Sustainability of protein production by bioreactor processes using wind and solar power as energy sources

Food production account for significant share of global environmental impacts. Impacts are global warming, fresh water use, land use and some non-renewable substance consumption like phosphorous fertilizers. Because of non-sustainable food production, the world is heading to different crises. Both food- and freshwater crises and also land area and phosphorous fertilizer shortages are one of many challenges to overcome in near future. The major protein sources production amounts, their impacts on environment and uses are show in this thesis. In this thesis, a more sustainable than conventional way of biomass production for food use is introduced. These alternative production methods are photobioreactor process and syngas-based bioreactor process. The processes’ energy consumption and major inputs are viewed. Their environmental impacts are estimated. These estimations are the compared to conventional protein production’s impacts. The outcome of the research is that, the alternative methods can be more sustainable solutions for food production than conventional production. However, more research is needed to verify the exact impacts. Photobioreactor is more sustainable process than syngas-based bioreactor process, but it is more location depended and uses more land area than syngas-based process. In addition, the technology behind syngas-based application is still developing and it can be more efficient in the future.

Comparison of sustainability of technologies for water desalination

The aim of this work is to perform an in-depth overview on the sustainability of several major commercialized technologies for water desalination and to identify the challenges and propose suggestions for the development of water desalination technologies. The overview of those technologies mainly focuses on the sustainability from the viewpoint of total capital investment, total product cost, energy consumption and global warming index. Additionally, a systematic sustainability assessment methodology has been introduced to validate the assessment process. Conclusions are:1) Reverse osmosis desalination (RO) plants are better than multi-stage flash distillation (MSF) desalination plants and multiple-effect distillation (MED) desalination plants from the viewpoint of energy consumption, global warming index and total production cost; 2)Though energy intensive, MSF plants and MED plants secure their advantages over RO plants by lower total capital investment, wider applicability and purer water desalted and they are still likely to flourish in energy-rich area;3) Water production stage and wastewater disposal stage are the two stages during which most pollutant gases are emitted. The water production stage alone contributes approximately 80~90% of the total pollutant gases emission during its life cycle; 4)The total capital cost per m3 desalted water decreases remarkably with the increasing of plant capacity. The differences between the capital cost per m3 desalted water of RO and other desalination plants will decrease as the capacity increases; 5) It is found that utilities costs serve as the major part of the total product cost, and they account for 91.16%, 85.55% and 71.26% of the total product cost for MSF, MED and RO plants, respectively; 6) The absolute superiority of given technology depends on the actual social-economic situation (energy prices, social policies, technology advancements).

Purification and fractionation by nanotiltration in dairy and sugar and sweetener industry applications

Nanotiltration is a membrane separation method known for its special characteristic of rejecting multivalent ions and passing monovalent ions. Thus, it is commonly applied with dilute aqueous solutions in partial salt removal, like in drinking water production. The possibilities of nanofiltration have been studied and the technique applied in a wide branch of industries, e.g. the pulp and paper, the textile and the chemical processing industry. However, most present applications and most of the potential applications studied involve dilute solutions, the permeating stream being generally water containing monovalent salts. In this study nanotiltration is investigated more as a fractionation method. A well-known application in the dairy industry is concentration and partial salt removal from whey. Concentration and partial demineralization is beneficial for futher processing of whey as whey concentrates are used e.g. in baby foods. In the experiments of this study nanotiltration effectively reduced the monovalent salts in the whey concentrate. The main concern in this application is lactose leakage into the permeate. With the nanofiltration membranes used the lactose retentions were practically ? 99%. Another dairy application studied was the purification and reuse of cleaning solutions. This is an environmentally driven application. An 80% COD reduction by nanofiltration was observed for alkaline cleaning-in-place solution. Nanofiltration is not as commonly applied in the sugar and sweeteners industry as in the dairy industry. In this study one potential application was investigated, namely xylose purification from hemicellulose hydrolyzate. Xylose is raw material for xylitol production. Xylose separation from glucose was initially studied with xylose-glucose model solutions. The ability of nanofiltration to partially separate xylose into the permeate from rather concentrated xylose-glucose solutions (10 w-% and 30 w-%) became evident. The difference in size between xylose and glucose molecules according to any size measure is small, e.g. the Stokes diameter of glucose is 0.73 nm compared to 0.65 nm for xylose. In further experiments, xylose was purified into nanoliltration permeate from a hemicellulose hydrolyzate solution. The xylose content in the total solids was increased by 1.4—1.7 fold depending on temperature, pressure and feed composition.

