Title of Invention

"METHOD OF PURIFYING FISCHER TROPSCH DERIVED WATER"

Abstract A process for the production of highly purified water 44 from Fischer-Tropsch reaction water 12 includes distillation 14 as a primary treatment stage, biological treatment including anaerobic digestion 20 and aerobic digestion 22 as a secondary treatment stage, solid-liquid separation 32 as a tertiary treatment stage and a dissolved salt and organic removal stage 40 as final treatment stage.
Full Text METHOD OF PURIFYING F1SCHER-TROPSCH DERIVED WATER Field of the Invention
This invention relates to the purification of water produced during Fischer-Tropsch synthesis for which synthesis a variety of carbonaceous materials are used as feedstock.
Background to the Invention
The applicant is aware of processes for the synthesis of water from a carbonaceous feedstock, such as natural gas and coal, which processes also produce hydrocarbons.
One such process is the Fischer-Tropsch process of which the largest product is water and, to a lesser extent, hydrocarbons including olefins, paraffins, waxes, and oxygenates. There are numerous references to this process such as, for example on pages 265 to 278 of Technology of the Fischer-Tropsch process" by Mark Dry, Catal. Rev. Sci.Eng., Volume 23 (1&2), 1981.
The products from the Fischer-Tropsch process may be processed further, for example by hydroprocessing, to produce products including synthetic crude oil, olefins, solvents, lubricating, industrial or medicinal oil, waxy hydrocarbons, nitrogen and oxygen containing compounds, motor gasoline, diesel fuel, jet fuel and kerosene. Lubricating oil includes automotive, jet, turbine and metal working oils. Industrial oil includes well drilling fluids, agricultural oils and heat transfer fluids.
In certain areas where carbonaceous feedstocks are to be found, water is in short supply and a relatively costly commodity. Also, environmental concerns prevent the dumping of polluted water derived from the Fischer-Tropsch process into natural water ways and the sea thereby presenting a case for the production and recovery of useable water at the source of the carbonaceous feedstocks.
The carbonaceous feedstocks typically include coal and natural gas that are converted to hydrocarbons, water and carbon dioxide during Fischer-Tropsch synthesis. Naturally, other carbonaceous feedstocks such as, for example, methane hydrates found in marine deposits, can also be used.
Before the water produced during the Fischer-Tropsch process is purified in accordance with the present invention, it is typically subjected to preliminary separation aimed at isolating a water-enriched stream from the Fischer-Tropsch products.
The preliminary separation process includes condensing the gaseous product from the Fischer-Tropsch reactor and separating it in a typical three-phase separator. The three streams exiting the separator are: a tail gas, a hydrocarbon condensate including mainly hydrocarbons in the C5 to C20 range and a reaction water stream containing dissolved oxygenated hydrocarbons, and suspended hydrocarbons.
The reaction water stream is then separated using a coalescer that separates the reaction water stream into a hydrocarbon suspension and a water-rich stream.
The coalescer is capable of removing hydrocarbons from the reaction water stream to a concentration of between 10 ppm and 1000 ppm, typically 50 ppm.
The water-enriched stream thus obtained forms the feedstock for the method according to the present invention and will be denoted in this specification by the term "Fischer-Tropsch reaction water".
The composition of the water-enriched stream or reaction water is largely dependent on the catalyst metal used in the Fischer-Tropsch reactor and the reaction conditions (e.g. temperature, pressure) employed. The Fischer-Tropsch reaction water can contain oxygenated hydrocarbons including aliphatic, aromatic and cyclic alcohols, aldehydes, ketones and acids, and to a lesser extent aliphatic, aromatic and cyclic hydrocarbons such as olefins and paraffins.
The Fischer-Tropsch reaction water may also contain small quantities of inorganic compounds including metals from the Fischer-Tropsch reactor, as well as nitrogen and sulphur containing species that originate from the feedstock.
The influence of the type of Fischer-Tropsch synthesis used on the quality of Fischer-Tropsch reaction water is illustrated in typical organic analysis (Table 1) of Fischer-Tropsch reaction water generated from three different synthesis operating modes, namely:
(Formula Removed)
Table 1: Typical Organic Composition of Fischer-Tropsch reaction water from Different Fischer-Tropsch Synthesis Operating Modes
(Table Removed)
It is evident from the typical analyses of Fischer-Tropsch reaction waters of different origin (Table 1) that these waters, in particular HT Fischer-Tropsch reaction water, contain relatively high concentrations of organic compounds, and direct application or disposal of these waters is generally not feasible without further treatment to remove undesirable constituents. The degree of treatment of the Fischer-Tropsch reaction water depends largely on the intended application, and it is possible to produce a wide range of water qualities ranging from boiler feed water to partially treated water which may be suitable for discharge to the environment.
It is also possible to co-treat Fischer-Tropsch reaction water with other typical process waste water as well as rain water.
The water purification processes described in this invention may, after making minor adaptations, also be used for the processing of aqueous streams derived from generic synthesis gas conversion processes using metallic catalysts similar to the catalysts used during Fischer-Tropsch synthesis.
Summary of the Invention
According to a first aspect of the invention there is provided a process for the production of purified water from Fischer-Tropsch reaction water, which process includes at least the steps of:
a) a primary treatment stage comprising an equilibrium staged separation process having at least one stage for removing at least a fraction of non-acid oxygenated hydrocarbons from the Fischer-Tropsch reaction water to produce a primary water enriched stream;
b) a secondary treatment stage comprising biological treatment for removing at least a fraction of acidic oxygenated hydrocarbons from at least a portion of the primary water enriched stream to produce a secondary water enriched stream; and
c) a tertiary treatment stage comprising solid-liquid separation for removing at least some solids from at least a portion of the secondary water enriched stream.
The term "purified water" is to be interpreted as meaning an aqueous stream having a COD of between 20 and 500 mg/l, a pH of between 6,0 and 9,0, a suspended solids content of less than 250 mg/l and a total dissolved solids content of less than 600 mg/l.
The non-acid oxygenated hydrocarbons are typically comprised of compounds selected from the group including: alcohols, aldehydes and ketones, more specifically from the group including: acetaldehyde, propionaldehyde, butyraldehyde, acetone, methyl-propyl-ketone, methanol, ethanol, propanol, butanol, pentanol, hexanol, and heptanol.
The acidic oxygenated hydrocarbons are typically selected from the group including: formic acid, acetic acid, propionic acid, butyric acid, valeric acid, hexanoic acid, heptanoic acid, and octanoic acid.
A number of equilibrium staged separation processes are suitable for use in the primary treatment stage. Such processes may include conventional distillation processes typically used in the refining and petrochemical industry as well as solvent extraction using either conventional liquid solvents or liquefied gases.
