Case Study

Saturated Brine Purification with Ca/Mg Removal

Allows Local Salt Use

Increased Supply Chain Stability

Improved Cost Efficiency

Reduced Environmental Impact

Introduction

Salt plays a critical role in various industrial processes, including chemical manufacturing, water treatment, food processing, and de-icing. In the chemical industry, it is a primary raw material for the production of chlorine and caustic soda through electrolysis. Salt is also essential in textile dyeing, leather tanning, and as a preservative in food production. However, local salt sources cannot always be used due to variations in purity, mineral content, and physical form. Impurities like calcium, magnesium, or heavy metals can interfere with sensitive industrial processes, requiring refined or specifically processed salt that may not be available locally. As a result, industries often rely on imported or specially treated salt to meet strict quality standards and ensure consistent performance.

The use of low-quality salt in the chlor-alkali process, in particular could result in several adverse effects including:

Electrolyser Damage: Impurities like calcium, magnesium, and iron can scale or foul the electrolyser membranes and electrodes, reducing efficiency and lifespan.
Lower Product Purity: Contaminants can carry over into the chlorine, hydrogen, and caustic soda products, affecting their purity and making them unsuitable for sensitive applications.
Increased Maintenance Costs: Fouling and corrosion from impurities lead to more frequent cleaning, maintenance, and part replacements, increasing operational costs.
Energy Inefficiency: Impurities can increase electrical resistance in the electrolyser, leading to higher energy consumption per unit of product.
Waste Management Issues: Additional impurities create more waste by-products, complicating disposal and increasing environmental compliance costs.
Process Disruptions: Poor-quality salt can cause inconsistent operation, unplanned downtime, or even process failures, affecting overall productivity.

ICMQ Filtration Pty Ltd was engaged by our client, a chlor-alkali producer, to develop a process that would permit the use of locally sourced (low-quality) salt for their new chlor-alkali plant located in Queensland, Australia.

Client Impact

Having to source high purity salt internationally would have affected the profitability of the client’s chlor-alkali plant and increased the project risk profile due to the following:

Increased Costs: Importing salt involves transportation, tariffs, and handling fees, raising the overall cost compared to using local sources.
Supply Chain Vulnerability: Relying on international suppliers makes industries more susceptible to disruptions from geopolitical tensions, shipping delays, or natural disasters.
Environmental Impact: Long-distance transport of salt by ship, rail, or truck contributes to carbon emissions and environmental degradation.
Economic Dependence: Dependence on foreign suppliers can affect national economic resilience, especially if supply is limited or prices rise due to global demand shifts.
Quality Control Challenges: Variability in quality from different international sources may lead to inconsistencies in industrial processes and increase the need for additional testing or refinement.
Regulatory Complications: Importing salt may require compliance with international trade regulations, customs procedures, and safety standards, complicating logistics.

ICMQ Solution

Our team developed a membrane-based process that proved successful in the removal of calcium and magnesium and other contaminants commonly found in salt, from locally sourced Queensland salt. This process was initially developed at a bench scale in our laboratories to demonstrate proof of concept before completing the design and construction of the full-scale plant, the TMF-1000.

Our TMF-1000 is a modular, membrane-based, transportable, containerised processing plant specifically designed to remove calcium and magnesium (Ca/Mg) hardness in addition to other contaminants from locally sourced industrial salt. By streamlining the purification of saturated brine, the TMF-1000 offers operational and environmental benefits. The TMF-1000 was designed to integrate seamlessly with the clients proposed chlor-alkali plant to ensure consistent and predictable operation.

Key features of the TMF-1000 include:

Cross Flow Filtration: High resilience to membrane fouling and blockage.
Variable Throughput: Adjustable to meet production needs.
Easy Maintenance: Simple access for upkeep and a built-in Clean-in-Place (CIP) system.
High Processing Capacity: Can handle up to 7 tonnes of salt or 24,000 litres of brine per day.

Client Outcomes and Benefits

Implementation of our TMF-1000 into the client’s chlor-alkali plant improved overall operational efficiency for the client with benefits including:

Allows Local Salt Use

Reduces dependency on overseas suppliers.

Increased Supply Chain Stability

Mitigates risks from global disruptions.

Improved Cost Efficiency

Significantly lowers procurement and operational costs.

Reduced Environmental Impact

Cuts down on transportation emissions, reducing the carbon footprint and Scope 3 emissions.

ICMQ was able to solve a long-standing industrial challenge for our client while offering sustainable benefits to the client, to the environment and to the local economy.

Addressing the complex nature of industrial wastewater requires a holistic understanding of the specific contaminants involved, technological advancements, and a commitment to sustainable and environmentally friendly treatment practices.

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