EPA-600/2-76-260
October 1976
Environmental Protection Technology Series
INDUSTRIAL WASTEWATER RECLAMATION
WITH A 400,000-GALLON-PER-DAY
VERTICAL TUBE EVAPORATOR
Industrial Environmental Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Cincinnati, Ohio 45268
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Health Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
This document is available to the public through the National Technical Informa-
tion Service, Springfield, Virginia 22161.
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EPA-600/2-76-260
October 1976
INDUSTRIAL WASTEWATER RECLAMATION
WITH A 400,000-GALLON-PER-DAY
VERTICAL TUBE EVAPORATOR
by
William C. Lang
John H. Crozier
Frank P. Drace
Keith H. Pearson
The General Tire & Rubber Company
Akron, Ohio 44329
Project No. 12020 GUT
Project Officer
Fred Ellerbusch
Industrial Pollution Control Division
Industrial Environmental Research Laboratory
Cincinnati, Ohio 45268
INDUSTRIAL ENVIRONMENTAL RESEARCH LABORATORY
OFFICE OF RESEARCH AND DEVELOPMENT
U.S. ENVIRONMENTAL PROTECTION AGENCY
CINCINNATI, OHIO 45268
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DISCLAIMER
This report has been reviewed by the Industrial Environmental
Research Laboratory, U.S. Environmental Protection Agency,
and approved for publication. Approval does not signify that
the contents necessarily reflect the views and policies of the
U.S. Environmental Protection Agency, nor does mention of trade
names or commercial products constitute endorsement or recommen-
dation for use.
IT
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FOREWORD
When energy and material resources are extracted, processed, con-
verted, and used, the related pollutional impacts on our environment
and even on our health often require that new and increasingly more
efficient pollution control methods be used. The Industrial Environ-
mental Research Laboratory - Cincinnati (lERL-Ci) assists in developing
and demonstrating new and improved methodologies that will meet these
needs both efficiently and economically.
This report, "Industrial Wastewater Reclamation with a 400,000
Gallon-Per Day Vertical Tube Evaporator", is a product of the above
efforts. It concludes that physical/chemical treatment methods continue
to be a most important tool in the control of industrial pollution.
This study combined several program objectives in demonstrating one
such treatment method, multi-stage evaporation, for pollution control
and the associated reuse of the recovered water in the process. These
results can be applied by the rubber manufacturing industry, and others,
in their search for more complete water reuse. For further information
on the subject, contact the Industrial Environmental Research Laboratory,
Edison, NO field station 08817.
David 6. Stephan
Director
Industrial Pollution Control Division
Cincinnati
*
m
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ABSTRACT
A 14-effect vertical tube evaporator (VTE) was built to recover water
from a synthetic rubber manufacturing plant wastewater stream con-
taining a 3,500 ppm dissolved solids, mostly chlorides and sulfates,
and organics in excess of 100 ppm. The unit was designed to produce
10.5 pounds of water per pound of steam. Recovered water, containing
near-zero organics and very low total dissolved solids, was recycled
to the manufacturing process.
Performance over short periods exceeded design. Continuous operation
for extended periods was rendered impossible due to fouling and corro-
sion of the copper alloy heat exchange surfaces. Corrosion was traced
to the presence of 2 to 5 ppm of sulfides in the wastewater feed.
The unit was retubed with titanium. This eliminated the corrosion, but
the fouling continued. All attempts to reduce fouling by pretreating
the wastewater feed stream were unsuccessful.
Except for the problems caused by the fouling of the heat transfer
surfaces, the unit operated satisfactorily. If the fouling can be
brought under control, this method has a high probability of providing
an economical method of renovating wastewater streams containing water
soluble salts and organic chemicals. Direct operating costs varied
from $0.80 to $8.44 per thousand gallons of water recovered.
This report was submitted in fulfillment of R & D Project 12020 GUT
by The General Tire & Rubber Company under the partial sponsorship of
the U.S. Environmental Protection Agency. The work was completed in
January 1975.
IV
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CONTENTS Page
DISCLAIMER ii
Foreword ill
Abstract 1v
List of Figures vi
List of Tables vii
Acknowledgement vi i i
Introduction 1
Conclusions 6
Recommendations & Future Work 8
Mechanical Description of the VTE 9
Process Design and Description of the VTE 12
Summary 12
Wastewater Characteristics 12
Scale Formation 15
Design Operation 18
Construction 24
Operation . 28
Initial Operation 28
Ammonia in Product 29
Feedheater Foul ing/Corrosion 30
Biocide Treatment 42
Wastewater Feed Chiorination 42
Bio-Oxidation of the Wastewater Feed 43
On-Stream Feedheater Cleaning 45
Chemical Cleaning 46
Substitute Material of Construction 46
Other Pretreatment Techniques 48
Calcium Sulfate Scale 49
Operating Data 50
Economics 57
Capital Cost 57
Operating Cost 59
References 63
Appendix - Operating Data 64
Technical Report Data 90
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FIGURES
Number Page
1 Vertical Tube Evaporator Cross Section Detail 10
2 Simplified Process Flow Diagram 13
3 Relationship Between Heat Transfer Coefficient 16
and Brine Concentration
4 Vertical Tube Evaporation Operating Line and 17
Scaling Limits
5 Construction Site as of duly 30, 1971 25
6 Construction Site as of November 5, 1971 26
7 Completed Facility 27
8 Holes in Tube 35
9 Dark Area to the Right of Hole. Dark Area Was 36
Material Not Removed by NaCN Solution
10 Same Section as Figure 9 But Showing More of 37
the Dark Area
11 General View Showing Surface Condition 38
12 End View of a Cut Tube 39
13 Dark Section Corrosion Product 40
14 End View 41
15 Gain Ratio vs. Time 52-56
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TABLES
Number Page
1 Typical Quality of Wastewater Feed 14
2 Product Water Quality Characteristics from Pilot 18
Plant Data
3 Typical Design Operation Summary 19
4 Averaged Data February 1972 Performance Run of 28
70-Hour Duration
5 Product Water Composition During Initial Operation 29
6 Analyses of Samples Taken from Preheater Tubes in 31
May 1972
7 Analyses of Samples Taken from Preheater Tubes in 31
July 1972
8 Analyses of Samples Taken from Preheater Tubes in 32
September 1972
9 Analyses of Samples Taken from Preheater Tubes in 32-33
September and October 1972 (During a period in
which chlorination appeared to be oxidizing sulfides
but aggravating fouling by creating organic com-
pounds more likely to deposit on tube surfaces.)
10 Analyses of Samples Taken from Corroded Evaporator 34
Tubes During March 1973
11 Trickling Filter COD Reduction 45
12 Capital Costs and Pilot Plant Costs 58
13 Operating Cost Data 60-61
14 Percent VTE Operating Time 61
15 Steam and Electricity Usage 62
16 Operating Data Nomenclature 64
vii
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ACKNOWLEDGMENT
The General Tire & Rubber Company gratefully acknowledges the contribu-
tions of former project officers George J. Putnicki and Joseph W. Field
III, Richard L. Hill, Director or Contracts and Grants; of the Region VI
Office and Dr. Herbert Skovrenk of the Office of Research and Development
of the United States Environmental Protection Agency, whose collective
support and guidance was invaluable throughout the project.
vi ii
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INTRODUCTION
This report covers the installation and operation of a 14-effect evap-
orator located at The General Tire & Rubber Company's synthetic rubber
plant at Odessa, Texas. This plant has a nominal rated capacity of
40,000 tons per year of butadiene-styrene type synthetic rubber (GRS)
and employs 250 people. It is located in a semi-arid area of Western
Texas, and there are no permanent flowing streams in the vicinity to
provide dilution of the plant effluent. This plant was constructed in
1957. For the first 10 years, the plant effluent was used by an oil
producing company for water flooding of an oil field for the secondary
recovery of crude oil. At the completion of the 10-year contract
period, the oil company declined to exercise their option for renewal
due to the difficulties they had encountered in treating the water for
water flooding which is the same as would be required for the deep well
injection method of disposal. In 1968, an 89-acre plastic lined solar
evaporation pond was constructed as a temporary measure and also as the
ultimate final sink for the disposal of the concentrated brine which
would be the by-product of any process to recover and reuse part of the
water.
As a permanent solution to the disposal problem, it will be necessary
to recover part of the water in order to reduce the volume of brine to
be disposed of by solar evaporation, deep well injection or spray drying.
The use of membrane-type processes such as reverse osmosis and electrical
dialysis for the recovery of the wastewater were considered to have a
much lesser chance of success than the distillation process due to the
fact that any fouling of the membranes would seriously reduce or com-
pletely eliminate the possibility of producing high-quality product
water whereas with the distillation unit fouling of the heat transfer
surface would only reduce the efficiency of the unit and would not
seriously hamper its ability to produce high-quality reusable water at
a reasonable rate.
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The economical removal of water soluble salts from plant effluents has
always caused an almost insurmountable problem. Although the production
of distilled water from brines has been accomplished for a considerable
time, the end use of the water on the larger units was for drinking
purposes; and as generally there was no other fresh water in the area,
cost was of no consideration. It should also be noted that these de-
salination plants used as a feed either well water containing a high
salt content or sea water. In either case, the feed stock had more or
less a constant composition and was free from organic contaminants. In
treating industrial effluents in addition to the dissolved salts,
organic chemicals may also be present, and the composition of the ef-
fluent is not constant as it must accept whatever wastes the production
plant wishes to dispose of. The conceptual design of the 14-stage
vertical tube evaporator erected at the synthetic rubber plant, owned
and operated by The General Tire & Rubber Company, at Odessa, Texas,
indicated that the effluent from the plant could be treated in an
evaporator and would accomplish three goals:
1. Recover up to a maximum of 80% of the water for reuse in the
plant, thus alleviating a possible water shortage in case of a
serious drought in this semi-arid area.
2. Reduce the quantity of concentrated brine that would have to
be disposed of in the solar evaporation ponds.
3. Accomplish the above at a cost of between $1 and $1.25 per
thousand gallons of water reclaimed, including the charges for
depreciation of the capital equipment required.
The facility built under this grant demonstrates the applicability of a
multiple effect vertical tube evaporator to the renovation of chemical
plant wastes containing both inorganic and organic chemicals. The
product water contained less than 10 parts per million of dissolved
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salts, and the volume of the concentrated brine was reduced to a reason-
able volume for ultimate disposal. While this process was demonstrated
on the effluent from a synthetic rubber plant producing GRS type rubber,
the principle is applicable to a wide spectrum of chemical and indus-
trial plant effluents, including those where the ultimate disposal of
the brine requires it to be taken to dryness in an auxiliary piece of
equipment such as a flash dryer.
The chemical wastewater effluent from The General Tire & Rubber Company's
Synthetic Rubber Plant, Odessa, Texas, at flow rates up to 750,000 gpd
contains dissolved solids, mostly sulfates and chlorides in concentra-
tions of approximately 3,500 ppm, in addition to organics of approxi-
mately 250 ppm. The evaporation plant is used to obtain high-quality
water for reuse in the synthetic rubber manufacturing process. The
residual concentrated brine is disposed of by means of existing plastic-
lined solar evaporation ponds containing a total area of 89 acres.
In order to prevent ground water pollution, for the past several years,
The General Tire & Rubber Company Odessa Plant had been disposing its
aqueous industrial wastes by discharging them into these solar evapora-
tion ponds. These ponds gradually filled to the point where it was
probable that production would have had to be curtailed within a short
time. An alternate solution to waste handling was therefore essential.
From theoretical and pilot plant studies, The General Tire & Rubber Com-
pany decided that evaporation of the rubber plant wastewater by the
vertical tube process coupled with discharge of the concentrated brine
to the existing solar evaporation ponds would provide wastewater renova-
tion and an ultimate wastewater disposal system that completely abated
water pollution and also would be economically acceptable.
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Specific objectives of the project were to determine:
1. The ratio of the quantity of pure product water to the quantity
of wastewater feed.
2. The amount of pure product water per unit of thermal energy
applied, the "gain ratio" or "economy ratio."