Paperitehdasintegraatin tuorevesien käsittely kloorikaasun korvaavalla menetelmällä

Työn tarkoitus on löytää paperitehdasintegraatin tuorevesien käsittelyyn kloorikaasun korvaava desinfiointimenetelmä Stora Enso Publication Papers Oy Ltd.:n Anjalan tehtailla. Tehtaalla on ympäristöluvassaan velvoite selvittää mahdollisuudet tuoreveden desinfiointiin käytettävän kaasumaisen kloorin korvaamiseen hypokloriitilla. Kloorikaasun käyttö tehtaalla on työturvallisuusriski, ja jäännösklooripitoisuuksien hallittavuus kloorikaasua käytettäessä on heikko. Työssä tutkittava vesijae on kemiallisesti puhdistettu vesi. Koeajossa käytettävät kemikaalit ovat 10 % natriumhypokloriitti (NaOCl) ja kantaja-aine eli bromikloori- di-metyyli-hydantoiini (BCDMH). Tuloksista voidaan päätellä, että NaOCl:lla ja NaOCl:lla yhdessä BCDMH:n kanssa saavutetaan veden käyttökohteessa korkeammat aktiivisen kloorin jäännöspitoisuudet kuin kloorikaasulla. NaOCl:n ja kaksikomponenttisysteemin käyttökustannukset ovat kuitenkin yli kuusinkertaiset kloorikaasuun verrattuna. NaOCl annosteltuna yhteen pisteeseen olisi vaivattomin menetelmä kloorikaasun korvaamiseen. NaOCl:n annostelulla kahteen pisteeseen voitaisiin saavuttaa korkeampia jäännöspitoisuuksia kuin yhden pisteen annostelulla, mutta menetelmä vaatii lisätutkimuksia. Kaksikomponenttisysteemillä saavutetaan korkeimmat aktiivisen kloorin jäännöspitoisuudet, mutta sen seurantamenetelmien luotettavuudesta tulee varmistua ennen menetelmän käyttöönottoa. Korroosion ehkäisyn ja työturvallisuuden kannalta sekä NaOCl että NaOCl yhdessä BCDMH:n kanssa ovat turvallisempia vaihtoehtoja kuin kaasukloori.

Choice of Optimal MembraneProcesses for Economical Treatment of Paper Machine Clear Filtrate

In this thesis membrane filtration of paper machnie clear filtrate was studied. The aim of the study was to find membrane processes which are able to produce economically water of sufficient purity from paper machine white water or its saveall clarified fractions for reuse in the paper machnie short circulation. Factors affecting membrane fouling in this application were also studied. The thesis gives an overview af experiments done on a laboratory and a pilot scale with several different membranes and membrane modules. The results were judged by the obtained flux, the fouling tendency and the permeate quality assessed with various chemical analyses. It was shown that membrane modules which used a turbulence promotor of some kind gave the highest fluexes. However, the results showed that the greater the reduction in the concentration polarisation layer caused by increased turbulence in the module, the smaller the reductions in measured substances. Out of the micro-, ultra- and nanofiltration membranes tested, only nanofiltration memebranes produced permeate whose quality was very close to that of the chemically treated raw water used as fresh water in most paper mills today and which should thus be well suited for reuse as shower water both in the wire and press section. It was also shown that a one stage nanofiltration process was more effective than processes in which micro- or ultrafiltration was used as pretreatment for nanofiltration. It was generally observed that acidic pH, high organic matter content, the presence of multivalent ions, hydrophobic membrane material and high membrane cutoff increased the fouling tendency of the membranes.

