Oil-containing waste catalyst gasification and deoiling roasting method and device

Abstract

This invention relates to a method and apparatus for the gasification, deoiling, and roasting of oil-containing waste catalysts in the field of hazardous waste disposal and utilization technology. The apparatus includes a fluidized bed gasifier, a secondary combustion chamber, a rotary kiln, an ignition burner, a supplementary combustion burner, a deoiled material conveying device, a mixing and feeding device, a waste heat boiler, an air preheating device, a blower, a quench tower, a dust collector, a deacidification tower, a flue gas reheater, an induced draft fan, a chimney, and a flue gas recirculation fan. This invention belongs to a pyrometallurgical process for the disposal and utilization of oil-containing waste catalysts. Through the method described in this invention, oil-containing waste catalysts are deoiled in a fluidized bed gasifier to produce combustible gas and deoiled material. The heat generated after the combustible gas is fully combusted in the secondary combustion chamber enters the rotary kiln to roast the mixture of the deoiled material and alkaline materials, generating sodium-based material. The subsequent treatment process of the sodium-based material discharged from the rotary kiln is not within the scope of this invention. The flue gas discharged from the rotary kiln undergoes purification treatment such as dust removal and acid removal in subsequent flue gas treatment processes, thereby achieving ultra-low emission standards. This invention achieves efficient recovery and utilization of precious metals from waste catalysts using a low-cost, low-energy pyrometallurgical process.

Description

Technical Field

[0001] This invention relates to the field of hazardous waste disposal and utilization technology, and in particular to a method and apparatus for gasification, deoiling, and roasting of oil-containing waste catalysts. Background Technology

[0002] Waste catalysts generated during the hydrorefining of petroleum products are classified as hazardous waste. They contain a high proportion of oil and components such as carbon, hydrogen, and sulfur. Oil-containing waste catalysts may contain carcinogenic substances such as benzene and polycyclic aromatic hydrocarbons; they also contain heavy metals such as nickel, molybdenum, and cobalt, which can pollute the environment if leached in water; they also contain some metals in the form of active sulfides, which may spontaneously combust upon contact with air, releasing toxic hydrogen sulfide gas; and nitride coke deposited on the catalyst can generate and release toxic HCN gas under certain conditions.

[0003] The disposal of these spent catalysts requires scientific methods and the recycling of metals to ensure environmental safety and human health. During disposal and comprehensive utilization, oil-containing spent catalysts must first undergo deoiling treatment to facilitate subsequent oxidation roasting.

[0004] Therefore, there is an urgent need in the market for a technical solution that can effectively remove oil, reduce energy consumption, reduce carbon emissions, and lower operating and maintenance costs while ensuring the recycling and reuse of waste catalysts. Summary of the Invention

[0005] To address the aforementioned technical problems, this invention discloses a method and apparatus for gasifying, de-oiling, and roasting oil-containing waste catalyst. In this invention, the oil-containing waste catalyst is de-oiled in a fluidized bed gasifier to produce combustible gas and de-oiled material. The heat generated after the combustible gas is fully combusted in the secondary combustion chamber enters a rotary kiln to roast the mixture of the de-oiled material and alkaline materials, generating sodium-based material. The flue gas discharged from the rotary kiln undergoes subsequent flue gas treatment processes, including dust removal and acid removal, to achieve ultra-low emission standards. The technical solution of this invention is implemented as follows: A method and apparatus for gasifying, de-oiling, and roasting oily waste catalysts, the apparatus comprising a fluidized bed gasifier, a secondary combustion chamber, a rotary kiln, an ignition burner, a supplementary combustion burner, a de-oiling material conveying device, a mixing and feeding device, a waste heat boiler, an air preheating device, a blower, a quench tower, a dust collector, a deacidification tower, a flue gas reheater, an induced draft fan, a chimney, and a flue gas recirculation fan.

