Success stories
Steam system for magnesium hydroxide extraction
Project description
Steam solution for a customer engaged in the production of sea salt who needed to recover in the process a residue that is essential to close the production cycle.
Original situation:
Challenges posed by the client:
The client is a company dedicated to the production of sea salt that was facing a challenge related to sustainability and the valorization of by-products.
The production process generates a concentrated brine that until now was dumped into the sea. The R&D department is promoting a new process to recover the magnesium contained in the brine by reacting it with concentrated ammonia solution, obtaining magnesium hydroxide as a new value-added product.
This process generates a liquid waste rich in ammonium, the recovery of which is essential to close the production cycle. The objective of the project is to recover the ammonium in the form of a concentrated ammonia solution for subsequent reuse.
The customer needed a flexible, efficient and suitable solution for a pilot plant, capable of generating steam under the required conditions, with thermal control and the possibility of condensate recovery.
Proposed solution:
Customized steam solution developed by Giconmes.
Proposed solution:
Giconmes proposed a modular SKID platform, designed to meet the specific needs of this pilot plant:
- Two independent steam generation modules, model NGV60120(60 kW each), with components in contact with water/steam made of AISI-316 stainless steel. The equipment is delivered with the option of complete stainless steel fairing.
- Condensate recovery tank (DRC00160) of 160 liters in stainless steel AISI-304.
- Timed flushing system, which performs programmed discharges to avoid accumulation of dissolved solids (TDS), keeping water conductivity low and avoiding incrustations without the need for additional sensors.
- AISI-304 stainless steel supporting structure, which gives support and robustness to the whole installation.
- In the heat exchanger, an external pressure reduction and temperature control system is proposed, which guarantees steam inlet at 1 BARG and 100 °C.
- For the Ring Column, a basic configuration with mechanical pressure reducer is offered, but there is the possibility of installing a more advanced configuration with digital flow and pressure control system, consisting of processor, control valve and digital flow meter.
- Giconmes also includes the management of the registration of the pressure equipment with the competent industrial authorities.
Technology used:
- NGV60120 DUO made with all components in contact with water and fairing in A-304
- Condensate tank 160 liters
- Water treatment system
- Timed purge system
- Pressure reduction system
CHALLENGES
We meet customer requirements
Valorization of a previously wasted waste, since ammonia is now recovered as a reusable product, closing the process cycle and improving sustainability.
Transformation of the pilot into a functional and efficient plant, since, thanks to a precise control of the heat input, temperature and pressure are regulated at both critical points of the process.
Savings, scalability and reduced maintenance: condensate recovery, automatic drains and an adaptable system that allows for expansions without changing the base equipment.
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FAQs
We understand that many questions may arise. Here are some of the most common ones.
There are no emissions beyond those produced during the electricity production process. Consequently, emissions can be neutral depending on the electricity mix. Electric steam boilers are the present and the future.
Absolutely. In fact, it is recommended to achieve maximum efficiency. There is no problem with remote control as long as it complies with current regulations.
A steam generator is a pressure vessel that, together with the piping network, is subject to regulatory control and complementary technical instructions, according to the regulations published in Royal Decree 809/2021, of September 21. Maintenance is divided into a part that can be easily fulfilled by the owner:
- Know and apply the manufacturer’s instructions regarding use, safety measures, and maintenance.
- Not to put the installation into service or prevent the operation of pressure equipment if the requirements of the Regulation are not met.
- Having at least the following documentation for the pressure equipment while they are installed: Declaration of conformity, manufacturer’s instructions (if applicable), and, if necessary, installation certificate, along with other supporting documentation (such as installation project, record of the last periodic inspection, certifications of equipment repairs or modifications, and any other documentation required by the relevant technical instruction complementary to this regulation). For detailed contents, refer to Annex IV of the regulation. Making this documentation available to the competent authority of the autonomous community and the companies responsible for maintenance, repair, or periodic inspections.
- Use the pressure equipment within its intended operating limits as specified by the manufacturer and take it out of service if it no longer meets the necessary safety requirements.
- Perform maintenance on the installations, pressure equipment, safety accessories, and control devices in accordance with the operating conditions and manufacturer’s instructions, and examine them at least once a year.
- Arranging for the necessary periodic inspections as required by Article 6 of the regulation.
- Having and maintaining an up-to-date record of pressure equipment categories I to IV, as defined in RD 709/2015, of July 24, or equipment similar to these categories according to Article 3.2 of the regulation, as well as their installations.
It is known that by applying heat to water, it transforms into steam at the boiling point and atmospheric pressure. From there, depending on the required saturation degree of steam for its proper application, we need to increase the pressure to obtain a higher temperature. To change the temperature and saturation degree of steam, we always need to modify the pressure.
It is a unit of pressure equivalent to 1 kg/cm2, 0.98 atmospheres, or 14.50 PSI.
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