When distillation is used as the primary treatment stage, the bulk of the non-acid oxygenated hydrocarbons contained in the Rscher-Tropsch reaction water are removed, leaving predominantly mono-carboxylic acids (e.g. acetic acid, propionic acid) and optionally trace quantities of non-acid compounds. As a result of the presence of organic acids, the primary water enriched stream is known as Fischer-Tropsch acid water.
The overheads from distillation may be recovered and worked-up to products, or may be used for fuel or as an energy source.
The primary treatment stage may include degassing of the Fischer-Tropsch reaction water before further processing to remove compounds having a very low boiling point and dissolved gases from the Rscher-Tropsch reaction water.
Typically, Fischer-Tropsch reaction water originating from HTFT iron catalyst processes which water has undergone primary treatment has limited application due to the relatively high concentrations (> 1% by mass) of organic acids remaining in the Fischer-Tropsch acid water, and further treatment of the water is required. In contrast, Fischer-Tropsch reaction water originating from cobalt-based LTFT processes which water has undergone primary treatment contains significantly lower organic acid concentrations ( The biological treatment may include anaerobic treatment or aerobic treatment or a combination of anaerobic and aerobic treatment. The anaerobic and/ or aerobic treatment methods may be the same as are conventionally used for domestic and industrial wastewater treatment.
The anaerobic and/ or aerobic treatment may include adding nutrients in the form of nitrogen (e.g. urea, ammonia or ammonium salts) and phosphorus (e.g. phosphate salts) containing compounds to accelerate microbiological degradation of the organic constituents. In addition, pH control using alkali salts such as lime, caustic and soda ash may be required due to the acidity of the water.
Fischer-Tropsch acid waters originating from both HTFT and LTFT processes lend themselves to anaerobic digestion since they contain mainly readily digestible short-chain mono-carboxyiic acids such as acetic, propionic, butyric and valeric acids. Anaerobic technologies that have been successfully evaluated include Up-flow Anaerobic Sludge Blanket (UASB) processes, Fixed Bed systems, Fluidized Bed reactors, Stirred Tank reactors, Membrane Bioreactors, and Baffled reactors.
Apart from a water-rich stream, namely the secondary water enriched stream, anaerobic digestion typically yields methane, carbon dioxide and sludge as byproducts.
The methane may be released to the environment via an acceptable system or, preferably, recovered. Recovered methane may be used as a fuel or energy source or returned for reforming (where natural gas is used as a feedstock for the Fischer-Tropsch synthesis process) or it may be chemically or biologically converted to products.
The sludge may be incinerated, used as land fill or as a fertiliser or soil conditioner.
A wide range of technologies may be used in the aerobic treatment of the water originating from step a). Such technologies may be selected from the group including: Activated Sludge processes, High-rate Compact Reactors, Biological Aerated Filters, Trickling filters, Rotating Biological Contacters, Membrane
Bioreactors, and Fluidised Bed reactors. The aerobic production of Single Cell Protein (SCP) has also been successfully developed.
Apart from a water-rich stream, namely the secondary water enriched stream, aerobic treatment typically yields carbon dioxide and sludge as byproducts. The carbon dioxide may be released to the environment. The sludge may be incinerated, used as land fill, fertilizer, soil conditioner or as a source of SCP.
Removal of the majority of the organic material from Fischer-Tropsch acid waters originating from LTFT processes may be undertaken in a single biological treatment step.
Removal of the majority of the organic material from acid waters originating from HTFT processes may require a bulk organic carbon removal step (anaerobic digestion) followed by a second biological polishing step (aerobic digestion) to remove residual organic material (see also Example 2 below).
The tertiary treatment stage may be aimed at removing suspended solids from the secondary water-enriched stream produced during biological treatment.
Suspended solid removal may be achieved by methods selected from the group including: sand filtration, membrane separation (e.g. micro- or ultrafiltration), sedimentation (with or without the use of flocculants), dissolved air flotation (with or without the use of flocculants) and centrifugation.
Local discharge standards or the intended application will dictate the required level and type of tertiary treatment.
Applications for the purified water produced by the method described above may include its use as cooling water, irrigation water or general process water.
The purified water typically has the following characteristics:
(Table Removed)
The Fischer-Tropsch reaction which generates the Fischer-Tropsch reaction water may also produce other Fischer-Tropsch products. These Fischer-Tropsch products may be processed further, for example by hydroprocessing, to produce products including synthetic crude oil, olefins, solvents, lubricating, industrial or medicinal oil, waxy hydrocarbons, nitrogen and oxygen containing compounds, motor gasoline, diesel fuel, jet fuel and kerosene. Lubricating oil includes automotive, jet, turbine and metal working oils. Industrial oil includes well drilling fluids, agricultural oils and heat transfer fluids.
According to a second aspect of the invention, there is provided a process for the production of highly purified water from Fischer-Tropsch reaction water, said process including at least the steps of:
a) a primary treatment stage including an equilibrium staged separation process
having at least one stage for removing at least a fraction of non-acid
oxygenated hydrocarbons from the Fischer-Tropsch reaction water to produce
a primary water enriched stream;
b) a secondary treatment stage comprising biological treatment for removing at
least a fraction of acidic oxygenated hydrocarbons from at least a portion of
the primary water enriched stream to produce a secondary water enriched
stream;
c) a tertiary treatment stage comprising solid-liquid separation for removing at
least some solids from least a portion of the secondary water enriched stream
to produce a tertiary water enriched stream; and
d) a final treatment stage comprising a dissolved salt and organic removal stage
for removing at least some dissolved salts and organic constituents from at
least a portion of the tertiary water enriched stream.
The term "highly purified water" is to be interpreted as meaning an aqueous stream having a COD of less than 50 mg/l, a pH of between 6,0 and 9,0, a suspended solids content of less than 50 mg/l and a total dissolved solids content of less than 100 mg/l.
The non-acid oxygenated hydrocarbons are typically comprised of compounds selected from the group including: alcohols, ketones and aldehydes, more specifically from the group including: acetaldehyde, propionaldehyde, butyraldehyde, acetone, methyl-propyi-ketone, methanol, ethanol, propanol, butanol, pentanol, hexanol, and heptanol.
The acidic oxygenated hydrocarbons are typically selected from the group including: formic acid, acetic acid, propionic acid, butyric acid,valeric acid, hexanoic acid, heptanoic acid, and octanoic acid.
A number of equilibrium staged separation processes are suitable for use in the primary treatment stage. Such processes may include conventional distillation processes typically used in the refining and petrochemical industry as well as solvent extraction using either conventional liquid solvents or liquefied gases.