[0006] One outlet of the fluidized bed gasifier is connected to the secondary combustion chamber, which is connected to the rotary kiln. One outlet of the rotary kiln is connected to the waste heat boiler. The ignition burner is installed at the bottom of the fluidized bed gasifier, and the supplementary combustion burner is installed in the secondary combustion chamber. The material outlet at the bottom of the fluidized bed gasifier is connected to the deoiling material conveying device. The mixing feed device is connected to the deoiling material conveying device and mixes the deoiling material discharged from the fluidized bed gasifier with alkaline materials before conveying it into the rotary kiln. The air preheating... The inlet of the device is connected to the outlet of the waste heat boiler. The outlet of the blower is connected to the air-side inlet of the air preheating device through a duct. The flue gas-side outlet of the air preheating device is connected in sequence to the quench tower, the dust collector, the acid removal tower, the flue gas reheater, the induced draft fan, and the chimney through a flue. The flue gas recirculation fan is connected to the outlet flue of the dust collector and the lower air inlet of the fluidized bed gasifier to extract a portion of the recirculated flue gas and send it back into the fluidized bed gasifier.

[0007] The feed inlet of the fluidized bed gasifier is the inlet of oil-containing waste catalyst, which serves as the bed material for fluidization.

[0008] The ignition burner heats the bed material of the fluidized bed gasifier to 650-750℃. The oil and carbon, hydrogen, sulfur and other compound components carried by the oily waste catalyst are ignited. In the oxygen-deficient environment of the fluidized bed gasifier where the primary air excess air coefficient is less than 1.0, incomplete combustion produces combustible gases such as CO. The combustible gases are discharged from the top of the fluidized bed gasifier to the secondary combustion chamber.

[0009] The fuel is re-ignited in the secondary combustion chamber by the secondary combustion burner, and the combustible gas is completely burned with the assistance of secondary air. The heat generated by the combustion is used to roast the waste catalyst deoiling material and alkaline materials in the rotary kiln to generate sodium-based materials.

[0010] Preferably, the alkaline material can be sodium carbonate or hazardous waste alkali residue.

[0011] Preferably, the fuel for the fluidized bed gasifier and the secondary combustion chamber is selected from one of the following: natural gas, coal gas, pulverized coal, fuel oil, biomass fuel, or other combustibles with a calorific value of 3000 kcal / kg or higher.

[0012] Preferably, the deoiled material conveying device includes a material cooling function.

[0013] Preferably, the waste heat boiler may be equipped with SNCR ammonia liquid nozzles in the flue according to the content of nitrogen oxides (NOx) in the flue gas composition.

[0014] Preferably, the air preheating device can be divided into multiple stages, including a high-temperature air preheater and a low-temperature air preheater.

[0015] The inlet of the air preheating device is connected to the outlet of the waste heat boiler, the outlet of the blower is connected to the air-side inlet of the air preheating device through a duct, and the flue gas-side outlet of the air preheating device is connected in sequence to the quench tower, the dust collector, the acid removal tower, the flue gas reheater, the induced draft fan and the chimney through a flue.

[0016] Preferably, the hot air discharged from the hot air outlet of the air preheating device is sent into the fluidized bed gasifier as primary air and into the secondary combustion chamber as secondary air.

[0017] Preferably, the flue gas recirculation fan is connected to the dust collector outlet flue and the lower air inlet of the fluidized bed gasifier. The flue gas recirculation fan draws a portion of the recirculated flue gas from the dust collector outlet flue and sends it back into the fluidized bed gasifier.