3. The performance of the plant at various feed rates.
4. The corrosion resistance of the construction materials.
5. The rate of scaling or fouling, if any, on the heat exchange
surfaces.
6. The overall utilities requirements.
7. The engineering data to further optimize the design of future
VTE plants for industrial wastewater application.
8. The concentrations of organics and dissolved solids in the pure
product water compared to concentrations in the wastewater feed.
9. From the above, the cost of the reclaimed water.
The engineering design of the VTE facility, materials procurement, and
start-up services were furnished by Envirogenics Company, El Monte,
California. Engineering design of auxiliary facilities and construction
supervision was carried out by the Central Engineering Department of
The General Tire & Rubber Company, Akron, Ohio.
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After a brief initial period of operation at above design specifications,
the VTE performance rapidly deteriorated, due to fouling and corrosion
of the copper-nickel alloy feedheater and evaporator tubes. The focus
of development efforts throughout the balance of the demonstration
period was on identifying the cause of and evaluating remedies for the
fouling/corrosion problem.
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CONCLUSIONS
The applicability of a 14-effect vertical tube evaporator (referred to
as VTE) for the purpose of renovating an industrial waste stream con-
taining approximately 3,500 ppm of inorganic salts, mostly sodium and
potassium chlorides and sulfates, and approximately 100 ppm of organic
chemicals plus 200 ppm of ammonium ion was demonstrated for a period
of approximately two years with the following results:
1. The product water was uniformly of very high quality, contain-
ing less than 10 ppm of total dissolved solids; ammonia was
reduced to one-fifteenth (1/15) of the concentration in the
feed stock to the VTE. In order to reduce the ammonia to 3 to
5 ppm as required by the plant, the ammonia in the raw effluent
was reduced from 200 ppm to 50 ppm by process changes elsewhere
in the plant. The water was successfully used as process water
throughout the demonstration period in a 6RS type synthetic
rubber plant at a rate of 200,000 to 300,000 gallons per day.
2. As a result of the removal of the high quality water for reuse,
the volume of the brine containing the water soluble solids was
reduced to approximately 35% of its original volume. Because
of the fouling problems encountered, the unit was deliberately
run at a low recovery rate. The recovery rate is governed
only by the fouling characteristics of the effluent feed.
3. High unexpected corrosion rates on the 70-30 and 90-10 copper-
nickel alloys used for the heat transfer surfaces was encoun-
tered. This was traced to the presence of 2 to 5 ppm of sulfide
ion in the effluent feed stock. These sulfides resulted in
part from the anaerobic bacteriological decomposition of the
sulfates in the feed holding tanks and partly to sulfur -
containing organic chemicals used in the plant.
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4. In addition to the fouling caused by the sulfide corrosion,
serious fouling also resulted from the organic chemicals and
precipitation of iron and aluminum compounds.
5. Retubing the heat exchangers and evaporator with titanium tubes
eliminated the corrosion problem but not all of the fouling
problems.
6. The high rate of fouling resulted in a typical operating cycle
of three (3) weeks on stream and one week down for cleaning
which caused high maintenance and operating costs. These direct
costs varied from $0.80 per thousand gallons to $8.44 (see
Table 13).
7. Calcium sulfate scaling did not occur.
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RECOMMENDATIONS AND FUTURE WORK
Although the product water was very pure, less than 10 parts per million
of dissolved solids, and the unit operated unattended while reclaiming
wastewater from the butadiene-styrene synthetic rubber plant, to eval-
uate this type of equipment for other processes, pilot scale experiments
are necessary using actual virgin plant effluents in order to accurately
assess such parameters as corrosivity and fouling tendencies. The
economical use of this type of equipment depends on maintaining contin-
uously a high heat transfer coefficient and having no corrosion or
fouling of the thin-wall heat transfer surfaces.
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MECHANICAL DESCRIPTION OF THE VTE
Major components of the VTE as originally built are:
Fourteen vertical evaporator effects in a single vessel, approximately
9 feet in diameter by 73 feet long; one single-pass feedheater per
effect for effects 1 through 13, 2.0 feet in diameter by 17.5 feet
long; two, four-pass feedheaters for effect 14, 3.0 feet in diam-
eter by 17.5 feet long; and associated feed, circulating, and product
pumps. A low-temperature degassifier 3.5 feet in diameter by 36.3
feet tall and a high-temperature degassifier 2.0 feet in diameter by
13.0 feet tall is also provided; along with a two-stage air ejection
system and a barometric heat rejection condenser. Auxiliary facili-
ties consist of a cooling tower for final heat rejection, a building
housing instrumentation and electrical controls, and an array of
remote monitering instruments. Figure 1 shows a typical transverse
section of the evaporator.
The facility was made corrosion resistant to the known characteristics
of the wastewater stream (see Table 1) by providing surface coating or
alloy materials for the brine-contacted areas. The evaporators were
tubed with 90-10 Cu-Ni tubes 2 in. outside dimension by 6 feet long,
roller expanded into carbon steel tube sheets, the upper tube sheet was
clad on the side exposed to the liquid waste with Type 316 S.S. The
evaporator water boxes are Type 316 S.S. with Type 316 S.S. clad remov-
able covers. The evaporator sumps are mono-calcium aluminate cement-
lined up to the knitted wire mesh entrainment separators, and above that
point they are carbon steel. The feedheaters were tubed with 3/4inch
70-30 Cu-Ni tubes, roller expanded into Type 316 S.S. clad tube sheets.
The condensate outlet in each feedheater is sized to receive the flash-
ing accumulation of distillate. The shell is carbon steel, but the heads
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are Type 316 S.S. All feedheater and evaporator tubes are accessible
for mechanical cleaning or replacement, if required.
Pumps are all Type 316 S.S. insofar as wetted parts are concerned,
except distillate, cooling water, and condensate pumps which are cast
iron, with bronze or stainless steel trim, as is appropriate. Pipe-
lines are glass-reinforced epoxy or stainless steel for handling waste
and concentrate; and carbon steel for water and steam vapor. The
degassifiers are epoxy lined.
Both the feedheater and evaporator tubes are "enhanced." The feedheater
tubes are spirally indented and the evaporator tubes are longitudinally
corrugated. Design coefficients for feedheaters were developed by
extensive tests at the University of Michigan, Heat Transfer Research
Institute. The design heat transfer coefficient values used vary with
absolute temperature and range from a low of 620 to a high of 1010 BTU
per hour-sq. ft.-F . Evaporator tubes of the longitudinally corrugated
type were installed in the Envirogenics test evaporator, which was then
fed actual wastewater from the Odessa Plant and operated over the bulk
of the plant design conditions. The resulting coefficients were used
for design purposes. They also vary with absolute temperature and
have values ranging from a low of 660 to a high of 1,170 BTU per hour-
sq. ft.-F°. The final design was augmented by providing approximately
10% excess tubes over the design value.
As discussed elsewhere in this report, sulfide attack on the 90-10 and
70-30 copper-nickel heat exchange surfaces led to the decision to re-
place both feedheater and effect tubing with titanium tubes of similar
enhanced surface characteristics.
11
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PROCESS DESIGN AND DESCRIPTION OF THE VTE
SUMMARY
The plant is a 14-effect vertical tube evaporator, forward fed, and re-
generatively feed-heated in the same number of stages as the effects.
It is designed to receive clarified wastewater normally containing
3,500 ppm total dissolved solids at a pH of 6 and 75° F. This feed
can be concentrated to 6.7 times its inlet concentration, by removing
85% of its weight as recovered water which is delivered from the sump
of the last feedheater at 110° F. The concentrate is discharged from .
the sump of effect 14 at 110.4° F. The concentration limit is governed
by the scaling characteristics of the feedwater.
A simplified process flow diagram is shown on Figure 2.
WASTEWATER CHARACTERISTICS
Separate wastewater streams emanate from the major operations of the
synthetic rubber plant and are combined in a neutralization pit and
clarified prior to discharge to a holding pond. Sanitary wastes are
treated in the municipal sewage treatment plant. The present rubber
plant total wastewater effluent flow rate averages 0.523 million
gallons per day (mgd) and is expected to increase to 0.74 mgd upon
anticipated plant expansion.
12
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co
LOW PRESSURE
STEAM
E-IOO
14 EFFECT VERTICAL
TUBE EVAPORATOR
PRESSURE
REDUCTION FLOW
MEASUREMENT
CONDENSER WATER
SUPPLY FROM
COOLING TOWER
X
P-ll
EFFECT2
FEED
PUMP
P-12
EFFECTS
FEED
PUMP
P-23
EFFECT 14
FEED
PUMP
SLOWDOWN
PUMP
HI
C
6HPRESSUR4
[STEAM SUPPLY
TO ATMOSPHERE
EJECTOR SYSTEM
HOTWELL L
SUMP
HOT WELL
PUMP
oou
OHO:
t Ul
tl
HX3
FEED HEATER
HX302
FEED HEATER
P-2
HOT FLASHED
FEED PUMP
FEED HEATER
CAUSTIC SODA
FROM TI02 a P-SI
SODIUM SULFITE
FROM TIOI a P-50
-2401
FEED SUR6E
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_ HX3I8
HX3I4 FEED HEATER
FEED HEATER .
4C02aAIR
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-------
The feed to the VTE unit was taken from this holding pond. The typical
characteristics of this wastewater are presented in Table 1.
Table 1. TYPICAL QUALITY OF WASTEWATER FEED
Total dissolved solids, TDS 3,500 mg/1
Total suspended solids 10 mg/1
Chemical oxygen demand, COD 250 mg/1
Oil and grease 100 mg/1
Hardness, CaC03 250 mg/1
pH 6
Calcium, Ca"1"1" 50 mg/1
Magnesium, Mg++ 25 mg/1
Sodium, Na+ 300 mg/1
Potassium, K+ 500 mg/1
Ammonium, NH4+ 200 mg/1
Iron, Fe 2 mg/1
Chloride, Cl" 350 mg/1
Sulfate, S04= 2,000 mg/1
Bicarbonate, HC03~ 50 mg/1
14
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SCALE FORMATION
In an evaporation process, scale formation on heat transfer surfaces is
especially critical. To determine the scaling potential of the calcium
sulfate-containing synthetic rubber plant wastewater effluent under the
conditions of the proposed vertical tube evaporation process, 55 gallons
of the wastewater was subjected to evaporation in an Envirogenics pilot-
scale evaporator. The evaporator has a product capacity of about 12 gph.
Heat transfer coefficient measurements were made over the range of
wastewater concentration factors to be encountered in the proposed
process. Results are shown in Figure 3, which clearly indicates the
absence of scaling at concentration factors up to 9, which is well above
the maximum proposed concentration factor of 6.7. These measurements
were conducted at the temperature expected at the cold end of the
evaporation train, namely 110° F., where the wastewater is most
concentrated. At this low temperature, calcium sulfate scale takes the
form of the dihydrate, called gypsum. At elevated temperatures, the
scale in operating plants takes on the form of the hemihydrate, or
plaster of paris, which has a much lower solubility at elevated temper-
atures than gypsum.
15
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Figure 3. Relationship between heat transfer coefficient and brine
concentration
800
cc.
UJ
LL.
-------
Figure 4. Vertical tube evaporation operating line
and scaling limits
10
DIHYDRATE SATURATION
- d (Minimum Value)
No observed scaling in
test loop
\
HEMIIIYDRATE
SATURATION
SLOWDOWN
85% Recovery
HEATING
I I
100
140
180 220
TEMPERATURE, °F
260
300
Product water qualities were determined at selected points in the process
and are presented in Table 2, together with the unconcentrated wastewater
quality. The results indicate that as the concentration factor increases,
and concomitantly the evaporation temperature decreases, both the inorgan-
ic and organic content of the distillate decreases. Thus the concentra-
tions of these constituents in the aggregated product water resulting
17
-------
from evaporation over the complete range of concentration factors up to
6.7 should be much lower than those indicated in Table 2, and 95-percent
removals of both inorganic and organic wastewater constituents is
anticipated.
