Let’s compare the production data with that of the experts – is our level of consumption reasonable?
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By comparing with our senior colleagues, we can see if our consumption is reasonable. Our company has a design capacity of 250,000 tons, and at present its production load is 270,000 tons. Recently, we have been experiencing some strange phenomena: once there was calcium carbonate precipitation in the brine tank, and the aluminum ion levels in the secondary brine were consistently above the allowed limits. We use sea salt with a main content of over 94%, 0.2% calcium, and 0.02% magnesium; the control parameters are set in accordance with those of the industry, with the pH of the brine being controlled at 10.0. Brine production stage: consumption of ferric chloride is 0.28, caustic soda is 2.0, and soda ash is 13.0. Electrolytic chlorohydrogen treatment process: sodium sulfite 0.4, concentrated sulfuric acid 15.0; reward for power consumption reduction is 2220. I’m not sure how other factories manage this. A brine pretreater combined with a Kai membrane process, using Asahi Kasei electrolyzers for electrolysis.
Generally, the design of production facilities includes a margin; with a capacity of 250,000 tons, an increase to 270,000 tons represents less than 10%, and as long as all relevant parameters are under control, there is no problem. Judging from your consumption levels, the pressure of the brine during each cycle is quite high. The presence of sediment in the brine filtration tank indicates that the membrane has been overloaded, which is very dangerous. If the quality of the brine does not meet the required standards, it’s better to reduce the load. The operation of electrolysis relies primarily on the quality of the brine; if the brine quality is poor, although alkali production may increase in the short term, the lifespan of the membrane will be reduced. Overall, it’s not advisable to focus solely on high loads and high production rates. The ion membrane is of utmost importance. An electricity consumption of over 2200 is a bit high for a new tank – the value should not exceed 2100 for new tanks and membranes. It’s likely that the calcium content in the brine is too high. If possible, please send me the ICP test results for the secondary brine so I can take a look.
The ICP test for the primary brine was successful, and the ICP test for the secondary brine was also successful; the calcium ion level in the primary brine was kept below 1.5 PPM, while the calcium and magnesium levels in the secondary brine were kept below 20 PPB. However, there is sediment at the bottom of the brine tank after membrane filtration; this can also be referred to as SS. But the analysis laboratory is unable to detect it because the sediment cannot be sampled. Some people in the industry suggested measuring the turbidity of saltwater; I checked some information and found that there is no requirement for turbidity among my peers. I have a headache. You said that the Kay membrane is overloaded; I know it is overloaded too. What does being overloaded mean? What are the hazards?
It’s hard to say for sure. Since the parameters in the saltwater are within acceptable limits and the amount of sediment does not increase over time, it’s sufficient to pay close attention to changes in the tank voltage during normal operation. If the voltage remains stable, then there’s no need to worry too much. If the cell voltage rises and the electrolysis efficiency decreases, it’s best to have someone outside analyze the quality of the brine
OP, is there a leak in the membrane tube of your Kai membrane filter?； Or maybe the pH meter at V-408 is giving inaccurate readings; check it carefully. I have a question: is ICP also used for analyzing saltwater as well? That’s amazing! As for the power consumption at 2200, it depends on the operating time of the electrolyzer and ion membrane, as well as the current efficiency