Cascade (chemical engineering)

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A diagram showing a cascade of three fixed-bed reactors (and three fired heaters associated with them). CatReformer.png
A diagram showing a cascade of three fixed-bed reactors (and three fired heaters associated with them).

In chemical engineering, a cascade is a plant consisting of several similar stages with each processing the output from the previous stage. Cascades are most commonly used in isotope separation, distillation, flotation and other separation or purification processes.

Chemical engineering branch of science that applies physical sciences and life sciences together with applied mathematics and economics to produce, transform, transport, and properly use chemicals, materials and energy

Chemical engineering is a branch of engineering that uses principles of chemistry, physics, mathematics, biology, and economics to efficiently use, produce, design, transport and transform energy and materials. The work of chemical engineers can range from the utilisation of nano-technology and nano-materials in the laboratory to large-scale industrial processes that convert chemicals, raw materials, living cells, microorganisms, and energy into useful forms and products.

Isotope separation is the process of concentrating specific isotopes of a chemical element by removing other isotopes. The use of the nuclides produced is various. The largest variety is used in research. By tonnage, separating natural uranium into enriched uranium and depleted uranium is the largest application. In the following text, mainly the uranium enrichment is considered. This process is a crucial one in the manufacture of uranium fuel for nuclear power stations, and is also required for the creation of uranium based nuclear weapons. Plutonium-based weapons use plutonium produced in a nuclear reactor, which must be operated in such a way as to produce plutonium already of suitable isotopic mix or grade. While different chemical elements can be purified through chemical processes, isotopes of the same element have nearly identical chemical properties, which makes this type of separation impractical, except for separation of deuterium.

Distillation method of separating mixtures based on differences in volatility of components in a boiling liquid mixture

Distillation is the process of separating the components or substances from a liquid mixture by using selective boiling and condensation. Distillation may result in essentially complete separation, or it may be a partial separation that increases the concentration of selected components in the mixture. In either case, the process exploits differences in the relative volatility of the mixture's components. In industrial chemistry, distillation is a unit operation of practically universal importance, but it is a physical separation process, not a chemical reaction.

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Cascade process

Cascade process is any process that takes place in a number of steps, usually because the single step is too inefficient to produce the desired result. For example,in some uranium-enrichment processes the separation of the desired isotope is only poorly achieved in a single stage; to achieve better separation the process has to be repeated a number of times, in a series, with the enriched fraction of one stage being fed to the succeeding stage for further enrichment. Another example of cascade process is that operating in a cascade liquefier. [1]

Examples

If a still removes 99% of impurities from water (leaving .01 the original amount of impurities), a cascade of three stills will leave (1-0.99)3 = 0.000001 = 0.0001% the amount of impurities (99.9999% removed).

Still apparatus used to distill miscible or immiscible (e.g. steam distillation) liquid mixtures

A still is an apparatus used to distill liquid mixtures by heating to selectively boil and then cooling to condense the vapor. A still uses the same concepts as a basic distillation apparatus, but on a much larger scale. Stills have been used to produce perfume and medicine, water for injection (WFI) for pharmaceutical use, generally to separate and purify different chemicals, and to produce distilled beverages containing ethanol.

Related Research Articles

Nuclear fission nuclear reaction or a radioactive decay process in which the nucleus of an atom splits into smaller parts

In nuclear physics and nuclear chemistry, nuclear fission is a nuclear reaction or a radioactive decay process in which the nucleus of an atom splits into smaller, lighter nuclei. The fission process often produces free neutrons and gamma photons, and releases a very large amount of energy even by the energetic standards of radioactive decay.

Enriched uranium is a type of uranium in which the percent composition of uranium-235 has been increased through the process of isotope separation. Natural uranium is 99.284% 238U isotope, with 235U only constituting about 0.711% of its mass. 235U is the only nuclide existing in nature that is fissile with thermal neutrons.

Nuclear fuel cycle Process of manufacturing and consuming nuclear fuel

The nuclear fuel cycle, also called nuclear fuel chain, is the progression of nuclear fuel through a series of differing stages. It consists of steps in the front end, which are the preparation of the fuel, steps in the service period in which the fuel is used during reactor operation, and steps in the back end, which are necessary to safely manage, contain, and either reprocess or dispose of spent nuclear fuel. If spent fuel is not reprocessed, the fuel cycle is referred to as an open fuel cycle ; if the spent fuel is reprocessed, it is referred to as a closed fuel cycle.

Fractional distillation is the separation of a mixture into its component parts, or fractions. Chemical compounds are separated by heating them to a temperature at which one or more fractions of the mixture will vaporize. It uses distillation to fractionate. Generally the component parts have boiling points that differ by less than 25 °C (77 °F) from each other under a pressure of one atmosphere. If the difference in boiling points is greater than 25 °C, a simple distillation is typically used.

Fractional freezing process used to separate substances with different melting points

Fractional freezing is a process used in process engineering and chemistry to separate substances with different melting points. It can be done by partial melting of a solid, for example in zone refining of silicon or metals, or by partial crystallization of a liquid, as in freeze distillation, also called normal freezing or progressive freezing. The initial sample is thus fractionated.