Table 2. PRODUCT WATER QUALITY CHARACTERISTICS FROM PILOT PLANT DATA
Concentration
Factor3
1.0
1.43
1.76
1.92
2.69
Brine Product
ECb
5495
CODC
311
ECb
-
37
37
43
26
CODC
-
32
34
28
18
TOCd
-
9.1
7.4
7.1
4.5
By volume
Electrical conductivity, micromhos/cm at 25° C.
°Chemica1 oxygen demand, mg/1
Total organic carbon, mg/1
DESIGN OPERATION
As a basic design case, a feed rate of 640,000 gpd was assumed, for
which a process design was selected. Components have been sized
throughout to handle 700,000 gpd feed. The plant is designed to operate
without modification over a range of feed rates from 200,000 to 700,000
gpd, and recovery percentages from 40% to 85%. Table 3 summarizes im-
portant flows and other parameters for the design case.
18
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Table 3. TYPICAL DESIGN OPERATION SUMMARY
Parameter
Feed rate
Product
Steam
Concentrated brine
Cooling water
gpm
447
307
*
140
668
gpd
644,000
442,000
-
202,000
963,000
#/hr.
222,600
152,000
13,900
70,600
333,000
Electric demand 68KW
Water recovered 68%
The process takes clarified wastewater at 75° F. from the holding ponds.
It is heated through two stages of feedheating to a temperature of
125° F., adjusted to a pH of 4.5 with sulfuric acid, and fed to a vacuum
degassifier. In the degassifier, the feed is deaerated and decarbonated,
and the low-boiling organics are removed as the liquid flashes down to
123° F. The pH of the feed is brought to near-neutral when sodium
hydroxide and sodium sulfite are added to scavenge trace oxygen. The feed
then proceeds through the individual feedheaters where it is heated by
the product water from the associated effect. After traversing the feed-
heater circuit, the feed enters a boiler-steam-heated exchanger, Hx301,
wherein its temperature is raised to 297° F. prior to introduction to the
high temperature degassifier. Upon introduction to the high temperature
degassifier the hot feed flashes down to 295° F. during which the remain-
ing volatile fraction of the oils present are removed in a vent stream.
NOTE: The venting or discharge of the volatile organics to the atmosphere
may be prohibited by the new Federal, State or Local air pollution
regulations. These regulations must be checked for each location
in regard to the specific organic chemicals to be vented.
19
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Since the process liquid is continuously cooling from the high tempera-
ture degassifier throughout the remaining process, further volatiliza-
tion of oils will be nil. Organics appearing in the distillate during
the evaporation-condensation process which follows are calculated to be
less than 1 ppm in the product water if any at all are present, based
on the range of oils and organics which may be expected to appear in a
waste stream from the processing plant.
The two-temperature-level degassing design provides for removal of a
wide range of volatile organics, not only protecting the purity of the
product water, but also eliminating them from contact with the evapora-
tion train, where some species might add significantly to corrosion
problems.
The deaerated, degassified feed is introduced to the first effect
evaporator upper water box where it flows through stainless steel
distributors and onto the inside of the tubes in a thin film. Boiler
steam on the outside of the tubes condenses giving up its latent heat
to the falling film inside the tubes, causing it to boil, resulting in
the generation of a quantity of steam almost equal to that condensed.
The mixture of waste liquid and product vapor issues forth from the
bottom of the falling film tube bundle where the liquid falls to the
bottom of the sump. The vapor is drawn out and upwards through a
knitted wire mesh entrainment separator to the relatively cold outside
surface of the falling film tubes of the second effect where it condenses,
acting as the heating steam for the second effect. The accumulated,
slightly concentrated waste liquid is withdrawn from the first effect
sump and pumped to the top water box of effect two. At this point it
flows through porcelain distributors and gravitates down the inside of
the tubes in the same manner as for the first effect. The feed to the
20
-------
second effect is superheated, relative to the second effect evaporating
pressure, hence a portion vaporizes as the pressure is reduced through
the distributors, contributing to production and reducing the liquid
temperature to provide the potential for heat transfer.
The distillate draining from the outside of the tubes in the first
effect is delivered to the product sump of the associated feedheater,
along with adequate vapor to heat the feed. Each subsequent effect
operates in the same manner, delivering its distillate to the feedheater
product channel where it joins the accumulating stream of combined dis-
tillate (product). Since the temperature level is less in each subse-
quent feedheater, the accumulated distillate flashes on entering each
feedheater as it is transferred in series from exchanger to exchanger
through seal loops. The vaporization cools the distillate and produces
vapor which condenses on the feedheater tubes, thus providing for dis-
tillate cooling and simultaneous heat recovery from the product. The
combined product stream is removed from the plant at 110° F. from the
sump of the coldest operating feedheater. In this manner the waste
liquid is successively concentrated in each effect and finally dis-
charged from the sump of the last effect at 110.4° F. The vapor pro-
duced in the last effect is condensed by cooling water in a direct
contact barometric condenser.
Vent vapor streams are removed at appropriate points in the process,
either to the atmosphere from super-atmospheric operations, or to the
appropriate level of vacuum header. Venting thus continuously removes
non-condensibles and avoids blanketing of the heat transfer surfaces.
The vent vapors are eventually pumped to the atmosphere by steam jet-air
ejectors, with cooling water-cooled barometric-type intercondensers.
21
-------
The temperature profile over the plant is established and maintained by
(1) the application of boiler steam to the first effect and the final
feedheater; (2) the application of cooling water to the direct contact
final condenser; and (3) the continuous removal of non-condensibles.
It should be noted that excess surface and pumping capacity has been
provided over that required for the design process case. Since the
plant will have a fixed surface area, and it operates on the basis of
Q » U A A T where both U, the overall heat transfer coefficient, and A,
the heat transfer surface area, may be considered fixed, the overall
temperature difference will be reduced as the rate of evaporation is
reduced. Thus, the actual top temperature for the feed liquid in the
design case (644,000 gpd feed and 68% recovery) is about 280° F. The
system is completely self-regulating as the rate of operation varies,
since the first effect operating control automatically reduced the steam
input as the wastewater feed flow is throttled.
An additional source of flexibility is inherent in the system. While
the steam rate is automatically proportioned to feed rate, the ratio is
adjustable. If a lower recovery is desired, one merely reduces the
steam applied for a given feed rate (or raises the "feed to steam ratio").
The automatic control also assures that overconcentration will not occur.
A pressure regulator on the steam line limits the maximum temperature on
the first effect.
This particular system is also quite insensitive to variations in the
quality of the feed with the provision for two-step removal of volatiles
and the fact that the salt content has little effect on evaporation.
This allows for performance over a wide range of waste feed conditions,
which could very well occur in an industrial wastewater application
such as this.
22
-------
Utility requirements for the VTE are steam, electricity, cooling water,
and instrument air. The plant receives 250-psig steam, dry and
saturated, which is reduced to 75 psig prior to use in the first effect.
The plant also receives cooling water at 75° F. and returns this cooling
water, augmented by the vapor from the 14th effect, at 106° F. Three-
phase electric power at 60 cycles and 480 volts is required for all
pump drivers and/or to energize a step-down transformer to supply single
phase power for lighting, control, and fractional HP motor drives.
23
-------
CONSTRUCTION
Field construction was begun during June 1971, and the installation
completed during February 1972.
Figures 5 through 7 are photographs showing various stages of construc-
tion. Figure 5 shows the construction site as of July 30, 1971, with
foundations completed and effect circulating pumps set in place. In
Figure 6, taken November 5, 1971. the evaporator vessel has been set
with the feedheaters placed underneath; the vacuum degassifier, control
building, and cooling tower are seen in the background. Figure 7 shows
the completed facility.
The mechanical contractor for the project was Ref-Chem Corporation,
Odessa, Texas.
Total capital cost for the VTE installation was $1,184,783. See section
entitled Economics for a breakdown of the capital costs including the
cost of the solar evaporation ponds and pilot plant equipment.
24
-------
ro
Ul
Figure 5. Construction site, July 30, 1971
-------
-
rvs
i,,
~ .
Figure 6. Construction site, November 5, 1971
-------
PO
Figure 7. Completed facility
-------
OPERATION
INITIAL OPERATION
The VTE was brought on stream during January 1972, and normal mechanical
and instrumentation run-in problems were corrected. The first heat and
material balances calculated around the unit showed that thermal per-
formance exceeded design specifications, with feed and steam rates at
design, the product rate was higher as was the resultant gain ratio.
Averaged data for a 70-hour performance run made during the first week
of February 1972 is presented in Table 4.
Table 4. AVERAGED DATA FEBRUARY 1972 PERFORMANCE RUN
OF 70-HOUR DURATION
. ;
Parameter Measured value Design value
Feed rate 623,500 gpd (432 gpm) 644,000 gpd (447 gpm)
Production 475,488 gpd (330 gpm) 442,382 gpd (307 gpm)
Steam rate 13,976 Ib./hr. 13,900 Ib./hr.
Feed concentration - 4.2 3.19
brine
Water recovery 76% 68%
The eight-day average for period June 27 to July 7, 1972:
Feed rate 300.5 gpm
Production rate 185.4 gpm
Steam rate 170 pounds per min. = 10,200 pounds per hour
Gain ratio 10.2
Water recovery 62%
During the period of February to June 27, 1972, operation of the unit was
sporadic as we attempted to solve some of the operational and fouling
problems. Table 5 shows the product water analysis for four of these
short runs.
28
-------
2/6/72
9.2
55.5
2.8
ND
0.88
10.3
10.0
3/26/72
6.0
60.4
1.1
9.9
1.12
13.0
0
3/27/72
7.2
53.4
1.2
25.0
0.45
51.5
10.0
3/29/72
7.0
32.0
1.2
6.0
0.42
12.5
6.8
Table 5. PRODUCT WATER COMPOSITION DURING INITIAL OPERATION
Product Water Composition
pH at 22° C.
Specific conductance.
micromhos/cm
Chloride, Cl ppm
Sulfate, S04 ppm
Phenol ppm
TOC ppm
Ammonia nitrogen,
as N ppm
AMMONIA IN PRODUCT
The biggest problem with the quality of the product water during this
period was the carryover of the ammonia. Ammonia is detrimental to the
synthetic rubber polymerization reaction. The cause of this was traced
to the inability of the degassification system to reduce ammonia in the
feed to design levels. Experimental work led to the addition of an
acidification step after the high temperature degassifier to maintain
the feed pH at less than 7.0, thus maintaining the ammonia in solution
as ammonium ion. The problem was further reduced by a changeover from
ammonium hydroxide to sodium hydroxide neutralization in a waste treat-
ment step upstream of the VTE and ammonia level in the wastewater feed
dropped to about 50 ppm. These changes resulted in production of water
of such quality as to allow recycling to the synthetic rubber process,
with ammonia held well under 10 ppm.
29
-------
Operation of the unit after June 27, 1972, utilized the above operational
changes; and generally the ammonia was approximately 5 ppm or below, and
the total dissolved solids were below 10 ppm. This data is included in
Table 6 along with the operating data.
FEEDHEATER FOULING/CORROSION
During March 1972, the first indication of feedheater fouling was
evidenced by a decay in VTE efficiency as measured by the gain ratio.
This necessitated the first of what became an almost monthly routine of
shutting down the VTE unit, disassembling the feedheaters, scouring the
tubes with a high-pressure (10,000-pound-per-square-inch) water jet, and
reassembling of the feedheaters. Each such cleaning was quite satis-
factory in producing a clean metal surface, but as the 70-30 copper-
nickel tube surface progressively roughened from corrosive attack, the
technique became less effective. The spiral indentations precluded
drilling of the tubes, but the deposits being soft were readily removed
and did not require such severe treatment. Figures 8 through 14 are
microphotographs of corroded feedheater tubes.
By July 1972, a randomly selected feedheater tube from the hot end of
the VTE showed corrosion penetration of one-half the tube wall. By
September 1972, some corrosive attack of the vertical tubes was noted;
although, at an apparently lower rate than the attack on the feedheater
tubes. Throughout the program, the type 316 stainless steel piping,
pumps, and cladding appeared unaffected by corrosion.