[0018] A method for gasifying and de-oiling roasting of oil-containing waste catalyst, using an oil-containing waste catalyst gasification and de-oiling roasting device, includes the following steps: S1, oil-containing waste catalyst is fed into the fluidized bed gasifier from the feed inlet, and the waste catalyst serves as the bed material for fluidization; S2, the ignition burner heats the bed material temperature of the fluidized bed gasifier to 650-750℃, and the oil and carbon, hydrogen, sulfur and other compound components carried by the oil-containing waste catalyst are ignited. In the oxygen-deficient environment of the fluidized bed gasifier where the primary air excess air coefficient is less than 1.0, incomplete combustion produces combustible gases such as CO. The combustible gases are discharged from the top of the fluidized bed gasifier to the secondary combustion chamber. S3, the oil-containing waste catalyst becomes de-oiled material and is discharged from the bottom of the fluidized bed gasifier. It is then fed into the mixing and feeding device via the de-oiled material conveying device. After being mixed with alkaline materials in the mixing and feeding device, it is fed into the rotary kiln. S4, a portion of supplementary combustion fuel is introduced into the supplementary combustion burner, and the combustible gas is completely burned with the assistance of secondary air. The heat generated by combustion is used to roast the deoiled waste catalyst and alkaline materials in the rotary kiln to generate sodium-based materials. The sodium-based materials are sent to subsequent processing processes, which are not within the scope of this invention patent. S5, Waste heat recovery and flue gas treatment: S5.1, the high-temperature flue gas from the rotary kiln outlet enters the waste heat boiler to recover a portion of the waste heat. S5.2, the flue gas from the outlet of the waste heat boiler enters the air preheating device to recover part of the waste heat, and the discharged hot air is sent into the fluidized bed gasifier as primary air and into the secondary combustion chamber as secondary air. S5.3, the flue gas with reduced temperature enters the quench tower for temperature regulation, and the flue gas temperature at the outlet of the quench tower should be within the allowable range of the dust collector. S5.4, the flue gas from the outlet of the quench tower enters the dust collector for dust removal treatment; S5.5, the flue gas recirculation fan draws a portion of the recirculated flue gas from the dust collector outlet flue and sends it back into the fluidized bed gasifier. S5.6, the remaining flue gas in the dust collector outlet flue enters the acid removal tower for acid removal treatment after passing through the flue gas reheater; S5.7 The flue gas, after acid removal treatment, is discharged sequentially through the flue gas reheater, induced draft fan and chimney.

[0019] The hazardous waste treated by this invention has a wide range of applications. It can not only achieve the deoiling and roasting of oily waste catalysts with low energy consumption and low carbon emissions, but also co-process industrial hazardous waste with a certain calorific value, and industrial waste liquid with a high or low calorific value.

[0020] The wastes treated by this invention include, but are not limited to, hazardous wastes with flammability (I) or toxicity (T), corrosivity (C), reactivity (R) and infectivity (In) generated by specific or non-specific industries as listed in the National Hazardous Waste List. Attached Figure Description

[0021] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only one embodiment of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0022] Identical parts are indicated by the same reference numerals. It should be noted that the terms "front," "rear," "left," "right," "up," and "down" used in the following description refer to directions in the accompanying drawings, while the terms "bottom surface," "top surface," "inner," and "outer" refer to directions toward or away from the geometric center of a specific part, respectively.

[0023] Figure 1 This is a simplified process flow diagram of an embodiment of a gasification deoiling and roasting method and apparatus for oil-containing waste catalysts.

[0024] In the above figures, the figure numbers indicate the following: 1-Fluidized Bed Gasifier 2-Ignition burner 3-Mixed Feeding Device 4-Secondary Combustion Chamber 5-Afterburner 6-Rotary Kiln 7- Waste Heat Boiler 8-Air preheating device 9-Blower 10-Quick cooling tower 11-Dust Collector 12-Flue Gas Reheater 13-Acid Removal Tower 14-Exhaust fan 15-Chimney 16-Oil removal conveying device 17- Flue Gas Recirculation Fan 41-Oil-containing waste catalyst 42-Oil-free feed 43-Alkaline materials 44-Sodium compound 45-Combustible Gas 46-Ignition Fuel 47-Refueling 48-A First Wind 49-Secondary wind 50-Recirculated Flue Gas 51-Hot air. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example

[0026] In one specific embodiment, such as Figure 1 As shown, a method and apparatus for gasification, deoiling, and roasting of oily waste catalysts are disclosed. The apparatus includes a fluidized bed gasifier 1, a secondary combustion chamber 4, a rotary kiln 6, an ignition burner 2, a supplementary combustion burner 5, a deoiled material conveying device 16, a mixing and feeding device 3, a waste heat boiler 7, an air preheating device 8, a blower 9, a quench tower 10, a dust collector 11, a deacidification tower 13, a flue gas reheater 12, an induced draft fan 14, a chimney 15, and a flue gas recirculation fan 17.