Girdler sulfide process

The Girdler sulfide (GS) process, also known as the Geib–Spevack (GS) process, is an industrial production method for filtering out of natural water the heavy water (deuterium oxide = D2O) which is used in particle research, in Deuterium NMR spectroscopy, deuterated solvents for proton NMR spectroscopy, in heavy water nuclear reactors (as a coolant and moderator) and in deuterated drugs.

Carbon-12 (12C) is the more abundant of the two stable isotopes of carbon, amounting to 98.93% of the element carbon; its abundance is due to the triple-alpha process by which it is created in stars. Carbon-12 is of particular importance in its use as the standard from which atomic masses of all nuclides are measured, thus, its atomic mass is exactly 12 daltons by definition. Carbon-12 is composed of 6 protons, 6 neutrons, and 6 electrons.

Gas centrifuge

A gas centrifuge is a device that performs isotope separation of gases. A centrifuge relies on the principles of centripetal force accelerating molecules so that particles of different masses are physically separated in a gradient along the radius of a rotating container. A prominent use of gas centrifuges is for the separation of uranium-235 from uranium-238. The gas centrifuge was developed to replace the gaseous diffusion method of uranium-235 extraction. High degrees of separation of these isotopes relies on using many individual centrifuges arranged in cascade, that achieve successively higher concentrations. This process yields higher concentrations of uranium-235 while using significantly less energy compared to the gaseous diffusion process.

Gaseous diffusion

Gaseous diffusion is a technology used to produce enriched uranium by forcing gaseous uranium hexafluoride (UF6) through semipermeable membranes. This produces a slight separation between the molecules containing uranium-235 (235U) and uranium-238 (238U). By use of a large cascade of many stages, high separations can be achieved. It was the first process to be developed that was capable of producing enriched uranium in industrially useful quantities.

Technetium-99m generator

A technetium-99m generator, or colloquially a technetium cow or moly cow, is a device used to extract the metastable isotope 99mTc of technetium from a decaying sample of molybdenum-99. 99Mo has a half-life of 66 hours and can be easily transported over long distances to hospitals where its decay product technetium-99m is extracted and used for a variety of nuclear medicine diagnostic procedures, where its short half-life is very useful.

Downstream processing refers to the recovery and the purification of biosynthetic products, particularly pharmaceuticals, from natural sources such as animal or plant tissue or fermentation broth, including the recycling of salvageable components and the proper treatment and disposal of waste. It is an essential step in the manufacture of pharmaceuticals such as antibiotics, hormones, antibodies and vaccines; antibodies and enzymes used in diagnostics; industrial enzymes; and natural fragrance and flavor compounds. Downstream processing is usually considered a specialized field in biochemical engineering, itself a specialization within chemical engineering, though many of the key technologies were developed by chemists and biologists for laboratory-scale separation of biological products.

Molecular laser isotope separation (MLIS) is a method of isotope separation, where specially tuned lasers are used to separate isotopes of uranium using selective ionization of hyperfine transitions of uranium hexafluoride molecules. It is similar to AVLIS. Its main advantage over AVLIS is low energy consumption and use of uranium hexafluoride instead of vaporized uranium.

The Helikon vortex separation process is an aerodynamic uranium enrichment process designed around a device called a vortex tube. Paul Dirac thought of the idea for isotope separation and tried creating such a device in 1934 in the lab of Peter Kapitza at Cambridge. Other methods of separation were more practical at that time, but this method was designed and used in South Africa for producing reactor fuel with a uranium-235 content of around 3–5%, and 80–93% enriched uranium for use in nuclear weapons. The Uranium Enrichment Corporation of South Africa, Ltd. (UCOR) developed the process, operating a facility at Pelindaba to produce hundreds of kilograms of HEU. Aerodynamic enrichment processes require large amounts of electricity and are not generally considered economically competitive because of high energy consumption and substantial requirements for removal of waste heat. The South African enrichment plant has apparently been closed.

Liquid fluoride thorium reactor

The liquid fluoride thorium reactor is a type of molten salt reactor. LFTRs use the thorium fuel cycle with a fluoride-based, molten, liquid salt for fuel. In a typical design, the liquid is pumped between a critical core and an external heat exchanger where the heat is transferred to a nonradioactive secondary salt. The secondary salt then transfers its heat to a steam turbine or closed-cycle gas turbine.

Air separation chemical process

An air separation plant separates atmospheric air into its primary components, typically nitrogen and oxygen, and sometimes also argon and other rare inert gases.

Recrystallization (chemistry) separation process

In chemistry, recrystallization is a technique used to purify chemicals. By dissolving both impurities and a compound in an appropriate solvent, either the desired compound or impurities can be removed from the solution, leaving the other behind. It is named for the crystals often formed when the compound precipitates out. Alternatively, recrystallization can refer to the natural growth of larger ice crystals at the expense of smaller ones.

The COLEX process is a chemical method of isotopic separation of lithium-6 and lithium-7, based on the use of mercury. COLEX stands for column exchange.

References

  1. oxford dictionary of science, 4th edition, 1999. ISBN   0-19-280098-1