\
Analysis of samples taken from the feedheater tubes are shown in
Tables 6 thru 10. The corrosion of the copper was undoubtedly caused
by the presence of the sulfide ion with the major foul ant being cop-
per sulfide and later on organic materials. The source of the sulfide
ion was traced to organic sulfides used in the manufacturing process
and anaerobic bacterial action in the effluent feed holding pond
reducing the sulfates to sulfides.
30
-------
The total concentration of these sulfide ions ranged from 2 to 5 ppm,
with some much higher and lower levels at times. This amounts to 0.44
to 1.11 pounds per hour or 10.7 to 26.7 pounds per day in the 644,000
gallons per day of effluent feed.
Table 6. ANALYSES OF SAMPLE TAKEN FROM PREHEATER TUBES
DURING MAY 1972
Silica, Si02
Copper, as Cu
Nickel, as Ni
Iron, as Fe
Chromium, as Cr
Sulfur, as S
Organics
0.03%
58.3
4.1
0.14
0.31
12.7
Not over 20
Table 7. ANALYSES OF SAMPLES TAKEN FROM PREHEATER TUBES
IN JULY 1972
Sample Source
Copper, as Cu
Nickel, as Ni
Sulfur, as S (total)
HX301
55.8%
1.1
15.9
1st Effect
Tube Sheet
41.6%
0.3
12.3
HX31 5
43.7%
18.4
4.6
31
-------
Table 8. ANALYSES OF SAMPLES TAKEN FROM PREHEATER TUBES
IN SEPTEMBER 1972
Sample
Organic matter
Acid insolubles
Sulfur, S
Nickel, Ni
Aluminum, Al
Copper, Cu
Iron, Fe
Light, Granular
Material
44%
1.9
5.7
0.7
2.. 5
0.7
0.6
Moist, Dark Appearing
Material
38%
0.8
3.9
0.5
3.9
0.3
0.3
Table 9. ANALYSES OF SAMPLES TAKEN FROM PREHEATER TUBES
IN SEPTEMBER AND OCTOBER 1972
(During a period in which chlorination appeared to be oxidizing sulfides
but aggravating fouling by creating organic compounds more likely to
deposit on the tube surfaces.)
Weight Percent
Constituent
Loss on Ignition
Aluminum (as AKO-)
Calcium (as Ca)
Magnesium (as Mg)
Carbonate (as Co~)
Acid Insolubles (Si02)
Copper (as Cu)
11 Sept. Samples
No. 1
44.0
4.7
12.6
2.1
NR
1.9
0.7
No. 2
38.0
7.4
4.6
2.5
NR
0.8
0.3
23 Oct. Sample
No. 3
21.6
59.1
0.03
0.32
4.6
2.6
NR
Continued on next page
32
-------
Table 9 (continued). ANALYSES OF SAMPLES TAKEN FROM PREHEATER TUBES
IN SEPTEMBER AND OCTOBER 1972
Constituent
Nickel (as Ni)
Iron (as Fe)
Phosphate (as P04)
Sulfur
Total (as S04)
Sulfide
Elemental (as S)
Material extractable in
MIBK/ether (1/1)
Total Carbon
Organic Carbon (total carbon
less carbonate carbon)
Total Hydrogen
Total Nitrogen
Weight Percent
11 Sept. Samples
No. 1
0.7
0.6
NR
17.1
NR
NR
NR
NR
NR
NR
NR
No. 2
0.5
0.3
NR
11.7
NR
NR
NR
NR
NR
NR
NR
23 Oct. Sample
No. 3
NR
NR
0.05
4.4
none detected
<0.003
1.2
3.55
2.62
2.42
0.75
33
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Table 10. ANALYSES OF SAMPLES TAKEN FROM CORRODED EVAPORATOR TUBES
DURING MARCH 1973
Emission Spectrographic Data
(approximate wt %)
Sample
Color
Si
Mn
Cr
Mg
Fe
Ca
Ag
Ni
A1
CU
Tube 1
White
0.05
0.1
0.1
0.5
0.8
0,1
0.05
1.0
5.0
Blue
0.05
0.1
0.05
0.5
0.8
0.5
0.05
1.0
3.0
Black
0.1
0.1
0.1
0.5
0.8
0.5
0.1
1.0
3.0
Tube 2
White
0.05
0.05
0.1
0.5
0.8
0.5
0.05
1.0
5.0
Blue
0.1
0.5
0.05
0.5
0.8
0.75
0.05
1.0
3.0
Black
0.1
0.1
0.05
0.5
0.8
0.5
0.05
1.0
3.0
Major component greater than 90%
Atomic Absorption
Ni 1.14%
Cu 39.6
Ca 1.7
Figures 8 thru 14 are microphotographs of corroded preheater tubes.
34
-------
U)
in
Figure 8. Holes in tube
-------
CTl
Figure 9. Dark area to the right of hole. Dark area
was material not removed by NaCN solution
-------
OJ
rn
!
:o -^
NX, . X
I i 1
,.
- , , . -
Figure 10. Same section as Figure 9 but showing more of the dark area
-------
it
CO
00
Figure 11. General view showing surface condition
-------
Co
10
Figure 12. End view of a cut tube
-------
Figure 13. Dark section corrosion product
-------
Figure 14. End view
-------
BIOCIDE TREATMENT
*
Sulfate^reducing micro-organisms were identified in the feed stream in
concentrations of 500-700 bacteria per milliliter. This indicated a
bacteriological mechanism might be triggering the problem and the feed
was treated with a biocide over a one-month period. The results were
negative and the biocide was discontinued.
WASTEWATER FEED CHLORINATION
Some early potential solutions to the sulfide problem, including such
techniques as stripping hydrogen sulfide from the feed stream with air,
feed pH adjustments, slow sand filtration, charcoal filtration, aerating
the holding ponds, flocculation, time stabilization, and reaction with
iron or copper or zinc salts, yielded to chlorination of the feed stream
as being the most efficient and expedient technique available to
eliminate sulfide in the feed. The theory behind chlorination of the
feed is that sulfide constituents are oxidized to innocuous sulfates
which do not contribute to corrosion of the copper alloy tubes.
A chlorinator was installed on the wastewater feed stream in early July
1972 and was operated during most of the balance of the demonstration
period. Contact times were varied between 30 seconds and 30 minutes,
while the chlorine residual was held between 0.4 to 0.8 ppm. Sulfide
levels of generally less than 0.2 ppm were attained. The remaining
chlorine was eliminated by reaction with the sodium sulfite normally
added to the feed after deaeration as an oxygen scavenger, thus reducing
42
-------
the possibility of chlorine corrosion of the tubes. First indications
were that chlorination substantially reduced both fouling and corrosion;
however, qualitative evaluations of fouling rate were clouded somewhat
by frequent periods of operation at low rates, which would tend to
increase fouling. Early optimism as to chlorination's efficacy in re-
ducing fouling waned, however, as the experiment continued, until it was
ultimately believed that chlorination was contributing to the fouling.
The mechanism for this enhancement of fouling is believed to be that
some organics were being chlorinated and the reaction product was
depositing on the tubes. Feed chlorination was continued in spite of
the increased fouling, however, as it was fairly certainly established
that chlorination did lower the rate of corrosion, although not
eliminating it.
Reliance on chlorination exclusively, even if efficacious, was not
considered the ultimate solution to the fouling/corrosion problem of the
copper alloy tubes. In addition to a considerable corrosion potential
in feeding large amounts of chlorine, chlorination does not oxidize
elemental sulfur, organic sulfides, or some organic compounds which may
be involved in the mechanism of fouling and which, although unaffected
by chlorination at ambient temperatures, break down at the higher,
evaporator temperatures. Additionally, there was a possibility that
chlorination might produce elemental sulfur which could react with the
copper.
BIO-OXIDATION OF THE WASTEWATER FEED
Bench-scale studies indicated bio-oxidation was a feasible means of
oxidizing sulfides as well as oxidizing the organics in the feed. Bio-
oxidaticn does not suffer from the drawbacks attending high-level
chlorination and will oxidize sulfide-producing compounds that may be
unaffected by chlorine but which break down at the high temperatures in
43
-------
the VTE. Additionally, organic constituents would likewise be oxidized.
Based on these studies, a 30-gallon-per-minute, rock-fill, pilot-scale
trickling filter was installed at the VTE site to treat a sidestream of
the VTE feed.
In the trickling filter pilot plant operation, wastewater is taken from
the exis-ting holding pond and pumped to the top of the trickling filter
to flow over the rock fill, contacting the biological growth on the rock
surfaces, with oxidation of sulfide and organic compounds. Air is pull-
ed through the filter cocurrently with the wastewater. From the trick-
ling filter, the treated wastewater flows by gravity to a settling tank
for removal of any of the biological growth that has sloughed from the
trickling filter rock fill. From the settling tank, the wastewater flows
to a feed tank from which it is pumped through a sand/gravel filter
which simulates the existing traveling media filter in the plant system.
After filtration, the treated feed is pumped through a series of six,
single-tube heat exchangers which simulate the range of conditions
experienced in the VTE feedheaters. This arrangement of heat exchangers
is tubed with both 70-30 copper-nickel tubes and titanium tubes and
instrumented so that the rate of fouling can be determined.
It was contemplated that bio-oxidation, if successful in the pilot scale
and installed on a full scale would be followed by low-level chlorination
to scavenge residual sulfides.
The trickling filter was put on stream in December 1972 after inoculation
with domestic sewage. After several weeks of operation, it became
apparent that no greater than 31 percent reduction in COD could be
achieved (Table 11). More recent and more extensive bench-scale experi-
ments confirmed that bio-oxidation alone is apparently inapplicable to
the particular system of organics in the wastewater; although, sulfide
reductions of over 90 percent have been realized in bench scale tests.
44
-------
The latter finding lost significance, due to the decision to retube the
VTE with titanium tubes (see Page 47). The pilot plant was kept operat-
ing during the shutdown of the VTE for retubing and studies with it
alone or in combination with one or more of the other feed pretreatment
techniques was continued. The test bank of heat exchangers was utilized
in subsequent pretreatment evaluations to determine rate of fouling and
corrosion and also for tests on methods of cleaning.
Table 11. TRICKLING FILTER COD REDUCTION
Date Feed COD Outlet COD % Reduction
407 15.9
252 22.0
272 26.9
282 27.9
268 20.7
258 31.8
ON-STREAM FEEDHEATER CLEANING
A parallel thrust in the program to solve the feedheater problems was a
search for a suitable method to clean the feedheaters without the
necessity of shutdown or disassembly, or, at least, no more than a brief
interruption in operation. One approach investigated was an on-stream
mechanical cleaning system. This system automatically and continuously
circulates abrasive sponge rubber balls through the heat exchanger tubes
during operation to wipe accumulated matter from the walls. This tech-
nique is commonly used on the condensers in West Coast power plants and
one such system is being used in a seawater desalination plant located
at Rosarito Beach, Tijuana, Mexico. A manual system was installed and
operated briefly. Although it did appear to have some beneficial value,
continuous use was prevented by lack of mechanical facilities to handle
12/7/72
12/18/72
12/22/72
12/27/72
1/3/73
1/5/73
472
323
372
391
338
378
45
-------
the balls and the unsuitabillty of the sponge rubber balls for operation
at the highest temperatures in the evaporator. Both of these problems
were studied, but the cost involved compared to the anticipated results
did not seem to warrant the expenditure.
CHEMICAL CLEANING
In addition to the mechanical cleaning method described in the previous
paragraph and the high-pressure water flushing method, various chemical
cleaning methods were investigated with the hope that the cost of dis-
mantling the unit could be avoided. The most promising of these were:
1. A 1% inhibited hydrochloric acid
2. Sodium hypochlorite
The inhibited hydrochloric acid gave a spectacular improvement in the
gain ratio the first time it was used. Two subsequent attempts to acid
clean the unit did not result in any increase in thermal efficiency.
Due to the possible damage from corrosion to the unit, acid treating was
discontinued. The sodium hypochlorite proved highly successful in the
laboratory in removing feedheater tube deposits; however, when it was
used on the feedheater in the plant, it was only slightly effective.