[0027] One outlet of the fluidized bed gasifier 1 is connected to the secondary combustion chamber 4, which is connected to the rotary kiln 6. One outlet of the rotary kiln 6 is connected to the waste heat boiler 7. The ignition burner 2 is installed at the lower part of the fluidized bed gasifier 1, and the supplementary combustion burner 5 is installed at the secondary combustion chamber 4. The material discharge port at the lower part of the fluidized bed gasifier 1 is connected to the deoiling material conveying device 16. The mixing feed device 3 is connected to the deoiling material conveying device 16 and mixes the deoiling material 42 discharged from the fluidized bed gasifier 1 with the alkaline material 43 before conveying it into the rotary kiln 6. The air preheating device... The inlet of the device 8 is connected to the outlet of the waste heat boiler 7. The outlet of the blower 9 is connected to the air-side inlet of the air preheating device 8 through a duct. The flue gas-side outlet of the air preheating device 8 is connected in sequence to the quench tower 10, the dust collector 11, the acid removal tower 13, the flue gas reheater 12, the induced draft fan 14, and the chimney 15 through a flue. The flue gas recirculation fan 17 connects the outlet flue of the dust collector 11 to the lower air inlet of the fluidized bed gasifier 1 to extract a portion of the recirculated flue gas 50 and send it back into the fluidized bed gasifier 1.

[0028] Oily waste catalyst 41 is de-oiled in fluidized bed gasifier 1 to produce combustible gas 45 and de-oiled material 42. The heat generated by the complete combustion of combustible gas 45 in secondary combustion chamber 4 enters rotary kiln 6 to achieve the roasting process of the mixture of de-oiled material 42 and alkaline material 43 to generate sodium-based material 44.

[0029] In this embodiment, the fuel for the ignition burner 2 and the afterburner 5 is selected from one of the following: natural gas, coal gas, pulverized coal, fuel oil, biomass fuel, or other combustibles with a calorific value of 3000 kcal / kg or higher.

[0030] In this embodiment, the air preheating device 8 recovers the waste heat of the flue gas to heat the air. The hot air 51 is sent into the fluidized bed gasifier 1 as primary air 48 and into the secondary combustion chamber 4 as secondary air 49.

[0031] In this embodiment, the acid removal tower 13 can more efficiently remove acidic substances or any residual ammonia from the flue gas.

[0032] In this embodiment, the waste heat boiler 7 and the air preheating device 8 work together to recover the heat from the flue gas discharged from the rotary kiln 6, thereby generating steam and hot air.

[0033] In a preferred embodiment, the flue gas reheater 12 is connected to the dust collector 11. This embodiment utilizes the heat from the flue gas at the outlet of the dust collector 11 to heat the flue gas at the outlet of the acid removal tower 13, thereby improving the efficiency of waste heat recovery and utilization.

