H2S、SO2And/or NH3By the exhaust gas stream of |
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US8454929B2 (en) * | 2010-04-21 | 2013-06-04 | Tessenderlo Kerley, Inc. | Continuous process for preparation of calcium thiosulfate liquid solution |
US10005667B2 (en) | 2015-12-30 | 2018-06-26 | Tessenderlo Kerley, Inc. | Sulfur dioxide scrubbing system and process for producing potassium products |
ES2685144B2 (en) * | 2017-03-31 | 2019-04-11 | Tessenderlo Kerley Inc | Continuous process for the preparation of a liquid solution of calcium thiosulfate, improved |
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US20140054464A1 (en) * | 2012-08-20 | 2014-02-27 | Sabic Innovative Plastics Ip B.V. | Real-time online determination of caustic in process scrubbers using near infrared spectroscopy and chemometrics |
US9084975B2 (en) * | 2012-08-20 | 2015-07-21 | Sabic Global Technologies B.V. | Real-time online determination of caustic in process scrubbers using near infrared spectroscopy and chemometrics |
US9636629B2 (en) | 2012-08-20 | 2017-05-02 | Sabic Global Technologies B.V. | Real-time online determination of caustic in process scrubbers using near infrared spectroscopy and chemometrics |
CN108473382A (en) * | 2015-12-30 | 2018-08-31 | 泰森德洛克利公司 | Method for oxidation for producing potassium thiosulfate |
EP3397602A4 (en) * | 2015-12-30 | 2019-09-04 | Tessenderlo Kerley, Inc. | Oxidation process for producing potassium thiosulfate |
CN114364632A (en) * | 2019-07-03 | 2022-04-15 | 泰森德洛集团公司 | From a compound containing H2S、SO2And/or NH3By the exhaust gas stream of |
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