PeroxideTriangleDiagrams TAPPI
PeroxideTriangleDiagrams TAPPI
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ABSTRACT: When hydrogen peroxide is mixed with caustic soda, an auto-accelerating reaction can lead to gen-
eration of significant amounts of heat and oxygen. On the basis of experiments using typical pulp mill process con-
centration and temperatures, a relatively simple kinetic model has been developed. Evaluation of these model
results reveals that hydrogen peroxide-caustic soda systems are extremely sensitive to hydrogen peroxide:caustic
soda ratio, transition metal contamination, and temperature. Small changes in initial conditions can result in a closed
system becoming explosive. Analysis of model results was used to develop guidelines for safer application of hydro-
gen peroxide in a mill setting.
Application: Because peroxide at 10% cannot generate an explosive mixture with sodium hydroxide, mills that
either install new or retrofit bleaching systems should consider installing a dilution system that will take the peroxide
from the storage concentration of 50% to 10% before introduction into the mixer.
H ydrogen peroxide is an environmentally compatible ready source of oxygen; thus, typical extinguishing technol-
bleaching chemical that has been employed in kraft ogy that uses exclusion of oxygen as a mode of action (e.g.,
mills for many years. As part of a bleaching sequence, foams or dry powders) is much less effective.
hydrogen peroxide brightens and provides brightness Runaway decomposition of hydrogen peroxide has result-
stabilization, if used as the last stage in a multistage bleach ed in catastrophic events in several mills over the last 15 years.
plant [1–4]. Because hydrogen peroxide bleaching does Two bleach plants experienced pump explosions when hy-
not delignify fibers, it does not produce as many soluble drogen peroxide came into contact with caustic soda (NaOH)
by-products as other popular bleaching chemicals; thus, it in the absence of pulp and resulted in serious injuries [12,13].
can reduce organic load to wastewater treatment plants. Both mills had been using 50%-concentration hydrogen per-
Hydrogen peroxide is delivered to pulp mills via tank oxide without incident for several years.
truck or railcar. Truck deliveries are near 50% con- Other incidents, one in Europe and one in North
centration [5]. Railcar deliveries may be either at America, resulted from rapid decomposition with-
TAPPI
50% or 70% concentration. If a mill receives hy- in a storage tank when an organic chelant was
PEERS 2012
drogen peroxide deliveries at 70% concentra- mistakenly mixed with hydrogen peroxide
tion, it is routinely diluted to 50% concentration Honorable [8,14]. In those cases, the explosions were like-
as it is unloaded. Thus, industrial-strength hy- Mention ly caused by a combination of alkaline-catalyzed
drogen peroxide employed in kraft pulp bleach- decomposition and rapid oxidation of an organic
ing is generally near 50% concentration. chemical.
Under proper storage conditions, hydrogen perox- Alkali-catalyzed decomposition of hydrogen per-
ide decomposes at a rate of about 1% per year [6]. oxide follows second-order reaction kinetics, as
Traces of transition metals (e.g., iron, copper, and shown in Eq. (1) [15]. The rate of decomposition
manganese) increase hydrogen peroxide decompo- depends on the concentration of both hydrogen
sition [7], and suppliers add stabilizers to sequester these metals. peroxide (HOOH) and its conjugate base (HOO-):
Fifty-percent-concentration hydrogen peroxide solutions repre-
sent major safety hazards, such as skin burns; eye injuries; po- dP/dt = –2k (HOOH) (HOO–) (1)
tential for rapid pressurization within tanks, pipes, pumps, and/
or storage vessels; potential for fire due to formation of oxygen In Eq. (1), P is total hydrogen peroxide concentration (i.e.,
during decomposition; hydrogen peroxide-organic vapor phase P = [HOOH] + [HOO-]) and t is time. Note that the 2 is due to
explosions; and runaway decomposition [8–11]. the consumption of two moles of hydrogen peroxide for every
During startup conditions, fires resulting from the reaction mole of reaction. Makkonen reported an apparent rate of
of hydrogen peroxide with partially dried pulp on standpipe 8 × 10–3 L/mol/s at 45°C [14]. The apparent rate follows the Ar-
walls have been reported. Industrial-strength hydrogen per- rhenius theory with an activation energy of 54.8 kJ/mol [15].