Molluscan radiations and landscape evolution in Miocene Amazonia

This PhD study aims to exploit the rich archive provided by the Miocene mollusc fauna of the Pebas Formation and other inland Miocene Amazonian formations to reconstruct landscape evolution and biotic development in lowland Amazonia during the Neogene. Over 160 samples from more than 70 Pebas Formation outcrops mostly collected by the author were processed for this study. Additional samples were collected in Andean areas of Colombia and Venezuela and further material from other northwestern South American basins was studied in museums. Pebas Formation samples and well log data made available by Occidental Peru from three wells in the Marañon Basin in Peru were also investigated. During this study four genera and 74 species from the Pebas Formation have been described and a further 13 species have been introduced in open nomenclature, and several species were reported for the first time. The number of mollusc species attributed to the Pebas fauna has increased from around 50 to 156. The Pebas fauna is characterised as aquatic, endemic and extinct, and is a typical representative of a long-lived lake fauna. Fluvial taxa are not common, (marginal) marine taxa are rare. An additional molluscan fauna from the Miocene Solimões Formation of Brazil, containing 13 fresh water species was also described. The newly documented fauna was used to improve biostratigraphic framework of Miocene Amazonian deposits. Twelve mollusc zones were introduced, the upper eleven of which cover a time interval of approximately seven million years covered previously by only three pollen zones. An age model calculated for the borehole data indicates that the Pebas Formation was deposited between c. 24 and 11 Ma. The areal distribution of the outcropping mollusc zones uncovered a broad dome structure, termed here the Iquitos-Araracuara anteclise in the study area. The structure appears to have influenced river courses and also contributed to edaphic heterogeneity that may have been in part responsible for the current high biodiversity in the study area. The Pebas system was a huge system (> one million km2) dominated by relatively shallow lakes, but also containing swamps and rivers. The system was fed by rivers draining the emergent Andes in the west and lowlands and cratons to the east. The Pebas system was located at sea level and was open to marine settings through a northern portal running through the Llanos Basin and East Venezuela Basin towards the Caribbean. Cyclical baselevel changes possibly related to Mylankhovitch cycles, have been documented in depositional sequences of the Pebas Formation. The composition of the Pebasian mollusc fauna implies that the system was mostly a fresh water system. Such an interpretation is matched by strontium isotope ratios as well as very negative δ18O ratios found in the shells, but is at odds with oligohaline and mesohaline ichnofacies found in the same strata. The mollusc fauna of the Pebas Formation diversified through most of the existence of the lake system. The diversification was mostly the result of in-situ cladogenesis. The success of some of the Pebasian endemic clades is explained by adaptation to fresh water, low oxygen, common unconsolidated lake bottoms (soup grounds) as well as high predation intensity. Maximum diversity was reached at the base of the late Middle to early Late Miocene Grimsdalea pollen zone, some 13 Ma. At the time some 85 species co-occurred, 67 of which are considered as Pebasian endemics. A subsequent drop in species richness coincides with indications of elevated salinities, although a causal relation still needs to be established. Apparently the Pebas fauna went (almost) entirely extinct with the replacement of the lake system into a fluvio-tidal system during the Early Late Miocene, some 11 Ma.

The effect of pulp washing on bleaching efficiency

The main aim of this study was to inspect the influence of the ultrafiltration implementation on the washing and on bleaching efficiency. Four cases corresponding to four washing stages were observed: two with hardwood pulp and two with softwood pulp; each case had a reference and a trial experiment. The experiments with hardwood pulp were arranged in a manner to explore predominantly the possibility of bleaching performance improvement by applying for washing instead of untreated filtrate (reference case) the same treated one (trial case). Despite that the ultrafiltration reduced the COD of the wash filtrates allowing the decreasing of COD carry-over to the bleaching stage it didn’t affect the bleaching performance. Another set was used in the experiments with softwood pulp. It implied the ultrafiltration and recirculation of the filtrate to the same washing stage with the purpose to reduce the volumes and pollution of the bleaching effluents. In one case the negative result was obtained which was expressed by worse parameters of the pulp after bleaching. Another case showed the opportunity to replace hot water with the filtrate and reduce the fresh water consumption.

