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Working Principle of the Saturator
The saturator plays a crucial role in the production of ammonium sulphate. Here's an overview of its working principle:
Step 1: Pre-Treatment of Coke Oven Gas
Coke oven gas, after primer cooling and purification from tar and naphthalene, is delivered to the pre-heater at a temperature of 50-60°C. The pre-heater ensures the normal water balance in the saturator.
Step 2: Saturation Process
The pre-heated coke oven gas enters the saturator through the main gas inlet and passes through the bubbler hood. The bubbler hood consists of 20 radially positioned elements that facilitate intensive mixing of the mother liquor.
Step 3: Reaction and Crystal Formation
As the coke oven gas bubbles through the mother liquor, it reacts with sulphuric acid to form ammonium bisulphate. This reaction is represented by the equation:
NH3 + H2SO4 → (NH4)2SO4
The ammonium bisulphate is then converted into ammonium sulphate, releasing heat in the process.
Step 4: Circulation and Mixing
To ensure optimal crystal growth and minimize gas/ammonia losses, the mother liquor is continuously mixed and circulated. The circulating pump pumps the mother liquor from the circulating pan to the conical part of the saturator, creating a circular motion.
Step 5: Acid Trap and Gas Flow
The gas from the acid trap is continuously delivered to the circulating pan, preventing the formation of acid-neutral zones in the saturator bath. The gas then flows to the bottom gas main, leading to the F.G.C., benzol section, and eventually to consumers.
Key Features and Benefits
- Automatic maintenance of mother liquor acidity within 4-5% using pH-meter station and control valve
- Continuous feeding of 6-8% acidified mother liquor solution from the liquor tanks
- Optimal crystal growth and minimized gas/ammonia losses due to thorough mixing and circulation
- Efficient heat management and energy recovery
By understanding the working principle of the saturator, operators can optimize its performance, ensuring efficient production of high-quality ammonium sulphate
