Design, Modelling, and Feasibility Evaluation of Heat-Assisted Falling-Film Evaporation Reactor for Pre-Concentration of Mine Leachate and Saline Water

Mine leachate and saline industrial wastewater streams are often treated as liabilities to be remediated or disposed of. These flows often contain substantial water and dissolved mineral resources that can be reclaimed. In this work, a waste-heat-assisted falling-film evaporation reactor was developed and assessed for application as a pre-concentration step before water and mineral recovery processes. Two case studies were considered: synthetic saline wastewater containing 80 g/L Na2SO4 and 70 g/L NaCl for salt recovery, and iron-rich mine water containing approximately 4000 mg/L Fe2+, 95 mg/L Fe3+, and 13,000 mg/L acidity as CaCO3 for downstream pigment and magnetite recovery. Saline water or mine leachate flows down a bank of vertical conduit pipes as a thin film while air flows through the pipe cores. Heat is transferred to the system from industrial waste gas externally. Psychrometric relationships, heat transfer, energy balances, and techno-economic analysis were used to assess the impact of air temperature, conduit diameter, column height, pipe material, and waste-gas temperature on overall reactor performance. Experiments were carried out to confirm expected psychrometric operation and establish appropriate operating temperatures while confirming the impact of conduit geometry on heat-transfer characteristics. A benchmark case of design evaporation rate equal to 100 L/h was chosen for comparison of all tests. Dry air operation was shown to be technically possible but severely limited by the moisture capacity of air; at 26 °C and 101.3 kPa, approximately 205,000 m3/h of air was required. When using industrial waste heat, the operation changed from psychrometric/mass-transfer-limited to heat-transfer-controlled. Using waste gas entering at 144 °C and exiting at 80 °C reduced airflow requirements to approximately 880 m3/h, allowing a much more compact reactor design with approximately 635 (12 mm diameter) conduit pipes. Relative to the 40 °C air benchmark, electrical power was reduced from approximately 24.7 kW to 2.9 kW, and screening-level reactor cost by ~84%. Findings demonstrated that appropriate waste heat enables the application of evaporation if there is sufficient local heat flux. Smaller conduit diameters, sufficient column height, and greater waste-gas inlet temperatures were all beneficial. Choice of material required trade-offs between heat-transfer coefficient, corrosion, and material cost.