When distillation is used as the primary treatment stage, the bulk of the non-acid oxygenated hydrocarbons contained in the Fischer-Tropsch reaction water are removed, leaving predominantly mono-carboxylic acids (e.g. acetic acid, propionic acid) and optionally trace quantities of non-acid compounds. As a result of the presence of organic acids, the primary water enriched stream is known as Fischer-Tropsch acid water.
The overheads from distillation may be recovered and worked-up to products, or may be used for fuel or as an energy source.
The primary treatment stage may include degassing of the Fischer-Tropsch reaction water before further processing to remove compounds having a very low boiling point and dissolved gases from the Fischer-Tropsch reaction water.
Typically, Fischer-Tropsch reaction water originating from HTFT iron catalyst processes which water has undergone primary treatment has limited application due to the relatively high concentrations (> 1% by mass) of organic acids remaining in the FT. acid water and further treatment of the water is required. In contrast, Fischer-Tropsch reaction water originating from cobalt-based LTFT processes which water has undergone primary treatment contains significantly lower organic acid concentrations ( The biological treatment may include anaerobic treatment or aerobic treatment or a combination of anaerobic and aerobic treatment. The anaerobic and/ or aerobic treatment methods may be the same as are conventionally used for domestic and industrial wastewater treatment.
The anaerobic and/ or aerobic treatment may include adding nutrients in the form of nitrogen (e.g. urea, ammonia or ammonium salts) and phosphorus (e.g. phosphate salts) containing compounds to accelerate microbiological degradation of the organic constituents. In addition, pH control using alkali salts such as lime, caustic and soda ash may be required due to the acidity of the water.
Fischer-Tropsch acid waters originating from both HTFT and LTFT processes lend themselves to anaerobic digestion since they contain mainly readily digestible short-chain mono-carboxylic acids such as acetic, propionic, butyric and valeric acids. Anaerobic technologies that have been successfully evaluated include Up-flow Anaerobic Sludge Blanket (UASB) processes, Fixed Bed systems, Fluidized Bed reactors, Stirred Tank reactors, Membrane Bioreactors, and Baffled reactors.
Apart from a water-rich stream, namely the secondary water-enriched stream, anaerobic digestion typically yields methane, carbon dioxide and sludge as byproducts.
The methane may be released to the environment via an acceptable system or, preferably, recovered. Recovered methane may be used as a fuel or energy source
or returned for reforming (where natural gas is used as a feedstock for the Fischer-Tropsch synthesis process) or it may be chemically or biologically converted to products.
The sludge may be incinerated, used as land fill or as a fertiliser or soil conditioner.
A wide range of technologies may be used in the aerobic treatment of the water originating from step a). Such technologies may be selected from group including: Activated Sludge processes, High-rate Compact Reactor, Biological Aerated Filters, Trickling filters, Membrane Bioreactors, and Fluidised Bed reactors. The aerobic production of Single Cell Protein (SCP) has also been successfully developed.
Apart from a water-rich stream, namely the secondary water-enriched stream, aerobic treatment typically yields carbon dioxide and sludge as byproducts. The carbon dioxide may be released to the environment. The sludge may be incinerated, used as land fill, fertilizer, soil conditioner or as a source of SCP.
Removal of the majority of the organic material from Fischer-Tropsch acid waters originating from LTFT processes may be undertaken in a single biological treatment step.
Removal of the majority of the organic material from acid waters originating from HTFT processes may require a bulk organic carbon removal step (anaerobic digestion) followed by a second biological polishing step (aerobic digestion) to remove residual organic material (see also Example 2 below).
The tertiary treatment stage may be aimed at removing suspended solids from the water-rich stream produced during biological treatment
Suspended solid removal may be achieved by methods selected from the group including: sand filtration, membrane separation (e.g. micro- or ultrafiltration), sedimentation (with or without the use of flocculants), dissolved air flotation (with or without the use of flocculants) and centrifugation.
Residua! organic species not removed during biological treatment and solids removal may be removed by methods selected from the group including: chemical oxidation using agents such as ozone and hydrogen peroxide, ultraviolet light generated free radicals and adsorption and/ or absorption processes including activated carbon treatment and organic scavenging resins.
Dissolved salts, originating from secondary treatment (i.e. pH control chemicals, nutrient addition) and/or from the co-treatment of other process effluents, can be further reduced by methods selected from the group including: ion exchange, reverse osmosis, nano-filtration and chemical precipitation processes including hot and cold lime softening.
Applications for the highly purified water produced by the method described above may include its use as boiler feed water and drinking water.
The highly purified water typically has the following characteristics:
(Table Removed)
Advantages inherent in the purified and highly purified water produced according to the present invention are that the water will contain only a small amount of dissolved solids because the Fischer-Tropsch reaction water is essentially a dissolved solids-free stream. The low levels of residual salts in the purified water are a result of controlled addition of chemicals used during the purification process sequence and/or the co-treatment of other dissolved solids containing effluents. The residual salts could include Ca, Mg, Na, K, CI, SO4, HCO3 and CO3 combinations. The low dissolved solids concentrations in Fischer-Tropsch reaction water can simplify and reduce the costs of the purification process.
The Fischer-Tropsch reaction which generates the Fischer-Tropsch reaction water may also produce other Fischer-Tropsch products. These Fischer-Tropsch
products may be processed further, for example by hydroprocessing, to produce products including synthetic crude oil, olefins, solvents, lubricating, industrial or medicinal oil, waxy hydrocarbons, nitrogen and oxygen containing compounds, motor gasoline, diesel fuel, jet fuel and kerosene. Lubricating oil includes automotive, jet, turbine and metal working oils. Industrial oil includes well drilling fluids, agricultural oils and heat transfer fluids.
Detailed Description of the Invention
The invention will now be described by way of the following non-limiting examples with reference to the accompanying drawing.
Figure 1 shows a simplified block diagram of a method according to the present invention including various treatment options.
The Rscher-Tropsch reaction water 12 is fed to a distillation column 14 for primary treatment.
Two streams 16 and 18 exit distillation column 14. Stream 16 contains predominantly organic constituents whilst stream 18 is a primary water enriched stream.
Stream 18 is then subjected to biological treatment. This can take the form of anaerobic treatment 20 and/or aerobic treatment 22. Apart from a secondary water-enriched stream 36, all three biological treatment options 20, or 22 and a combination of 20 and 22 produce sludge 28 and anaerobic treatment 20 in addition produces methane and carbon dioxide 30, whilst aerobic treatment produces carbon dioxide 38.