Nanosuodatuksen käyttö voimalaitoksen lisäveden valmistuksessa

Työssä selvitettiin nanosuodatuksen soveltuvuutta ja kannattavuutta voimalaitoksen lisäveden valmistuksessa. Kirjallisuusselvityksen ja nanosuodatuskokeiden tavoitteena oli arvioida nanosuodatukseen perustuvien lisäveden valmistusprosessien toiminnallista ja taloudellista kilpailukykyä perinteisiin prosesseihin verrattuna. Voimalaitoksen lisävedellä tarkoitetaan vesi-höyrykiertoon syötettävää vettä, joka korvaa kierrossa menetetyn veden. Nykyisin se valmistetaan vesijohto- tai pintavedestä käänteisosmoosiin ja ioninvaihtoon perustuvilla menetelmillä. Nanosuodatus on käänteisosmoosin tapaan kalvotekniikkaan perustuva erotusprosessi. Kaikki kalvot poistivat orgaanisen aineksen tehokkaasti (>90 %). Suolaretentioissa oli suuria eroja kalvojen välillä, vaikka kalvotoimittajien ilmoittamat retentiot olivat samaa tasoa. NF90-kalvo tuotti puhtainta permeaattia. Kahden kalvon (NF90 ja ESNA1-LF2) kohdalla havaittiin vuon alenemista, kun vuo oli kokeiden alussa noin 30 ja 40 L/m2/h. Likaantumisen merkkejä ei havaittu minkään kalvon kohdalla, kun vuoarvo oli maltillinen (n. 20 L/m2/h). Raakaveden vaikutus NF90-permeaatin laatuun oli vähäinen. Muilla kalvoilla raakaveden vaikutus permeaatin laatuun oli merkittävä. Investointi- ja käyttökustannusten perusteella nanosuodatukseen perustuvat lisäveden valmistusprosessit ovat kilpailukykyisiä nykyisiin lisäveden valmistusprosesseihin verrattuna. Pintavettä raakavetenä käyttävät nanosuodatusprosessit maksavat itsensä takaisin 3–5 vuodessa vesijohtovettä raakavetenä käyttävään käänteisosmoosiprosessiin verrattuna.

Electrocoagulation in the treatment of industrial waters and wastewaters

Chemical coagulation is commonly used in raw water and wastewater treatment plants for the destabilisation of pollutants so that they can be removed in the subsequent separation processes. The most commonly used coagulation chemicals are aluminium and iron metal salts. Electrocoagulation technology has also been proposed for the treatment of raw waters and wastewaters. With this technology, metal cations are produced on the electrodes via electrolysis and these cations form various hydroxides in the water depending on the water pH. In addition to this main reaction, several side reactions, such as hydrogen bubble formation and the reduction of metals on cathodes, also take place in the cell. In this research, the applications of electrocoagulation were investigated in raw water treatment and wastewater applications. The surface water used in this research contained high concentrations of natural organic matter (NOM). The effect of the main parameters – current density, initial pH, electric charge per volume, temperature and electrolysis cell construction – on NOM removal were investigated. In the wastewater treatment studies, the removal of malodorous sulphides and toxic compounds from the wastewaters and debarking effluents were studied. Also, the main parameters of the treatment, such as initial pH and current density, were investigated. Aluminium electrodes were selected for the raw water treatment, whereas wastewaters and debarking effluent were treated with iron electrodes. According to results of this study, aluminium is more suitable electrode material for electrocoagulation applications because it produces Al(III) species. Metal ions and hydroxides produced by iron electrodes are less effective in the destabilisation of pollutants because iron electrodes produce more soluble and less charged Fe(II) species. However, Fe(II) can be effective in some special applications, such as sulphide removal. The resulting metal concentration is the main parameter affecting destabilisation of pollutants. Current density, treatment time, temperature and electrolysis cell construction affect the dissolution of electrodes and hence also the removal of pollutants. However, it seems that these parameters have minimal significance in the destabilization of the pollutants besides this effect (in the studied range of parameters). Initial pH and final pH have an effect on the dissolution of electrodes, but they also define what aluminium or iron species are formed in the solution and have an effect on the ζ-potential of all charged species in the solution. According to the results of this study, destabilisation mechanisms of pollutants by electrocoagulation and chemical coagulation are similar. Optimum DOC removal and low residual aluminium can be obtained simultaneously with electrocoagulation, which may be a significant benefit of electrocoagulation in surface water treatment compared to chemical coagulation. Surface water treatment with electrocoagulation can produce high quality water, which could be used as potable water or fresh water for industrial applications. In wastewater treatment applications, electrocoagulation can be used to precipitate malodorous sulphides to prevent their release into air. Technology seems to be able to remove some toxic pollutants from wastewater and could be used as pretreatment prior to treatment at a biological wastewater treatment plant. However, a thorough economic and ecological comparison of chemical coagulation and electrocoagulation is recommended, because these methods seem to be similar in pollutant destabilisation mechanisms, metal consumption and removal efficiency in most applications.