Other chemical methods considered involved cyanides; but as the resul-
tant mixtures were highly poisonous and would create a very difficult
disposal problem, they were not tried in the plant.
SUBSTITUTE MATERIAL OF CONSTRUCTION
The original VTE feedheater tubes were specified as 70-30 copper-nickel
which is highly resistant at the temperatures encountered in operation
to the 10 components originally found by analysis in the Odessa waste-
water (ref. Table 1). This choice was based, in part, on short-term
46
-------
pilot-scale runs on a quantity of actual plant wastewater. Although the
reason is immaterial at this point, it is apparent that either the
original waste analysis was not complete enough to detect 2 to 5 ppm of
sulfide, the wastewater characteristics changed, the corrodant/foulant
was lost through reaction or evaporation when drums of waste were trans-
ported to the pilot plant, or some combination of factors. As noted,
further work has pointed to small quantities (2 to 5 ppm) of sulfide
compounds as the major factor in the corrosion/fouling problem.
In December 1972, it was discovered that the tubes in all but the two
feedheaters at the coldest end of the VTE had corroded to such an extent
that replacement was required. These tubes were replaced early in 1973
with titanium tubes with the same spirally indented shape as the original
copper-nickel tubes. Titanium is known to have excellent corrosion
resistance to all presently identified wastewater components including
suIfides. Stainless steel also would not be subject to sulfide attack;
however, it would not be particularly satisfactory as a tube material
because of its high susceptibility to stress corrosion cracking in a
chloride environment.
With the expected elimination of feedheater tube corrosion, it was
assumed the rate of fouling would be reduced, since the contribution of
copper sulfide would be eliminated. Fouling was not expected to be
eliminated entirely. Test tubes of titanium that had been installed in
some preheaters during the last few months of operation still showed
some evidence of fouling when inspected. Efforts were continued,
consequently, to find a feasible method of eliminating foulants through
pretreatment or through reducing the effect of the fouling by on-stream
cleaning.
47
-------
During the feedheater retubing operation, the vertical evaporator tubes
were inspected and found to be also in a severely corroded state. Plans
were made to also retube these with titanium tubes before the VTE was
again placed in service.
OTHER PRETREATMENT TECHNIQUES
In an effort to improve the bio-degradability of the wastewater
constituents, a laboratory investigation was carried out on ozonation of
the feed to determine if such treatment would enhance the bio-degrada-
bility of some of the organic molecules. Preliminary results indicated
BOD and COD reductions of 75 percent, with concurrent improvements in
color and turbidity. These results when compared to simple bio-treatment
suggested that it might be feasible simply to ozonate the feed and pro-
duce a feed stream acceptable to the VTE without any biological treat-
ment.
An ozonation pilot operation was constructed using the test bank of six
single tube heat exchangers from the bio-oxidation tests. A 1.7% mixture
of ozone in oxygen was generated at the plant site, and the feed stock
was treated at a rate of 200 ppm of ozone. While this treatment did
reduce the COD, fouling continued with the foulants now consisting of
iron oxide and aluminum salts. Fouling was much greater when the plant
was making alum (aluminum sulfate) coagulated rubber. Several chemical
after-treatments were tried to eliminate these new foulants, namely,
the addition of a dispersant, sodium sulfite, and sodium carbonate. The
net result of the ozonation tests was that ozonation by itself would not
eliminate the fouling.
An activated carbon adsorption pilot run was made. The carbon also
reduced the COD as did the ozonation; however, the iron and aluminum
foulants still remained. The aluminum source is the alum (aluminum
48
-------
sulfate) used to coagulate the synthetic latex and also used throughout
the plant to neutralize alkaline wastes and latex spills. The iron was
traced to the acid used in the pretreatment of the wastewater and to
complex iron organic compounds in the wastewater which were broken down
by both the ozonation and carbon adsorption and also by bacteriological
action. It is highly probable that these foulants had always been
4 5
present but were masked by the organic foulants and copper sulfide. '
CALCIUM SULFATE SCALE
One important observation over the period of operation of the VTE is
that essentially no calcium sulfate scale of either the dihydrate or
hemihydrate type formed on the evaporator tubes, in spite of wide varia-
tions in and unsettled.conditions of operation. This confirmed calcula-
tions and studies made during the design of the evaporator.
49
-------
OPERATING DATA
Table 16, Pages 65 to 89 in the appendix, presents the operating data and
chemical analyses for the period from June 27, 1972, through July 25, 1974.
After the unit was restarted on July 6, 1973, after the retubing opera-
tion, the laboratory analyses were discontinued as the reliability of
the process control instruments had been proven and could be depended
upon to sound an alarm and bypass the product receiving tanks if the
product water exceeded 10 ppm total dissolved solids.
It was anticipated at project inception that rather complete and extensive
data could be gathered during the project regarding operating and mainten-
ance costs; however, the continuing problems with heat exchange surface
corrosion and fouling precluded this.
With the exception of several short periods immediately following tube
cleaning, the efficiency of the VTE, as indicated by the gain ratio, was
below 10.0 due to feedheater fouling. The quality of the product water
was very high, and the unit constantly produced water under automatic
control of less than 10 parts per million of dissolved solids. The
product water was used in the manufacture of synthetic rubber throughout
the operating period.
Data in Table 16 are based on the following:
1. Liquid flows are the average based on meter readings taken over
a 10- to 20-minute period and are in gallons per minute. Steam
flows likewise are the average flow over the same 10- to 20^
minute period and are in pounds per minute.
50
-------
2. The product total and the gain ratio include the steam condensed
in the first effect. This is the proper method of accounting,
since an almost equal quantity of steam is taken from the final
effect and is condensed in the barometric condenser, thus being
sent to the cooling tower as make-up water. (An almost equal
quantity is evaporated in the cooling tower.) Thus, the quantity
of steam used is not counted as product. If a surface condenser
instead of a barometric condenser had been utilized, the steam
from the last effect would be collected with the product, and
the proper method of accounting would be to deduct from the
product total the quantity of steam fed to the first effect.
3. The analytical data shown is for grab samples taken at the same
time the operating data was taken, approximately 9:00 a.m. on
the dates indicated.
Figure 15 shows the decay in the gain ratio which is directly related to
the degree of fouling for the periods of continuous operation for the
entire operating period. Gain ratios of 10.0 or better are needed to
keep the operating costs reasonable. At a gain ratio of 10, 1,000
pounds of steam will produce 10,000 pounds of water or 1,205 gallons
making the fuel cost for the water per 1,000 gallons 83% of the cost of
steam per 1,000 pounds.
51
-------
Figure 15. Gain Ratio vs. Time
GAIN RATIO *WATER PRODUCED X
-.-
Ui
0
£
,
eJ
u.
DOV
K
Z
<
111
H
>
DO
DOW
IH-
* N -
N -J,
CL E /
- C L
0 W
N INC
DO WN -
DOWN-
D 0
D 0
DOV
DOV
eo
# °
E A N
L E '
, REP
A L U
DUO
W N -
e .
V
W N -
^.
, 8
N -
S
N
e
1 N G
' E L
.ACED
(
M
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9
c
c
r
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'i
a
A M
1 N
LEAK
0
*
.
'
LEA
C .
. E A
,
. E A
*
* 0 N
* 0 N
E*F
«pe"
*
e
NG F
0
K C
>l 1 Nt
0
N 1 N (
A
A
9,
0
L UE
m
EDHE/
N
E R
e
S P 1 1,
S P 1 I
e
N T
TER
C O A
L
. L
POJ
TUBES
»
4 D
_
(O
O
ft!
9
ID
N
8
« 0
0
9
t-
8
0
9
in
in
Cvl
^
9
10
ft v
-' Z
3
OOOpOpqop O O O O
52
-------
Figure 15 (continued). Gain Ratio vs. Time
GAIN RATIO *WATER PRODUCED/*STEAM
M ~i
Ul
<
2
K> 1
0
U.
o
tc.
z
Jj
>
oowt
i|- RE
TUBINC
> J
DOWN -
I
1
ERTIC
#
- CL
AL
I
6
9
9
9
E ANI*
.
r
EFFE
*
,
1 6
CTS
.
O
N
8
- I
2
m
m
M
8
o
tft
s
8 .
K
in «
~ Z
in
s
o
« rf
U.
Q
«)
N
o
K
10
2 I
ID
N
8 2
ID
~ 0
20
aoooooooooppo
53
-------
Figure 15 (continued). Gain Ratio vs. Time
GAIN RATIO *WATER PRODUCED / *STEAM
- 10 -
-
<
£
tf>
C>
Ik
Ej
ae
z
<
O.
H
3 <
r 5
3 C
-i f
3 <
y :
1
0
DOW
DOW
DOW
DOW
3 t
~ <
^
a 9
N
(
N
N
««
V
e
N
a
e
a
T>
3 C
3 t
' s«
t
C L
« 9
'# :
^ *
C L
,
^
W A
.»
I
. CL
e
& 9
0
3 <
li C
E A r
,
o
>
E A N
' .
T!R
9
i
E A N
e
3 <
D r
M N (
C
f
1 N 6
.
.* F
1 N 6
D
^
L U S
3
«
H E
o
«
D
o
»
\
o
n
m
CM
o
N
« Z
O
z
2
tf>
-------
Figure 15 (continued). Gain Ratio vs. Time
GAIN RATIO *WATER PRODUCED X *STEAM
.f
_ U| ._.
o
0.
K)
(9
U.
O
t-
K
Z '
O
IU
*
J
a
DOW
DOW
DOW
DOW
D OW
DOW
DOW
DOW
e
0
DOW
DOW
N
.
N
N
N
e
N
N
N
M
i
N
A
N -
E L
a .
W A
WA
«
WA
A C
%
A C
/
W A
A e
a
I
A C
e
C
*« *
E C J
L
TE R
T E R
e
T E R
a (
**
1 D
*
ji
1 D
4
T E R
8
'£ «
e
1 D
a (
.
LEA
f
i 1
R 1 C
J
%
C
w*
C
1
C L
>
a
e
C L
i
°<
6
OLE
C L
,
N 1 t
i 1
A L
1
LEA1
LC A
LEA
E A N
E A N
rLEA
A N
A N
6
T 1 E
NED
NED
NED
e
E D
E D
N ED
E D
E D
1 N
N
V
s Z
M
.
K
tft (L
Q
«n
o
8oi
- z
o
O
N
ffi
Ml lil
b.
o
8*
K
S-^
o ->
N
8IO
F.
s 6
in
So
ooooqoooo
^low o o» CD N: q>
55
-------
Figure 15 (continued). Gain Ratio vs. Time
GAIN RATIO *V»ATER PRODUCED/ *STEAM
IO
IU
f
in
u.
_ o_
P
*{
i C
i '_
> c
} S
P L A
.
> c
j -
DOM
DOW
N T
> <
f <
N
N
D 0
9 C
* 0
C LE
W A
W N
) <
> <
A N 1
I
T E R
WA
3 t
D 1
N 6
*
C L
<
T E R
«
3 (
^ <
E A r
,»
Cl
9
D
*°
E D
E A »
D 1
0
1 E D
3 1
r i
3 l
o
«
^|
n
«
A-
^)
O
85
S^
T>
M
N
8*
*
9 i«l
o 3
9 ^
9
ti
56
-------
ECONOMICS
CAPITAL COST (Refer to Table 12)
Purchase cost of the mechanical, battery-limits equipment for the VTE;
including the evaporator, feedheaters, pumps, instruments, degassing and
vacuum equipment, and supporting structural steel for these items; but
excluding the control room, cooling tower, electrical gear, and instal-
lation; was approximately $550,000. If titanium tubing had been
specified originally, the purchase cost of these items would have been
$590,000.
Total direct installed cost of the VTE facility was $1,184,784. This
figure is for all components directly associated with the VTE and
includes no investment in supporting facilities, such as utilities or
previously existing wastewater treatment equipment.
