Implementing a one-dimensional quick model for dynamic simulation and economic analysis of a forced circulation crystallizer

Forced circulation crystallizer is one of the main contributors in Zero Liquid Discharge wastewater treatment processes. This technology enables the extraction of pure water from wastewater and separates impurities in the form of crystals. In the present study, a fast one-dimensional (nodal) model with high accuracy is introduced to predict the dynamic performance of the crystallization process in an FC crystallizer. Besides, to design and optimize a crystallizer, the parameters affecting the system performance should be evaluated from thermodynamic and economic perspectives. For this purpose, the developed model is used to investigate the crystallizer thermo-economic performance. Results show that the performance of the crystallizer system has the most significant sensitivity to varying the inlet feed concentration, suspension concentration, and rotational speed of the circulation pump. Increasing the suspension concentration reduces the mean diameter of output crystals. Also, increasing the pump rotational speed by about two times decreases the mean size of output crystals by approximately 41.39 %. From an economic point of view, increasing the heat input has a significant effect on the reduction of the dynamic payback period. Also, increasing the inlet feed concentration by 36 % leads to a 7.84 % increase in the internal rate of return. •A fast one-dimensional model with high accuracy is introduced.•Thermo-economic performance of FC crystallizer is investigated.•The results of zero- and one-dimensional modeling are highly close to each other.•Mixing zone has significant role in the crystallization process.•Increasing the inlet feed concentration by 36 % leads to a 7.84 % increase in the IRR.