The next treatment stage involves solid-liquid separation 32 during which solids 34 and purified water 46 are produced.
An additional step involving the removal of dissolved salt and organic constituents 40 that produces concentrate 42 and highly purified water 44 can be performed after solid-liquid separation.
Depending on the final intended use of the purified 46 or highly purified water 44, the minimum water quality requirements are as set out in Table 2 below and the operating conditions of the equipment used in the method as well as suitable treatment options can be selected accordingly.
Table 2 Water Quality - Typical Requirements
(Table Removed)
Examples
Example 1 - Treatment of Fischer-Tropsch reaction water from a cobalt catalyst LTFT process
After separation of by-products, a water enriched stream from an LTFT process was degassed at atmospheric pressure. Free hydrocarbons in the water enriched stream were reduced to 0.01 % (mass %) using a coalescer. The composition of the Fischer-Tropsch reaction water thus obtained is given in Table 1 above.
Primary treatment of the Fischer Tropsch reaction water was undertaken using distillation. Analysis of the Fischer-Tropsch acid water bottoms of the distillation column is detailed in Table 3 below. With the exception of trace quantities of methanol, most other non-acid oxygenated hydrocarbons were removed from the FT reaction water during primary distillation leaving an organic acid enriched or primary
water enriched stream (i.e. 0.074 mass % organic acids) with a pH value of 3.5. The measured Chemical Oxygen Demand (COD) of the primary water enriched stream was in the order of 800 mg 02/I.
The primary water enriched stream was cooled from 70 °C to 35 °C using a plate heat exchanger and fed into an open equalization tank with a Hydraulic Residence Time(HRT)of 8-12h.
The primary water enriched stream underwent activated sludge treatment (aerobic treatment) to remove organic components.
The activated sludge system was operated under the following conditions:
• pH:7.2 to 7.5
• Dissolved oxygen concentration in basin: > 2 mg/l
• Temperature: 33-35°C
• HRT:±30 h
• COD loading rate: 0.5 -1 kg O2/m3.d
• F/M ratio: 0.2 -0.4 kg COD/kg MLSS.d
• Cell retention time (sludge age): 20 days
• Feed to recycle ratio: 1 :2.5
• Nutrients in the form of nitrogen and phosphorous containing compounds were added to sustain the process.
During activated sludge treatment an average organic component removal efficiency of 92 % (± 2 %) was achieved yielding an effluent containing 0.006 % (mass %) residual organic matter and a COD concentration of 64 mg O2/I. A sludge yield of 0.15 kg sludge/kg COD removed was obtained.
Activated sludge treatment yielded a secondary water-enriched stream that was subjected to sand filtration to reduce its SS concentration to 25 mg/l. The TDS of the purified water thus obtained was ca 50 mg/l. The purified water has application as a
both irrigation water and process cooling water. Sludge produced in the process was incinerated.
In order to produce a highly purified water stream, a portion of the purified water from the sand filter was diverted to a cross-flow membrane unit fitted with a 0.2 urn
2
polypropylene microfiltration membrane. A permeate flux rate of 70 - 80 l/m .h was obtained during stable operation of the unit, and the water recovery across the unit varied between 75 - 85 %. The resultant SS and COD concentrations in the permeate from the microfiltration unit were The pH of the purified water from the microfiltration unit was adjusted to pH 8.5 using sodium hydroxide, and the purified water was pumped to a reverse osmosis unit fitted with a high rejection sea water polyamide membrane. A permeate flux rate of 15 -25 l/m .h was obtained during stable operation of the unit, and the water recovery across the unit varied between 85 - 90 %. The reverse osmosis unit yielded a highly purified water stream containing COD and TDS concentrations of Table 3: Typical Composition of LT Fischer-Tropsch Reaction Water Feed and Acid Water Bottoms after Primary Treatment (Distillation)
(Table Removed)
Example 2 - Treatment of Fischer-Tropsch reaction water from an iron catalyst HTFT process
After separation of by-products, a water enriched stream from an HTFT process was degassed at atmospheric pressure for a period of 30 mm in an open vessel, frse hydrocarbons in the water enriched stream were reduced to 0.01 % (mass %) using a coalescer. The composition of the Fischer-Tropsch reaction water thus obtained is given in Table 4 below.
Primary treatment of the HT Fischer-Tropsch reaction water was effected using distillation. Analysis of the acid water bottoms from the distillation column is detailed in Table 5 below. It is evident from this analysis that most non-acid components were removed from the FT reaction water during primary distillation leaving an organic acid enriched or primary water enriched stream containing 1.2 % organic acids consisting predominantly of acetic acid. The measured COD of this stream was in the order of 16 000 mg O2/I-
The primary water enriched stream was cooled from 60 °C to 35 °C, and fed into an open equalization tank with a HRT of 8 - 12 h. The primary water enriched stream was fed to a Down-flow Packed Bed (DPB) anaerobic digester containing plastic packing material. Lime (Ca(OH)2) was dosed into the feed to a concentration of 500 mg/l in order to adjust the pH from pH 3 to pH 4.5. Nutrients were also added to sustain the process.
The DPB anaerobic digester was operated under the following conditions:
• Temperature - 35 to 38 °C
• pH-6.8-7.0
• HRT-25-30 h
• COD loading rate - 12 -16 kg O2/m3.d
• Feed to recycle ratio -1:4
The COD and SS concentrations of the water enriched stream obtained from anaerobic digestion were ca. 1400 mg O2/I and ca. 500 mg SS/I, respectively. The COD removal across the reactor was in excess of 90 %.
In order to further reduce the COD content, the water enriched stream obtained from anaerobic digestion was further subjected to aerobic treatment in an activated sludge basin.
Additional nutrient and lime dosing was not necessary and activated sludge treatment was conducted under the following conditions:
• pH: 7.2 to 7.5
• Dissolved oxygen concentration in basin : ± 2 mg/l
• Temperature: 33 - 35 °C
• HRT:±30 h
• COD loading rate: 0.8 -1.2 kg O2/m3.d
• F/M ratio: 0.2 - 0.4 kg COD/kg MLSS.d
• Cell retention time (sludge age): 20 days
• Feed to recycle ratio: 1:2.5
A sludge yield of 0.15 kg sludge/kg COD removed was achieved and the sludge produced was incinerated. The activated sludge treated effluent contained COD and SS concentrations of 100 mg O2/I and 70 mg SS/I, respectively.
Activated sludge treatment yielded a secondary water-enriched stream that was subjected to sand filtration to reduce its SS concentration to 15 mg/l.
The calcium concentration in the thus obtained tertiary water-enriched stream was ca. 230 mg/l and cold lime softening was used to reduce the concentration of calcium to ca. 30 mg/l giving a final TDS concentration of 95 mg/l. During the abovementioned treatment steps the COD concentration was further reduced to 45 O2 mg/l yielding a highly purified water stream.
Table 4: Composition of HT Fischer-Tropsch reaction water feed and acid water bottoms after primary distillation.
(Table Removed)
It is to be appreciated that the invention is not limited to any specific embodiment or configuration as hereinbefore generally described or illustrated, for example, rain water or water enriched streams from processes other than Fischer-Tropsch synthesis may be purified according to the method described above.






