Development of a low-pressure materials pre-treatment process for improved energy efficiency

Low pressure materials pre-treatment process has been developed as an alternative to the existing high-temperature sludge drying, limestone calcination, and limonite dehydroxylation. Using the thermodynamic equilibrium relationship between temperature and pressure represented by the Clausius-Clapeyron equation, the operational temperature of these reactions could be lowered at reduced pressure for increased energy efficiency. For industrial sludge drying, the evaporation rate was controlled by interfacial kinetics showing a constant rate with time and significant acceleration in the reaction could be observed with reduced pressure. At this modified reaction rate under low pressure, the rate was also partially controlled by mass transfer. Temperature of limestone calcination was lowered, but the reaction was limited at the calculated equilibrium temperature of the Clausius-Clapeyron equation and slightly higher temperatures were required. The energy consumption during limestone calcination and limonite dehydroxylation were evaluated, where lower processing pressures could enhance the energy efficiency for limestone calcination, but limonite dehydroxylation could not achieve energy-savings due to the greater power consumption of the vacuum pump under lower pressure and reduced temperatures.