Any process to concentrate or recover water from an effluent containing
water soluble salts such as is the case with synthetic rubber manufacture
and many other chemical operations must make provision for an ultimate
sink to receive these water soluble materials to prevent them from re-
entering the environment. For this reason, we have included in Table 12
the cost of constructing the 89-acre lined solar evaporation ponds which
were built in 1968. Including the cost of these ponds and the cost to
retube the unit with titanium, the total capital investment was $2,029,791
In addition, another $83,190 was spent for pilot plant facilities.
57
-------
Table 12. CAPITAL COSTS AND PILOT PLANT COSTS
I. Capital Cost Items
A. VTE unit installed (1971)a $1,184,783.90
B. Solar ponds (1968) 749,051.13
C. Retubing VTE with titanium tubes (1973) 95.956.15
Total capital cost $2,029,791.18
II. Expense Items (Pilot Plant)b
A. Chlorinator $ 2,170.10
B. Trickling filter 18,367.59
C. Activated carbon filter 7,733.96
D. Simulator 17,320.63
E. Ozonator 37.598.45
Pilot plant expenditures for equipment $ 83,190.73
and materials
a(1971) Indicates year in which unit was constructed.
Numbers for pilot plant do not contain any operating costs.
58
-------
OPERATING COST
Table 13 summarizes the direct operating costs; overhead, depreciation,
taxes, insurance, etc., are not included. The figures shown are the
totals for the calendar months indicated. Unit costs in dollars per
thousand gallons of product water ranged from a low of $0.80 to a high
of $8.44 with «n average of $3.848 per thousand for the period of July
1973 to and including July 1974 or, if the last two months which were
very high are excluded, an average cost of $3.154 is obtained for the
11-month period July 1, 1973, to May 30, 1974.
These costs include the cost of operating the pilot operations, cleaning,
and maintenance but do not include the cost of pilot plant equipment or
materials to construct.
Table 14 shows the operating hours, downtime hours and the percent operat-
ing time for various periods of attempted continuous runs for the period
of September 22, 1973, to July 29, 1974. This data is not available for
earlier runs because at that time the on-stream times were considered
too short to be of any value.
If the abnormal rate of fouling could be eliminated, the indications are
that the unit would operate unattended and would require a minimum of
maintenance. The net result should be an operating cost within the
reach of most plants requiring the recovery of water from effluents
containing water soluble salts and/or the concentration of brines for
ultimate disposal. As stated on Page 51, the fuel cost per 1,000 gallons
of water recovered would be 83% of the cost of 1,000 pounds of steam if
the gain ratio could be maintained at 10.0.
Table 15 shows the consumption of steam and electricity per 1,000 gallons
of water recovered and the cost per month for the period of June 1972
to July 1974.
59
-------
Table 13. OPERATING COST DATAd
Month
June 1972
July
Aug.
Sept.
Oct.
Nov.
Dec. \
Jan. 1973
Feb.
Mar.
Apr.
May
June
July
Aug.
Sept.
Oct.
Nov.
Dec.
Jan. 1974
Feb.
Mar.
Apr.
May
June
July
Operating
cost
$ 2,747
3,086
2,834
3,301
5,018
5,994
3,633
9,653
0
0
0
0
381
10,618
6,219
6,653
8,184
7,245
6,848
5,720
6,990
6,231
4,608
7,485
9,203
14,748
Materials
$ 1
11
176
4,270
576
957
802
202
138
87
83
510
608
159
140
868
864
2,438
968
1,356
1,538
399
1,121
1,786
607
968
Labor
$ 1,802
787
3,422
10,038
2,496
21 ,702
5,343
3,466
4,792
7,026
8,444
5,494
5,397
4,115
5,107
5,304
3,415
3,860
4,088
3,097
3,204
1,025
2,708
2,730
2,131
2,578
1000 gals.
product
3,526.66
4,864.87
6,700.14
4,380.43
3,019.74
3,968.84
1,176.99
5,671.37
0
0
0
0
0
4,346.40
6,398.13
4,485.50
4,119.00
5,322.10
4,914.43
4,481.83
3,639.06
1,141.00
2,657.68
3,684.27
1,732.61
2,167.22
Cost/1000
gals. prod.
$1.29
.80
.96
4.02
2.68
7.22
8.31
2.35
-
-
-
-
-
3.42
1.79
2.86
3.03
2.54
2.42
2.27
3.22
6.71
3.17
3.26
6.89
8.44
- See following page
60
-------
Table 13 (continued). OPERATING COST DATA3
- Definitions:
Operating costs - Includes only treatment chemicals, steam,
electricity and cleaning chemicals used.
Materials - Maintenance supplies, seals, pumps, pipe, fittings,
valves, etc., excluding equipment and materials used in
the construction of the pilot plants.
Labor - All direct labor charged to the unit for operation and pilot
plant work. Engineers, maintenance, operation including
labor to construct and alter pilot plants.
Table 14. PERCENT VTE OPERATING TIME
Startup
9/22/73(00:30)
11/9/73 (20:00)
12/17/73(17:00)
1/13/74(16:00)
2/13/74(21:00)
3/4/74 (01:00)
3/15/74(18:00)
4/11/74(21:00)
5/2/74 (02:00)
5/15/74(22:00)
5/24/74(20:00)
6/25/74(16:00)
7/13/74(00:00)
Shutdown
10/27/73(04:00)
12/10/73(14:00)
1/2/74(04:00)
2/12/74(04:00)
2/22/74(21:30)
3/11/74(04:00)
3/30/74(13:00)
4/29/74(01:30)
5/15/74(04:00)
5/20/74(06:00)
6/9/74 (16:00)
7/8/74 (02:00)
7/29/74(03:00)
Operating
hrs.
839
710
368
636
221
173
303
404
310
104
304
258
387
Downtime
hrs.
328
171
276
41
236
110
296
72
18
110
384
118
% Operating
time
72%
81
57
94
48
61
51
85
95
49
79
69
61
-------
Table 15. STEAM AND ELECTRICITY USAGE
Month
June 1972
July
Aug.
Sept.
Oct.
Nov.
Dec.
Jan. 1973
Feb.
Mar.
Apr.
May
June
July
Aug.
Sept.
Oct.
Nov.
Dec.
Jan. 1974
Feb.
Mar.
Apr.
May
June
July
Lbs. Steam/
1,000 Gals.
Prod.
1,047.3
653.0
397.6
664.3
1,837.0
1,741.0
3,516.6
2,080.8
0
0
0
0
0
2,850.7
1,128.4
1,646.1
2,046.6
2,007.0
1,180.4
1,470.8
2,314.1
6,222.8
1,901.7
2,382.0
6,637.0
2,168.7
Steam Cost
$/Month
$2,597
2,240
1,878
2,052
3,911
4,871
2,918
8,320
0
0
0
0
0
8,735
5,090
5,206
5,943
5,648
5,972
4,746
6,063
5,112
3,639
6,319
8,280
3,450
Electricity
KWH/ 1,000
Gals. Prod.
44.8
20.5
15.0
29.4
38.0
25.1
66.8
23.0
0
0
0
0
0
52.5
15.7
23.0
28.6
23.5
10.6
19.8
24.7
94.7
31.6
29.4
43.6
48.3
Elec. Cost
$/Month
$1,112
700
725
926
827
717
566
927
0
0
o
0
0
1,642
754
754
920
779
657
755
763
, 919
713
922
642
869
Total
$71,000 Gals.
$1.05
.60
.39
.68
1.57
1.41
2.95
1.63
-
-
-
-
-
2.39
.91
1.33
1.67
1.21
1.35
1.23
1.88
5.29
1.64
1.97
5.15
1.99
62
-------
REFERENCES
1. Young, E. H., etal., "Condensing of Steam on Horizontal Corrugated
and Bare Tubes," Report 60, Dept. of Chem. and Met. Eng. Heat
Transfer Lab., University of Michigan, 1968.
2. Chen, Kenneth Y., "Report Ozonation and Treatability Studies on Tire
and Rubber Wastewater," Environmental Engineering Programs, Univer-
sity of South California, Los Angeles, 1973.
3. Wood, R. 6., "Plant Effluent Ozonation Pilot Plant Studies," Unpub-
lished Interoffice Memo, The General Tire & Rubber Company, Odessa,
Texas, July 15, 1974.
4. Bearden, D. F., "Activated Carbon Pilot Plant," Unpublished
Interoffice Memo, The General Tire & Rubber Company, Odessa, Texas,
June 12, 1973.
5. Koraido, D. L., "Activated Carbon Adsorption Pilot Study," Unpub-
lished Letter - Calgon Corp. to The General Tire & Rubber Company,
Odessa, Texas, May 14, 1973.
63
-------
Waste feed:
Product:
Main steam:
Eff. 1 stm.
Prod. cond.
Gain ratio:
Brine ratio:
Sul.:
HX301:
Deaerator:
APPENDIX
Table 16. VTE OPERATING DATA NOMENCLATURE
Clarified wastewater feed to the VTE, gallons per minute.
Pure product water produced by the VTE, Including
condensed steam fed to the first effect but not evaporated
water sent to the cooling tower, gallons per minute.
Steam fed to first effect plus steam consumed by air
ejectors, pounds per minute.
Steam fed to first effect, pounds per minute.
Product conductivity, micromhos. Under "FLOWS," conduc-
tivity is the instantaneous reading taken from control
panel indicator when daily data is logged. The product
conductivity under "PRODUCT" is the value from laboratory
analysis of the grab sample.
Plant efficiency measurement, pounds of product per pound
of steam to first effect.
Brine ratio, quantity of brine divided by quantity of waste
feed.
Sulfide, parts per million.
Sample taken from preheated feed stream.
Sample taken from Deaerator/Decarbonator vessel.
64
-------
Table 16. VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
cn
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
pH
Cl", ppm
Sul., deaer.
pH, HX301
Product
pH
Prod. cond.
Cl", ppm
NH3, ppm
Slowdown
PH
Cl", ppm
1972
6/27 6/28
323 320
221 220
178 177
171 172
8.5 18
10.8 10.7
0.316 0.313
22
7
4
6/29
323
207
-
169
1
10.2
0.359
38
6
6
6/30
321
191
175
168
5
9.5
0.405
16
7
3
7/3
315
206
185
176
14
9.8
0.346
10
1.4
2
7/5
267
195
167
159
32
10.2
0.270
55
3
4
7/6
270
178
153
143
18
10.4
.341
26
3
6
1972
7/7
265
65
155
141
50+
»
-
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
CD
ai
Parameter
Flows
Waste Feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl", ppm
Sul., deaer.
pH, HX301
Product
PH
Prod. cond.
Cl", ppm
NH3, ppm
Slowdown
pH
Cl", ppm
1972
o
1
5*
n>
o
1"
o
Q»"
to
^
7/24
313
175
174
170
18
8.6
0.441
42
7
10.0
7/26
305
178
170
169
11
8.8
0.416
31
4.4
4.0
7/27
311
182
180
172
11
8.8
0.415
23
6.7
1.5
7/28
339
202
194
187
7
9.0
0.404
17
5
3
7/29
227
135
130
124
6.5
9.1
0.405
0.00
5.1
6.9
16
7
2
8.0
704
1972
8/5
o 303
1 199
1 182
! 171
2. 22
tu
# 9"7
2 0.343
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl~, ppm
Sul . , deaer.
pH, HX301
Product
pH
Prod. cond.
C1~, ppm
NH3, ppm
Slowdown
PH
Cl", ppm
1972
8/6
313
192
183
174
7
9.2
0.386
7.6
516
0.10
6.3
7.4
17
3
5
6.0
1069
8/7
311
192
183
175
12
9.2
0.383
7.5
563
0.00
7.6
8.2
32
5
6
6.7
1178
8/8
300
133
199
189
13
5.9
0.557
7.4
721
0.02
7.4
8.6
41
4
7
8/9
308
174
197
186
12
7.8
0.435
7.4
475
0.01
7.1
8.4
25
6
5
8/10
302
212
150
188
14
9.4
0.298
7.4
448
0.05
6.8
8.3
26
8
5
6.6
1037
8/11
300
206
200
188
15
9.1
0.313
7.5
246
0.01
7.0
8.1
26
5
6
6.7
1195
8/12
301
215
198
188
15
9.5
0.286
7.1
105
0.01
6.3
8.1
25
5
6
6.4
1225
1972
8/13
300
206
198
183
14
9.4
0.313
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
CJl
CO
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
pH
Cl", ppm
Sul. , deaer.
pH, HX301
Product
pH
Prod. cond.