We claim:
1. A process for the production of purified water from Fischer-Tropsch reaction water containing oxygenated hydrocarbons, aliphatic, aromatic and cyclic hydrocarbons and inorganic compounds, wherein the purified water is an aqueous stream having a COD of between 20 and 500 mg/l, a pH of between 6,0 and 9,0, a suspended solids content of less than 250 mg/l and a total dissolved solids content of less than 600 mg/l, and wherein the process includes the steps of:
a) a preliminary treatment stage for degassing the Fischer-Tropsch reaction water to remove compounds having a very low boiling point and dissolved gases from the Fischer-Tropsch reaction water;
b) a primary treatment stage comprising distillation for removing a fraction of non-acid oxygenated hydrocarbons from the Fischer-Tropsch reaction water to produce a primary water enriched stream;
c) a secondary treatment stage comprising biological treatment for removing fraction of acidic oxygenated hydrocarbons from a portion of the primary water enriched stream to produce a secondary water enriched stream; and
d) a tertiary treatment stage comprising solid-liquid separation for removing solids from a portion of the secondary water enriched stream.

2. The process as claimed in claim 1 wherein the non-acid oxygenated hydrocarbons are selected from the group including: alcohols, aldehydes and ketones.
3. The process as claimed in claim 1 wherein the acidic oxygenated hydrocarbons are selected from the group including: formic acid, acetic acid, propionic acid, butyric acid, valeric acid, hexanoic acid, heptanoic acid and octanoic acid.
4. The process as claimed in claim 1 wherein the biological treatment includes one or both of anaerobic treatment and aerobic treatment.

