Introduction:
In chemical production plants, the reclamation of high-temperature process condensate presents challenges due to the need for efficient and cost-effective treatment methods. A pilot test was conducted in a chemical production plant to evaluate the feasibility of using the PolyCera Titan ultrafiltration membrane for reclaiming high-temperature process condensate. The process involved treating condensate cooled by Organic Rankine Cycle (ORC) at 60°C using the PolyCera Titan ultrafiltration (UF) membrane and ion exchange resin, with the reclaimed water intended for reuse as boiler make-up water.
Background:
High-temperature process condensate, cooled to 60°C by ORC, typically contains impurities (oil and iron) that necessitate treatment before reuse. The pilot test aimed to assess the performance of the PolyCera Titan UF membrane in directly treating the 60°C condensate without the need for additional cooling.
Process Flow:
The treatment process involved the direct filtration of 60°C process condensate using the PolyCera Titan UF membrane, followed by treatment with ion exchange resin before reuse as boiler make-up water.
Results:
The pilot test yielded promising results:
- The PolyCera Titan UF membrane maintained a stable operating flux of 85 LMH, with a transmembrane pressure of less than 0.8 bar.
- The overall recovery rate of the system exceeded 98%, demonstrating the membrane’s high efficiency in reclaiming process condensate.
Value Proposition:
The utilization of PolyCera Titan UF membrane for high-temperature process condensate reclamation offers several significant benefits:
- Energy Saving: By directly filtering condensate at 60°C without the need for additional cooling, the PolyCera Titan membrane enables energy savings, reducing both heating and cooling energy consumption.
- Water Saving: Eliminating the need to cool condensate below 40°C reduces the consumption of circulating cooling water.
- No need of Iron Removal Filter and Activated Carbon Filter.
- Reduced Operating Costs: The overall reduction in energy, water, and chemical consumption contributes to lower operating costs, while the environmentally friendly operation aligns with sustainability goals.
Conclusion:
The successful pilot test demonstrates the effectiveness of using the PolyCera Titan UF membrane for reclaiming high-temperature process condensate in chemical production plants. The membrane’s ability to maintain stable performance at elevated temperatures offers significant energy and water savings while reducing operating costs and environmental impact.
Keywords
High-temperature process condensate, PolyCera Titan ultrafiltration membrane, Chemical plant, Reclamation, Boiler make-up water, Energy saving, Water saving.