Cl", ppm
NH3, ppm
Slowdown
PH
Cl", ppm
1972
8/14 8/15
265 295
203 195
198 192
183 178
14 11
9.3 9.1
0.233 0.339
6.1
378
0.03
6.8
8.9
16
4
5
6.2
1055
8/16
295
199
200
184
12
9.0
0.325
7.2
317
0.09
6.7
9.0
-
3
5
6.3
967
8/17
295
195
198
183
11
8.9
0.339
7.4
115
0.02
7.1
9.2
-
2
5
6.2
987
8/18
295
192
197
182
14
8.8
0.349
6.5
300
0.05
7.1
9.0
23
4
6
6.6
703
8/30
o 307
1 172
o 172
g 156
2. 25
S 9.2
0.440
7.1
369
0.09
7.6
8.2
28
3
6
7.4
879
1972
8/31
330
175
177
162
17
9.0
0.470
7.4
288
0.12
7.9
8.2
19
3
6
7.7
615
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
10
Parameter
Flows
<^MM^BM*MMIHIIIIIIII»
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. l/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl~, ppm
Sul. , deaer.
pH, HX301
Product
PH
Prod. cond.
Cl~, ppm
NH3, ppm
Slowdown
pH
Cl", ppm
1972
9/1
321
167
172
142
18
9.8
0.480
7.2
390
0.17
7.4
7.7
19
3
5
7.1
879
9/5
332
151
173
159
6
7.9
0.545
6.3
422
0.07
6.1
7.1
10
5
3
6.2
967
9/6
323
147
171
159
5
7.7
0.545
6.2
352
0.06
6.3
7.1 ,
9
5
4
5.9
967
9/7
323
137
168
153
5
7.5
0.576
8.4
317
0.06
6.9
7.1
11
5
5
5.8
704
9/8 9/11 9/12
286 240 256
122 96 97
163 146 147
147 131 131
12 7 10
6.9 6.1 6.2
0.573 0.600 0.621
8.0
223
0.09
7.0
7.5
15
6
4
6.7
523
1972
|
3
0
1
tO
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gptn
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl", ppm
Sul. , deaer.
pH, HX301
Product
pH
Prod. cond.
Cl", ppm
NH3, ppm
Slowdown
pH
Cl", ppm
1972
9/17 9/18
332 414
173 143
164 149
153 143
15 15
9.4 8.3
0.479 0.655
6.7
528
0.07
6.0
7.5
14
3
3
6.8
967
9/19
384
163
177
164
9
8.3
0.576
6.2
564
0.05
6.6
7.2
12
4
2
6.3
940
9/20
295
168
171
156
8
9.0
0.431
6.4
440
0.03
6.9
7.2
11
4
3
6.7
985
9/22 9/25
295 203
132 116
153 147
152 134
15 12
7.2 7.2
0.553 0.429
6.3
492
0.40
7.0
7.5
15
6
5
6.5
1126
1972
9/28
1 301
= 159
g 211
? 195
0> (
o 6
2 6.8
m 0.472
o
o>
J.
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl"8 ppm
Sul., deaer.
pH, HX301
Product
PH
Prod. cond.
Cl~, ppm
NH3, ppm
Blowdown
pH
Cl", ppm
1972
o
1
1
c
i
CD
fa
0
O
O
o>
td
10/2 10/3
347 352
167 178
225 220
21 1 200
8 2.5
6.6 7.4
0.519 0.494
5.2
466
0.38
6.0
7.5
6
6
3
6.1
967
10/4
250
136
163
141
7
8.0
0.456
6.1
383
0.14
6.8
8.2
10
8
3
6.8
957
10/5
257
151
180
160
8
7.9
0.412
6.2
357
0.12
7.2
8.4
10
6
3
6.9
1020
10/6
255
151
182
163
8
7.7
0.408
5.2
308
0.08
7.0
7.7
10
8
4
6.6
915
1972
10/9 10/10
355 354
158 152
212 206
177 172
10 14
7.4 7.4
0.555 0.571
6.6
440
0.14
6.9
7.4
17
6
5
6.8
932
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
ro
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl", ppm
Sul. , deaer.
pH, HX301
Product
pH
Prod. cond.
Cl", ppm
NH3, ppm
Bl owdown
pH
Cl", ppm
1972
10/11
355
154
210
176
12
7.3
0.566
6.1
458
0.15
6.7
7.2
17
7
7
6.5
793
10/12
362
149
209
173
13
7.2
0.588
5.6
598
0.22
6.5
6.8
18
9
5
6.3
1196
10/13
319
138
201
167
16
6.9
0.567
5.3
572
0.23
6.8
7.6
21
7
6
6.5
1073
10/16 10/17
251 258
117 132
173 183
141 149
18 20
6.9 7.4
0.534 0.488
6.6
633
0.42
7.1
8.1
26
8
6
6.6
1337
1
i
o
o»
Ol
w
%
o
Ol
o
n
S
i
i
I
-1
g
A
I/I
1972
11/3 11/6
298 303
131 116
188 187
165 167
11 7.5
6.6 5.8
0.560 0.617
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972,TO JULY 25, 1974
CO
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl", ppm
Sul. , deaer.
pH, HX301
Product
PH
Prod. cond.
Cl", ppm
NH3, ppm
Slowdown
pH
Cl", ppm
1972
11/7
278
143
190
173
5
6.9
0.486
8.4
434
0.10
7.4
6.3
8
7
3
6.0
869
11/8
285
142
201
177
3.5
6.7
0.502
8.8
438
0.07
6.3
6.3
8
8
3
6.1
883
11/9 11/11
273 265
146 146
203 208
183 185
6 13
6.7 6.6
0.465 0.449
8.8
398
0.05
6.8
6.8
10
7
3
6.5
801
11/12 11/13
265 261
142 144
203 206
183 185
15 12
6.5 6.5
0.464 0.448
8.7
438
0.12
6.7
7.9
16
11
5
6.7
1175
1972
11/14 11/15
254 232
139 120
203 188
183 164
13 14
6.3 6.1
0.453 0.483
8.7
390
0.15
7.4
8.4
17
11
5
7.2
727
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
Cl", ppm
Sul., deaer.
pH, HX301
Product
PH
Prod. cond.
Cl", ppm
NH3, ppm
Blowdown
PH
Cl", ppm
1972
o
i
m
3
c
o>
3-
o
i.
ro
2.
11/18 11/20 11/21
267 263 264
146 133 138
214 214 219
191 189 196
12 4 4.5
6.4 5.9 5.9
0.453 0.494 0.477
8.3
372
0.02
6.4
6.9
8
8
4
6.2
766
11/22
262
140
227
222
4.5
5.3
0.466
8.6
351
0.02
5.5
5.8
8
7
4
5.4
715
11/25
263
119
238
197
4.5
5.0
0.548
8.5
160
0.14
7.6
7.0
12
5
4
7.3
642
11/26
269
124
236
199
4
5.2
0.539
8.8
369
0.05
7.8
7.1
6
4
4
7.5
651
1972
11/27
263
122
234
195
4
5.2
0.536
8.5
365
0.09
6.7
6.2
7
5
4
7.3
691
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter 1972 1972
en
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl", ppm
Sul. , deaer.
pH, HX301
Product
PH
Prod. cond.
Cl", ppm
NH3, ppm
Slowdown
pH
Cl", ppm
11/28
258 §"
108 ^
230 o
182 8
3
4 J-
4.9
0.581
8.4
383
0.11
6.8
6.1
6
4
3
6.5
700
12/2 12/3
226 228
151 147
211 213
175 175
10 7
7.2 7.0
0.332 0.355
8.5
539
0.04
6.8
6.2
10
5
7
6.1
1649
12/4 12/5 12/8
227 213 192
146 119 117
224 211 224
180 167 182
6 4 20
6.8 5.9 5.4
0.357 0.441 0.391
7.7
504
0.03
5.7
6.9
155
10
8
5.6
1596
|
3
1
O
ft)
Qi
3
3
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
I
cr>
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
pH
Cl", ppm
Sul. , deaer.
pH, HX301
Product
PH
Prod. cond.
Cl", ppm
NH3, ppm
Slowdown
PH
Cl , ppm
1973
1/2 1/3
301 327
146 161
211 236
161 184
13 15
6.8 7.3
0.515 0.508
8.1
399
0.02
7.4
7.6
11
3
4
7.2
780
1/4
326
142
213
165
11
7.2
0.564
7.8
381
0.07
6.4
6.8
7
3
3
6.5
709
T/5 1/9
343 343
187 157
268 264
227 216
12 20
6.9 6.1
0.455 0.542
7.5
301
0.08
6.9
6.8
12
3
4
6.7
691
1/11 1/12
230 292
133 161
227 265
173 211
23 27
6.4 6.4
0.422 0.449
7.0
393
0.07
6.9
8.4
13
2
3
7.0
1000
1973
1/15
271
149
246
196
29
6.3
0.450
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Feed
PH
Cl", ppm
Sul. , deaer.
pH, HX301
Product
pH
Prod. cond.
Cl", ppm
NH3, ppm
Slowdown
PH
Cl", ppm
1973
1/18 1/19 1/23 1/24 1/25
292 293 289 309 291
148 143 132 136 115
250 245 265 275 256
206 204 202 213 197
25 23 13 11 11
6.0 5.8 5.4 5.3 4.9
0.493 0.512 0.543 0.560 0.605
6.7
426
0.08
7.4
8.3
14
4
5
6.9
775
1/26 1/29
310 255
116 78
266 286
215 179
11 21
4.5 3.6
0.626 0.694
6.7
400
0.12
7.1
8.7
13
4
5
6.6
746
1973
1
3
to
cr
IQ
(P
f*
n
5L
m
-h
-it
m
o
w>
00
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/m1n.
Prod. cond.
Gain ratio
Brine ratio
CO _
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1973
7/6
265
209
203
229
-
7.6
0.211
1973
7/20
326
195
215
193
11
8.4
0.402
7/9
316
230
215
195
-
9.8
0.272
7/23
307
174
204
173
16
8.4
0.433
7/10
314
215
204
182
17
9.9
0.315
7/26
273
130
155
112
14
9.7
0.524
7/11
315
223
222
224
20
8.3
0.292
7/27
243
113
146
107
12
8.8
0.535
7/12
319
219
213
184
16
9.9
0.313
|
=
o
1
a'
7/13
314
225
219
202
16
9.3
0.283
8/8
304
215
207
191
17
9.4
0.293
7/16
264
181
189
156
9
9.7
0.314
8/9
304
206
200
177
16
9.7
0.322
1973
7/19
299
198
213
190
11
8.7
0.338
1973
8/10
301
215
197
172
17
10.4
0.286
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1973
8/13
301
203
201
176
15
9.6
0.326
1973
8/23
246
175
203
177
17
8.2
0.289
8/14
247
185
188
160
13
9.6
0.251
8/24
274
182
211
200
19
7.6
0.336
8/15
248
188
192
162
14
9.7
0.242
8/27
227
152
197
170
18
7.5
0.330
8/16
249
186
192
164
15
9.5
0.253
8/28
227
145
202
176
19
6.9
0.361
8/17
333
201
213
209
16
8.0
0.396
|
3
TI
C
(/>
*^r
8.