5. The process as claimed in claim 4 wherein the aerobic treatment method is selected from group including: Activated Sludge processes, Biological Aerated Filters, Trickling filters, Rotating Biological Contacters, High-rate Compact Reactors, Membrane Bioreactors and Fluidised Bed reactors.
6. The process as claimed in claim 4 wherein the anaerobic treatment method is selected from the group including: Up-flow Anaerobic Sludge Blanket (UASB) processes, Fixed Bed systems, Fluidized Bed reactors, Stirred Tank reactors, Membrane Bioreactors and Baffled reactors.
7. The process as claimed in claim 1 wherein the tertiary treatment stage removes suspended solids from the secondary water-enriched stream produced during biological treatment.
8. The process as claimed in claim 7 wherein the suspended solid removal is achieved by one or more method selected from the group including: sand filtration, membrane separation, sedimentation with the us of flocculants, sedimentation without the us of flocculants, dissolved air flotation with the use of flocculants, dissolved air flotation without the use of flocculants, and centrifugation.
9. The process as claimed in claim 8 wherein the membrane separation method includes one or both of microfiltration and ultrafiltration.
10. A process for the production of highly purified water from Fischer-Tropsch reaction water containing oxygenated hydrocarbons, aliphatic, aromatic and cyclic hydrocarbons and inorganic compounds, wherein the highly purified water is an aqueous stream having a COD of less than 50 mg/l, a pH of between 6,0 and 9,0, a suspended solids content of less than 50 mg/l and a total dissolved solids content of less than 100 mg/l, wherein the process includes the steps of:


a) a preliminary treatment stage for degassing the Fischer-Tropsch reaction water to remove compounds having a very low boiling point and dissolved gases from the Fischer-Tropsch reaction water;
b) a primary treatment stage comprising degassing of the Fischer-Tropsch reaction water to remove compounds having a very low boiling point and dissolved gases therefrom followed by distillation of the degassed stream for removing a fraction of non-acid oxygenated hydrocarbons from the Fischer-Tropsch reaction water to produce a primary water enriched stream;
c) a secondary treatment stage comprising biological treatment for removing a fraction of acidic oxygenated hydrocarbons from a portion of the primary water enriched stream to produce a secondary water enriched stream;
d) a tertiary treatment stage comprising solid-liquid separation for removing solids from least a portion of the secondary water enriched stream to produce a tertiary water enriched stream; and
e) a final treatment stage comprising a dissolved salt and organic removal stage for removing dissolved salts and organic constituents from a portion of the tertiary water enriched stream.

11. The process as claimed in claim 10 wherein the non-acid oxygenated hydrocarbons are selected from the group including: alcohols, ketones and aldehydes.
12. The process as claimed in claim 10 wherein the acidic oxygenated hydrocarbons are selected from the group including: formic acid, acetic acid, propionic acid, butyric acid, valeric acid, hexanoic acid, heptanoic acid, and octanoic acid.
13. The process as claimed in claims 10 wherein the biological treatment includes one or both of anaerobic treatment and aerobic treatment.
14. The process as claimed in claim 13 wherein the aerobic treatment method is selected from group including: Activated Sludge processes, Biological Aerated Filters, Trickling