Ultrafiltration of pulp mill bleaching effluents

Main objective of this research was to find suitable polymeric ultrafiltration membranes with high retentions, good capacities and low fouling tendencies for the E2- and EP-effluent ultrafiltration. Purpose was to treat alkaline bleaching effluents with ultrafiltration in a way that permeates of the filtrations could be recycled back to process and the consumption of fresh water in the pulp mill could be reduced significantly. In the theoretical part of this work the challenges set by the pulp and paper indus-try processes for membranes were examined. An overview of the membrane tech-nology in the pulp industry was also provided. In addition process conditions in the chemical pulp bleaching and properties of bleaching effluents were discussed in literature study. In experimental part the E2- and EP-stage bleaching effluents from Stora Enso Imatra kraft pulp mill were ultrafiltered with CR250- and CR200-filters. Suitable membranes for ultrafiltration were chosen after screening experiments. Concentra-tion experiment was made for the E2-effluent in order to estimate water saving potential. The E2-effluent was finally ultrafiltered in the pulp mill in order to test the feasibility of ultrafiltration in a real industrial environment. Good membrane for the EP-effluent ultrafiltration based on the EP-screening ex-periments was polyethersulfone membrane UP020 with cut-off value of 20 000 Da. Polysulfone membrane UFX05 with cut-off value of 5 000 Da was promising membrane for the ultrafiltration of the E2-effluent. Based on the concentration filtration of the E2-effluent with UFX05 membrane the water saving potential could be 2.2 m3/Adt for the industrial scale ultrafiltration process. Retention re-sults, such as average COD retention of 60 %, from the trial filtration at the pulp mill with UFX05 membrane were modest compared to the screening experiments, where average COD retention was 75 %. Therefore tighter ultrafiltration mem-branes should be tested for the ultrafiltration of the E2-effluent. The UP020 mem-brane seemed to be suitable for the ultrafiltration of the EP-effluent however con-centration and pilot scale ultrafiltration experiments are needed to verify this.

Talousveden tuotannon ja jakelun tietohuollon kehittäminen julkisomisteisessa vesilaitoksessa

Vesilaitokset kuluttavat merkittäviä määriä energiaa, johon on alettu kiinnittää huomiota viime vuosina. Energiatehokkuuden edistämisen hidasteeksi on noussut puutteellinen tietohuolto sekä vesilaitosten yhteisten tunnuslukujen ja kriteerien puuttuminen. Diplomityön tavoitteena on selvittää tietohuollon ongelmia Tampereen Vedellä. Työn tavoitteena on myös tutkia veden tuotannon ja jakelun energiatehokkaiden ohjaustapojen löytämistä tietohuollon ja tunnuslukujen avulla. Työssä käytetyt metodologiat ovat Tampereen Veden työntekijöiden haastattelut, prototyypin analysointi sekä vedenottamoiden ominaisenergiaan liittyvien mittauspisteiden läpikäynti. Diplomityön tuloksena saatiin laaja kuva Tampereen Veden tietohuoltoon liittyvistä ongelmista. Merkittävimmät tietohuollon haasteet liittyvät työntekijöihin, järjestelmiin sekä mittauspisteiden puuttumiseen. Mittauspisteet ja niiden tallentuminen ovat edellytys tunnuslukujen luomiselle. Tunnuslukuja voidaan hyödyntää energiatehokkaiden ohjaustapojen löytämiseksi, mutta vesilaitosten yhteiset kriteerit tunnusluvuille puuttuvat. Energiatehokkuustunnuslukuja on tarve tutkia lisää ja kehittää yhteistyötä vesilaitosten välillä tunnuslukujen luomiseksi sekä vertailutietojen saamiseksi.