oxide fires are extremely dangerous because they provide a Because the decomposition from alkaline catalysis cannot be
JULY 2013 | VOL. 12 NO. 7 | TAPPI JOURNAL 59
BLEACHING
completely separated from decomposition due to trace transi- Hg Cell Membrane ET
tion metals [16], the interpretation of these data is difficult. As
examples, Makkonen measured slower decomposition rates NaCl <10 ppm <30 ppm 1.0 wt%
for reactions stabilized with magnesium or silicate [15], and
NaClO3 0.5 ppm 3 ppm 0.15%
Galbacs and Csanyi reported rates as low as 10–6 L/mol/s using
extreme methods to minimize inorganic contamination [16]. Na2CO3 0.02 wt% 0.03 wt% 0.1 wt%
The net reaction for hydroxide ion–catalyzed decomposi-
Na2SO4 10 ppm 15 ppm 0.01 wt%
tions produces two moles of water and one mole of oxygen for
every two moles of hydrogen peroxide, shown as Eqs. (2)-(4): Iron <1 ppm 1–5ppm 5–10 ppm
Calorimeter experiments
Experiments similar to the visual experiments were conduct-
ed with commercial-grade 48 wt % hydrogen peroxide, but
the stainless steel beaker was replaced with a glass vacuum
dewar to reduce the heat loss and reactions caused by the
stainless-steel container. A Teflon-coated, motor-driven stirrer
operating at 100 rpm was used to ensure complete and rapid
mixing. The three grades of caustic soda were used after dilu-
tion to 25% concentration with deionized water. For each ex-
periment a measured amount of hydrogen peroxide, approx-
imately 200 g, was mixed with various amounts of diluted
caustic soda, 35–85 g. Temperature data were collected at
approximately 8 Hz with the same computer system described
previously.
4. Initial rate at 50°C for various mixtures of hydrogen peroxide
RESULTS and caustic soda.
Calorimetric experiments were performed at various ratios of
hydrogen peroxide-to-caustic soda concentrations. Typical The results of the model can be used to estimate the initial
data are shown in Fig. 3. While the concentrations were reaction rate at 50°C due to both the alkali- and iron-catalyzed
similar, the temperature rises appear to occur at different reactions. The differences among the various grades of caustic
rates, with the caustic containing the highest iron concentra- soda become apparent. Inspection of Fig. 4 shows that for
tion (ET) being the fastest. Hg-cell caustic soda, approximately 70% of the initial rate is
The results from 21 similar trials were used to estimate the due to the alkali-catalyzed mechanism. For ET-grade caustic
rate constants for alkali- and iron-catalyzed decomposition. soda, the iron-catalyzed pathway dominates.
The rate equations were integrated using a fifth-order Runge- In a triangle diagram, Figs. 5–7, all possible compositions
Kutta method implemented in Microsoft Excel. Two parallel of a three-component mixture can be represented. Each ver-
reactions with different activation energies were assumed, and tex represents a different pure component. For example, pro-
the Solver function in Excel was used to optimize the kinetic gressing left to right along the base represents a progression
parameter values to minimize the squared error between the from pure water to pure hydrogen peroxide, with the mid-
model and the data for all the experiments at the same time. A point representing a 50:50 mixture. Because the kinetic pa-
single set of kinetic parameters was able to fit the data set span- rameters for the two reactions were estimated from the calo-
ning all 21 experiments, a total of 7500 temperature measure- rimetric experiments and the iron concentration is known, it
ments, with an average error of 0.5°C. The best fit of the data was possible to determine the time for a reaction mixture,
was obtained when the activation energies of the alkali- and with a particular composition, to reach 100°C. The results of
iron-catalyzed decomposition were set to 108 and 51.7 kJ/mol, this calculation, assuming an initial temperature of 50°C, are
respectively. The model also accounted for the heat carried represented as time contours on triangle diagrams (Figs. 5–7).
away by the evaporation of water from the mixture. For example, Fig. 5 shows that compositions enclosed by the
62 TAPPI JOURNAL | VOL. 12 NO. 7 | JULY 2013
BLEACHING
5. Reaction model results for mercury-cell grade caustic soda. 7. Reaction model results for ET-grade caustic soda. For a
For a mixture starting at 50°C, the contours represent the time mixture starting at 50°C, the contours represent the time
required to reach 100°C. The blue line represents the operating required to reach 100°C. The blue line represents the operating
line for typical mill operation. The pink line is our proposed line for typical mill operation. The pink line is our proposed
safer operating line. Graph axes are explained in the text. safer operating line. Graph axes are explained in the text.