£
.j.
r*
3-
^«
8/20
273
186
203
183
17
8.5
0.319
8/30
227
148
209
184
19
6.7
0.348
8/21
271
183
202
185
13
8.2
0.325
8/31
225
159
205
166
5
8.0
0.293
1973
8/22
246
178
199
173
17
8.6
0.276
1973
9/1
226
165
209
170
16
8.1
0.270
at
rt-
0)
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
00
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1973
9/2
277
162
207
170
14
7.9
0.415
1973
9/26
301
203
201
194
10
8.7
0.326
9/4
225
159
204
166
14
8.0
0.293
9/27
184
111
123
115
22
8.0
0.397
9/5
223
156
209
176
14
7.4
0.300
9/28
283
188
193
174
20
9.0
0.336
9/6
212
149
207
169
17
7.4
0.297
10/1
286
185
203
197
11
7.8
0.353
9/7
293
153
226
209
17
6.1
0.478
10/2
208
157
181
147
11
8.9
0.245
o
o
1
o
8
J
4.
-------
00
Table 16 (continued).
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1973
10/8
299
161
239
206
12
6.5
0.462
1973
10/19
257
157
223
182
16
7.2
0.389
VTE OPERATING DATA, JUNE
10/9
326
171
252
224
12
6.4
0.475
10/22
281
144
228
189
6
6.4
0.488
10/10
325
172
258
255
12
5.6
0.471
10/23
299
142
241
201
7
5.9
0.525
10/11
313
170
250
213
13
6.7
0.457
10/24
273
150
222
168
14
7.4
0.451
27, 1972,
10/15
301
170
245
202
-
7.0
0.435
10/25
255
169
233
189
-
7.5
0.337
TO JULY
10/16
295
161
234
170
11
7.9
0.454
10/26
295
162
243
203
11
6.7
0.451
25, 1974
1973
10/17 10/18
264 249
159 168
227 223
191 187
12
6.9 7.5
0.398 0.325
1973
11/10
f278
213
i
o
2 149
* mm
" 11.9
0.234
-------
00
PO
Table 16 (continued).
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/nrin.
Prod. cond.
Gain ratio
Brine ratio
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1973
11/12
307
226
219
162
15
11.6
0.264
1973
11/26
298
174
247
170
14
8.5
0.416
VTE OPERATING DATA, JUNE 27, 1972,
11/13
263
160
192
148
24
9.0
0.392
11/27
287
162
239
163
17
8.3
0.436
11/14
303
220
223
170
-
10.8
0.274
11/28
282
162
235
159
15
8.5
0.426
11/15
307
204
227
172
18
9.9
0.336
11/29
285
166
229
154
16
9.0
0.418
11/16
303
194
232
172
18
9.4
0.360
11/30
302
170
229
155
11
9.1
0.437
TO JULY 25 > 1974
11/19
316
194
238
162
13
10.0
0.386
12/3
302
164
229
157
18
8.7
0.457
11/20
327
195
250
169
13.5
9.6
0.404
12/4
243
152
210
143
11
8.9
0.374
1973
11/21
286
166
219
145
17
9.5
0.421
1973
12/5
253
141
211
145
6
8.1
0.443
-------
CO
oo
Table 16 (continued).
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1973
12/6
243
132
214
144
8.5
7.6
0.457
1973
12/24
203
138
184
123
15
9.4
0.320
VTE OPERATING DATA, JUNE
12/7
249
128
215
143
11
7.5
0.486
12/26
333
170
256
185
19
7.7
0.489
12/10
371
123
233
155
31
6.6
0.668
12/27
291
152
232
182
17
7.0
0.478
o
o
o
I
3
IQ
12/28
296
142
226
178
18
6.7
0.520
27, 1972,
12/18
332
228
245
131
11
14.5
0.313
12/31
336
136
271
209
16
5.4
0.595
TO JULY
12/19
272
181
234
182
9
8.3
0.335
o
i
fr
*
o.
o
1
1
25, 1974
12/20
279
143
218
167
9
7.1
0.487
1974
1/14
345
229
237
166
7
11.5
0.336
1973
12/21
298
183
254
202
7.6
0.386
1/15
323
226
238
164
6
11.5
0.300
-------
00
Table 16 (continued).
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1974
1/16
293
213
229
154
5
11.6
0.273
1974
1/27
244
185
202
137
-
11.3
0.242
VTE OPERATING DATA, JUNE 27, 1972,
1/17
287
193
215
144
3
11.2
0.328
1/28
305
203
237
161
7
10.5
0.334
1/18
286
192
204
137
4
11.7
0.329
1/30
308
202
232
158
2
10.7
0.344
1/19
310
190
210
142
-
11.2
0.387
1/31
345
200
238
172
3
9.7
0.420
1/20
283
183
211
143
-
10.7
0.353
2/1
327
170
214
149
-
9.5
0.480
TO JULY 25, 1974
1/21
256
173
197
128
3
11.3
0.324
2/2
250
150
195
139
-
9.0
0.400
1/25
238
158
181
115
21
11.5
0.336
2/4
282
168
248
170
6
8.2
0.404
1974
1/26
200
150
170
116
-
10.8
0.250
1974
2/5
290
171
255
185
5
7.7
0.410
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
CO
01
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1974
2/6
321
182
285
203
3
7.5
0.433
1974
2/18
313
147
274
196
15
6.3
0.530
2/7
309
172
261
177
2
8.1
0.443
2/19
289
157
264
185
23
7.1
0.457
2/8
358
183
286
198
1
7.7
0.489
2/21
313
150
293
209
7
6.0
0.521
2/11
309
157
247
172
-
7.6
0.492
'
a>
c*
n>
o
I
i
2/12
383
188
304
219
_
7.2
0.509
3/5
261
147
213
173
9
7.1
0.437
0
3
1
O
CL
O
1
i
3/6
306
171
251
203
10
7.0
0.441
2/14
275
153
219
158
-
8.1
0.444
3/7
303
192
236
193
8.3
0.366
1974
2/15
345
172
269
201
14
7.1
0.501
1974
3/8
331
190
242
198
9
8.0
0.426
-------
Table 16 (continued).
Parameter
Flows
^^^ki^H^H
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1974
3/9
362
204
257
211
_
8.1
0.436
1974
3/21
278
160
235
191
20
7.0
0.424
VTE OPERATING DATA, JUNE
3/10
344
194
243
200
_
8.1
0.436
3/25
289
153
227
185
24
6.9
0.471
3/16
| 306
* 198
i 238
o
£ 264
o
(D
S 6.3
^ 0.353
3/27 3/28
290 302
195 195
237 244
193 200
10 11
8.4 8.1
0.328 0.354
27, 1972,
3/17
382
183
218
178
_
8.6
0.521
3/30
291
172
226
185
7
7.8
0.409
TO JULY
3/18
275
188
229
180
16
8.7
0.316
o
=
i,
o!
o
is
1
25, 1974
3/19
282
145
229
185
23
6.5
0.486
4/13
249
178
200
175
14
8.5
0.285
1974
3/20
270
152
254
179
17
7.1
0.437
1974
4/14
248
164
200
174
9
7.9
0.339
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
CO
-J
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
1974
4/15
247
160
197
173
18
7.7
0.352
1974
4/26
312
122
241
212
19
4.8
0.609
4/16
248
152
197
174
17
7.3
0.387
o
o
£
1
fa
-s
O
1
1
4/17
251
147
201
174
15
7.0
0.414
5/2
319
183
121
177
24
8.6
0.426
4/18
301
160
215
200
12
6.7
0.468
5/3
302
150
111
173
12
7.2
0.503
4/19
299
160
213
198
14
6.7
0.465
5/6
286
155
215
191
13
6.8
0.458
4/22
365
180
250
153
17
9.8
0.509
5/8
304
161
235
211
13
6.4
0.470
4/24
292
117
188
179 '
14
5.5
0.599
5/9
299
157
228
203
^3
6.5
0.475
1974
4/25
334
142
241
215
14
5.5
0.575
1974
5/10
298
152
226
171
13
7.4
0.490
-------
oo
00
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter 1974 1974
Flows 5/13 5/16 5/17 5/25 5/26
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cond.
Gain ratio
Brine ratio
300
152
245
226
13
5.6
0.493
1974
6/3
310
163
298
205
14
6.6
0.474
0
3
^
Ql
f+
fD
O
fti
fD
Q.
6/5
299
165
313
211
11
6.5
0.448
295
165
215
225
19
6.1
0.441
o
I
1
c+
ft)
-J
o
8
294
155
223
193
16
6.7
0.473
6/27
308
167
352
234
18
6.0
0.458
0
3
'
Bl
ft>
O
1
1
6/28
269
138
504
201
19
5.7
0.487
306
187
274
164
-
9.5
0.389
7/1
269
138
337
219
24
5.3
0.487
300
168
272
166
-
8.4
0.440
7/5
271
128
591
219
24
4.9
0.528
0
3
fD
O
n
o*
Ol
H
3*
I/I
1974
0
3
1
JE
0*
c*
(D
O
1
i
n>
a.
-------
Table 16 (continued). VTE OPERATING DATA, JUNE 27, 1972, TO JULY 25, 1974
Parameter
Flows
Waste feed gpm
Product gpm
Main stm. #/min.
Eff. 1 stm. #/min.
Prod. cpnd.
Gain ratio
Brine ratio
1974
7/16
207
132
574
157
18
7.0
0.362
7/17
215
135
464
171
17
6.6
0.372
7/18
217
133
536
179
20
6.2
0.387
7/24
293
120
482
209
8
4.8
0.590
7/25
287
113
480
205
8
4.6
0.606
1974
§"
=
0
1
(O
00
IO
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing)
1. REPORT NO.
EPA-600/2-76-260
3. RECIPIENT'S ACCESSION-NO.
4. TITLE AND SUBTITLE
Industrial Wastewater Reclamation with a 400,000-
Gallon-Per-Day Vertical Tube Evaporator
5. REPORT DATE
October 1976 (Issuing date)
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
W. C. Lang, John H. Crozier, Frank P. Drace,
and Keith H. Pearson
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORGANIZATION NAME AND ADDRESS
The General Tire & Rubber Company
Akron, Ohio
10. PROGRAM ELEMENT NO.
IBB610
11. CONTRACT/GRANT NO.
12020 GUT
12. SPONSORING AGENCY NAME AND ADDRESS
Industrial Environmental Research Laboratory - Cin., OH
Office of Research and Development
U.S. Environmental Protection Agency
Cineinnati. Ohio 45268
13. TYPE OF REPORT AND PERIOD COVERED
Final
14. SPONSORING AGENCY CODE
EPA/600/12
15. SUPPLEMENTARY NOTES
16. ABSTRACT
A vertical tube evaporator (VTE) was built to recover water from a synthetic rubber
manufacturing plant wastewater stream containing 3,500 ppm dissolved solids, mostly
chlorides and sulfates, and organics in excess of 100 ppm. Unit designed to pro-
duce 10.5 Ibs. of water per pound of steam. Recovered water, containing near-zero
organics and solids, was recycled to the manufacturing process. Performance over
short periods exceeded design. Continuous operation for extended periods was ren-
dered impossible, due to fouling and corrosion of copper alloy heat exchange sur-
faces. Corrosion was traced to presence of 2 to 5 ppm of sulfides in the wastewater
feed. Unit was retubed with titanium. This eliminated the corrosion, but the
fouling continued. All attempts to reduce fouling by pretreating the wastewater
feed stream were unsuccessful. Outside of the problems caused by the fouling of the
heat transfer surfaces, the unit operated satisfactorily. If the fouling can be
brought under control, this method has a high probability of providing an economical
method of renovating wastewater streams containing water soluble salts and organic
chemicals. This report was submitted in fulfillment of R & D Project
12020 GUT, Program Element IBB610, by The General Tire & Rubber Company under the
partial sponsorship of the Environmental Protection Agency. Work completed
January 1975.
7.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
b.IDENTIFIERS/OPEN ENDED TERMS
Evaporation
Evaporators
Wastewater
Water Pollution
Concentration
Water Reclamation
Vertical Tube Evaporator
Synthetic Rubber Waste-
water
COSATI Meld/Group
13/B
3. DISTRIBUTION STATEMENT
Release to Public
19. SECURITY CLASS (This Report I
Unclassified
21. NO. OF PAGES
98
20. SECURITY CLASS (Thispage)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
90
HJSGPO: 1977-757-056/5489 Region 5-11
------- |