Arseeni ja elohopea maaperässä ja vesistöissä

Maapallon väestön kasvaessa ja tarpeen makealle vedelle, ruualle ja viljelymaalle noustessa on tärkeää alkaa kiinnittää entistä tarkemmin huomiota vesistöjen ja maaperän saastumiseen myrkyllisillä raskasmetalleilla. Erityisesti elohopea ja arseeni, jotka jo nyt vaikuttavat heikentävästi miljoonien ihmisten elämään eri puolilla maapalloa, on syytä ottaa huolelliseen tarkkailuun. Raskasmetallien päästölähteet voidaan jakaa kahteen luokkaan, luonnollisiin ja ihmisperäisiin. Ihmisperäisiin päästölähteisiin voidaan vaikuttaa muun muassa teollisuutta ja liikennettä koskevalla lainsäädännöllä. Luonnollisiin päästölähteisiin vaikuttaminen on huomattavasti haastavampaa, mutta niiden haittaa ihmisille on mahdollista pienentää muun muassa parempien vedenpuhdistustekniikoiden avulla. Tämän työn kirjallisuusosassa tullaan esittelemään erityyppisiä luonnossa esiintyviä arseenin ja elohopean yhdisteitä, suurimpia arseenin ja elohopean päästölähteitä, sekä näiden raskasmetallien haitallisia terveysvaikutuksia. Kokeellisessa osassa tullaan keskittymään arseenin analysointiin nestemäisistä näytteistä. Näytteinä käytettiin tuntemattomilta kaatopaikoilta otettuja suotovesinäytteitä, sekä Pien-Saimaan pintavesinäytteitä. Analyyseihin on käytetty ICP-AES laitteistoa sekä kapillaarielektroforeesia.

Veden desinfiointi UV-LED-valolla

Veden riittämätön puhdistus aiheuttaa riskin veden käyttäjille. Miljoonia kuolemia vuosittain aiheuttavien vesiteitse leviävien sairauksien ehkäisemiseksi vaaditaan tehokkaita juomaveden desinfiointimenetelmiä. Kuivuuden ja väestönkasvun myötä veden tarve on lisääntynyt ja vedenkulutus tulee yhä kasvamaan. Tästä syystä mahdollisuus kierrättää vettä hyödyntäen sitä esimerkiksi kasteluun on saanut yhä enemmän huomiota. Kierrätettävä vesi on kuitenkin käsiteltävä huolellisesti sen sisältämän mikrobiologisen kontaminaatioriskin vuoksi. Ultraviolettisäteily luokitellaan fysikaaliseksi desinfiointimenetelmäksi. Sen tehokkuus perustuu mikro-organismien absorboimaan UV-säteilyyn, jonka aiheuttamien DNA:ssa tai RNA:ssa tapahtuvien muutoksien seurauksena mikro-organismi inaktivoituu ja estyy lisääntymästä. UV-desinfioinnissa on tyypillisesti käytetty elohopeahöyrylamppuja. Vaihtoehtoinen UV-säteilyn lähde ovat LEDit eli valoa emittoivat diodit. Matalapaine-elohopeahöyrylamppujen emittoima säteily on aallonpituudella 254 nm ja keskipaine-elohopeahöyrylamppujen emittoima säteily on laajakaistaista säteilyä. Energiatehokkuuden lisäksi LEDien etuna on, että niillä voidaan tuottaa kapeakaista säteilyä aallonpituudella, joka parhaiten absorboituu DNA:han. Tämän diplomityön tarkoituksena oli tutkia, onko UVC-alueen aallonpituuksien yhdistelmillä synergistisiä etuja LEDien desinfiointitehokkuuteen, kun desinfioidaan virtaavaa vettä useilla säteilyannoksilla ja indikaattorimikrobina käytetään kolibakteeria. Tavoitteena oli myös tutkia tällä hetkellä saatavissa olevien LEDien desinfiointitehokkuutta energiatehokkuuden näkökulmasta. Yksittäisistä aallonpituuksista desinfiointitehokkuudeltaan parhaimmaksi osoittautui 260 nm, aallonpituuksien yhdistelmistä tehokkain oli 265 nm:n ja 260 nm:n yhdistelmä. Muilla aallonpituuksien yhdistelmillä ei saavutettu odotettua parempaa desinfiointitehokkuutta. Optiselta teholtaan parhaimmat LEDit, 265 nm, 270 nm ja 275 nm olivat kokeiden perusteella myös energiatehokkuuden kannalta tarkasteltuina parhaimmat sekä yksittäin että yhdistelminä. UVC-aallonpituuksia emittoivien LEDien optisen tehokkuuden paraneminen on edellytys LEDien hyödyntämiselle desinfioinnissa.