filters, Rotating Biological Contacters, High-rate Compact Reactors, Membrane Bioreactors and Fluidised Bed reactors.
15. The process as claimed in claim 13 wherein the anaerobic treatment method is selected from the group including: Up-flow Anaerobic Sludge Blanket (UASB) processes, Fixed Bed systems, Fluidized Bed reactors, Stirred Tank reactors, Membrane Bioreactors, and Baffled reactors.
16. The process as claimed in claim 10 wherein the tertiary treatment stage removes suspended solids from the secondary water-enriched stream produced during biological treatment.
17. The process as claimed in claim 16 wherein the suspended solid removal is achieved by one or more method selected from the group including: sand filtration, membrane separation, sedimentation with the use of flocculants, sedimentation without the use of flocculants, dissolved air flotation with the use of flocculants, dissolved air flotation without the use of flocculants, and centrifugation.
18 . The process as claimed in claim 17 wherein the membrane separation includes one or both of microfiltration and ultrafiltration.
19. The process as claimed in claim 10 wherein residual organic species are removed in the final treatment stage by one or more method selected from the group including: chemical oxidation, ultraviolet light generated free radicals, adsorption and/or absorption processes.
20. The process as claimed in claim 19 wherein the adsorption and/or absorption processes include one or both of activated carbon treatment and the use of organic scavenging resins.


21. The process as claimed in claims 10 wherein dissolved salts originating from secondary
treatment and/or from the co-treatment of other process effluents, are reduced in the
final treatment stage by one or more method selected from the group including: ion
exchange, reverse osmosis, nano-filtration, and chemical precipitation processes.
22. The process as claimed in claim 21 wherein the chemical precipitation processes are selected from one or both of hot lime softening and cold lime softening.

Documents:

4163-DELNP-2004-Abstract-(09-06-2011).pdf

4163-delnp-2004-abstract.pdf

4163-DELNP-2004-Claims-(09-06-2011).pdf

4163-delnp-2004-claims.pdf

4163-DELNP-2004-Correspondence Others-(09-06-2011).pdf

4163-delnp-2004-Correspondence Others-(20-06-2011).pdf

4163-delnp-2004-correspondence-others.pdf

4163-delnp-2004-description (complete).pdf

4163-delnp-2004-drawings.pdf

4163-DELNP-2004-Form-1-(09-06-2011).pdf

4163-delnp-2004-form-1.pdf

4163-delnp-2004-form-18.pdf

4163-delnp-2004-form-2.pdf

4163-delnp-2004-form-26.pdf

4163-DELNP-2004-Form-3-(09-06-2011).pdf

4163-delnp-2004-Form-3-(20-06-2011).pdf

4163-delnp-2004-form-3.pdf

4163-delnp-2004-form-5.pdf

4163-delnp-2004-pct-210.pdf

4163-delnp-2004-pct-408.pdf

4163-delnp-2004-pct-409.pdf

4163-DELNP-2004-Petition-137-(09-06-2011).pdf


Patent Number 252186
Indian Patent Application Number 4163/DELNP/2004
PG Journal Number 18/2012
Publication Date 04-May-2012
Grant Date 30-Apr-2012
Date of Filing 28-Dec-2004
Name of Patentee SASOL TECHNOLOGY (PTY) LTD
Applicant Address 1 STURDEE AVENUE, ROSEBANK 2196, JOHANNESBURG, SOUTH AFRICA
Inventors:
# Inventor's Name Inventor's Address
1 PHILIPS, TREVOR, DAVID 53, MACOWEN STREET SE2, 1911 VANDERBIJLPARK .
2 DANCUART KOHLER, LUIS, PABLO, FIDEL 20 LOMBARD STREET, 1947 VAALPARK, SOUTH AFRICA
3 DU PLESSIS, GERT, HENDRIK 15 VERMEET STREET, 2302 SECUNDA, SOUTH AFRICA
4 DU TOIT, FRANCOIS, JACOBUS 11 CULEMBORG STREET, 1947 SASOLBURG, SOUTH AFRICA
5 KOPER, EDWARD, LUDOVICUS 53 MACOWEN STREET, SE2, 1911 VANDERBIJLPARK, SOUTH AFRICA
6 VAN DER WALT, JANETTE GLENEDEN 39, CONSTANTIA AVENUE, 1947 VAALPARK, SOUTH AFRICA
PCT International Classification Number C02F 9/14
PCT International Application Number PCT/ZA2003/00081
PCT International Filing date 2003-06-18
PCT Conventions:
# PCT Application Number Date of Convention Priority Country
1 2002/4848 2002-06-18 U.S.A.
2 60/390,684 2002-06-18 U.S.A.