Spent Caustics Treatment

Caustics are widely used in petroleum refineries. Typical uses are to neutralize and to extract acidic materials that may occur naturally in crude oil, acidic reaction products that may be produced by various chemical treating processes, and acidic materials formed during thermal and catalytic cracking such as H2S, phenolics, and organic acids.

Spent caustics may therefore contain sulfides, mercaptides, sulfates, sulfonates, phenolates, naphthenates, and other similar organic and inorganic compounds [38]. Spent caustics can also be classified as phenolic and sulfidic [37]. Sulfidic spent caustics are rich in sulfides, contain no phenols, and can be oxidized with air. Phenolic spent caustics are rich in phenols and must be neutralized with acid to release and remove the phenols.

At least four companies process spent caustics to market the phenolics and the sodium hyposulfite. However, the market is limited and most of the spent caustics are very dilute, so the cost of shipping the water makes this operation uneconomic. Concentration can be increased by recycling spent caustics at the treater or recycling the spent caustics found in the water bottoms of intermediate product tanks [39].

Some refineries neutralize the caustic with spent sulfuric acid from other refining processes, and charge it to the sour water stripper. This removes the H2S. The bottoms from the sour water stripper go to the desalter, where the phenolics can be extracted by the crude oil.

Spent caustics usually originate as batch dumps, and the batches may be combined and equalized before being treated and discharged to the refinery sewer. Spent caustics can also be neutralized with flue gas to form carbonates. Sulfides, mercaptides, phenolates, and other basic salts are converted by the flue gas (reaction time 16-24 hours) stripping. Phenols can be removed, then used as a fuel or sold. H2S and mercaptans are usually stripped and burned in a heater. Some sulfur is recovered from stripper gases. The treated solution contains mixtures of carbonates, sulfates, sulfites, thiosulfates, and some phenolic compounds.

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