Catalytic direct synthesis of hydrogen peroxide in a novel microstructured reactor

The direct synthesis from hydrogen and oxygen is a green alternative for production of hydrogen peroxide. However, this process suffers from two challenges. Firstly, mixtures of hydrogen and oxygen are explosive over a wide range of concentrations (4-94% H2 in O2). Secondly, the catalytic reaction of hydrogen and oxygen involves several reaction pathways, many of them resulting in water production and therfore decreasing selectivity. The present work deals with these two challenges. The safety problem was dealed by employing a novel microstructured reactor. Selectivity of the reaction was highly improved by development a set of new catalysts. The final goal was to develop an effective and safe continuous process for direct synthesis of hydrogen peroxide from H2 and O2. Activated carbon cloth and Sibunit were examined as the catalysts’ supports. Palladium and gold monometallic and palladium-gold bimetallic catalysts were thoroughly investigated by numerous kinetic experiments performed in a tailored batch reactor and several catalyst charachterization methods. A complete set of data for direct synthesis of H2O2 and its catalytic decomposition and hydrogenation was obtained. These data were used to assess factors influencing selectivity and activity of the catalysts in direct synthesis of H2O2 as well as its decomposition and hydrogenation. A novel microstructured reactor was developed based on hydrodynamics and mass transfer studies in prototype microstractural plates. The shape and the size of the structural elements in the microreactor plate were optimized in a way to get high gas-liquid interfacial area and gas-liquid mass transfer. Finally, empirical correlations for the volumetric mass transfer coefficient were derived. A bench-scale continuous process was developed by using the novel microstructral plate reactor. A series of kinetic experiments were performed to investigate the effects of the gas and the liquid feed rates and their ratio, the amount of the catalyst, the gas feed composition and pressure on the final rate of H2O2 production and selectivity.

Kartoitus kloori-alkalitehtaan tuotantokapasiteetin kasvattamisesta / Kemira Chemicals Oy Joutseno

Kemira Chemicals Oy:n Joutsenon kloori-alkalitehtaalla valmistetaan elektrolyysin avulla lipeää, suolahappoa, natriumhypokloriittia ja vetyä. Tämän työn tavoitteena on kartoittaa kloori-alkalitehtaan tuotantokapasiteetin kasvatuksen yhteydessä esiin tulevat pullonkaulat, lähitulevaisuuden kunnossapitotarpeet sekä parhaat käytettävissä olevat teknologiavaihtoehdot kloori-alkalitehtaan osa-alueille, joihin tuotantokapasiteetin kasvatuspaineet kohdistuvat: elektrolyysi, lipeän haihdutus ja suolahappopolttimet. Pullonkaulojen kartoittaminen toteutettiin rakentamalla taulukkolaskentamalli kloori-alkalitehtaan prosesseista. Mallin avulla simuloitiin elektrolyysin kloorin tuotantoa, jota kasvatettiin asteittain 54 kt:sta/a aina 100 kt:iin/a asti ja tutkittiin prosessien käyttäytymistä. Tarkastelun pohjalta havaittiin, että kloorin tuotantoa kasvattaessa, tulee lisätä myös tuotantokapasiteettia suolahapon valmistukseen, elektrolyysiin, demineralisoidun veden valmistukseen ja lipeän haihdutuslaitokseen sekä suolahapon ja lipeän varastointikapasiteetteihin. Vaihtoehtoiset teknologiat määritettiin kirjallisuudesta ja laitetoimittajien esitteistä. Lähivuosien kunnossapitotarpeet kartoitettiin haastattelemalla tehtaan henkilökuntaa. Työstä eskaloitui useita jatkotutkimuskohteita, joita ovat bipolaari-teknologian soveltuvuus Joutsenon kloori-alkalitehtaalle, uusien HCl-polttimien esisuunnittelu, höyryn käytön tehostaminen nykyisessä lipeän haihdutuslaitoksessa sekä uusien haihdutusteknologioiden soveltuvuus Joutsenon kloori-alkalitehtaalle, höyry- ja jäähdytysverkostojen kartoitukset sekä demineralisoidun veden valmistuskapasiteetin kasvattaminen.