[0034] The steps of the gasification deoiling and roasting method for oil-containing waste catalyst using the system in this embodiment are as follows: S1, the oil-containing waste catalyst 41 is fed into the fluidized bed gasifier 1 from the feed inlet, and the waste catalyst serves as the bed material for fluidization; S2, the ignition burner 2 uses ignition fuel 46 to heat the bed material temperature of the fluidized bed gasifier 1 to 650-750℃. The oil and carbon, hydrogen, sulfur and other compound components carried by the oil-containing waste catalyst 41 are ignited. In the oxygen-deficient environment where the excess air coefficient of the primary air 48 of the fluidized bed gasifier 1 is less than 1.0, incomplete combustion produces combustible gas 45 such as CO. The combustible gas 45 is discharged from the top of the fluidized bed gasifier 1 to the secondary combustion chamber 4. S3, the oily waste catalyst 41 becomes deoiled material 42 and is discharged from the bottom of the fluidized bed gasifier 1. It is then fed into the mixing and feeding device 3 via the deoiled material conveying device 16. After being mixed with alkaline material 43 in the mixing and feeding device 3, it is fed into the rotary kiln 6. S4, a portion of supplementary combustion fuel 47 is introduced into the supplementary combustion burner 5, and the combustible gas 45 is completely burned with the assistance of secondary air 49. The heat generated by combustion is used in the rotary kiln 6 to roast the waste catalyst deoiled material 42 and alkaline material 43 to generate sodium-based material 44. Sodium-based material 44 is sent to subsequent processing processes, which are not within the scope of this invention patent. S5, Waste heat recovery and flue gas treatment: S5.1, the high-temperature flue gas from the outlet of rotary kiln 6 enters waste heat boiler 7 to recover a portion of the waste heat. S5.2, the flue gas from the outlet of the waste heat boiler 7 enters the air preheating device 8 to recover part of the waste heat, and the discharged hot air 51 is sent into the fluidized bed gasifier 1 as primary air 48 and into the secondary combustion chamber 4 as secondary air 49. S5.3, the flue gas with reduced temperature enters the quench tower 10 for temperature regulation, and the flue gas temperature at the outlet of the quench tower 10 should be within the allowable range of the dust collector 11. S5.4, the flue gas from the outlet of the quench tower 10 enters the dust collector 11 for dust removal treatment; S5.5, the flue gas recirculation fan 17 draws a portion of the recirculated flue gas 50 from the outlet flue of the dust collector 11 and sends it back into the fluidized bed gasifier 1; S5.6, the remaining flue gas in the outlet flue of the dust collector 11 enters the acid removal tower 13 for acid removal treatment after passing through the flue gas reheater 12. S5.7 The flue gas, after acid removal treatment, is discharged sequentially through the flue gas reheater 12, the induced draft fan 14 and the chimney 15.

[0035] In this embodiment, the oil-containing waste catalyst 41 is de-oiled in a fluidized bed gasifier 1 to produce combustible gas 45 and de-oiled material 42. The heat generated after the combustible gas 45 is fully combusted in the secondary combustion chamber 4 enters a rotary kiln 6 to calcine the mixture of its own de-oiled material 42 and alkaline material 43, generating sodium-based material 44. The flue gas discharged from the rotary kiln 6 undergoes subsequent flue gas treatment processes such as dust removal and acid removal for purification, thereby achieving ultra-low emission standards.

[0036] It should be noted that the above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method and apparatus for devolatilization of an oil-containing spent catalyst by gasification and calcination, characterized in that, The fluidized bed gasifier, the secondary combustion chamber, the rotary kiln, the ignition burner, the supplementary combustion burner, the oil-removed material conveying device, the mixed feed device, the waste heat boiler, the air preheating device, the air blower, the quenching tower, the dust collector, the acid removal tower, the flue gas reheater, the induced draft fan, the chimney, and the flue gas recirculation fan; One of the outlets of the fluidized bed gasifier is connected with the secondary combustion chamber, the secondary combustion chamber is connected with the rotary kiln, one of the outlets of the rotary kiln is connected with the waste heat boiler, the ignition burner is arranged at the lower part of the fluidized bed gasifier, the supplementary combustion burner is arranged at the secondary combustion chamber, the material outlet at the lower part of the fluidized bed gasifier is connected with the oil-removed material conveying device, the mixed feed device is connected with the oil-removed material conveying device and conveys the oil-removed material discharged from the fluidized bed gasifier and the alkaline material into the rotary kiln after mixing, the inlet of the air preheating device is connected with the outlet of the waste heat boiler, the outlet of the air blower is connected with the air inlet of the air preheating device through the air pipe, the flue gas outlet of the air preheating device is sequentially connected with the quenching tower, the dust collector, the acid removal tower, the flue gas reheater, the induced draft fan and the chimney through the flue, and the flue gas recirculation fan is connected with the flue of the outlet of the dust collector and the air inlet of the lower part of the fluidized bed gasifier to extract a part of the recirculated flue gas and send it into the fluidized bed gasifier again.

2. The oil-containing spent catalyst gasification deoiling roasting method and apparatus according to claim 1, characterized by, The oil-containing waste catalyst is subjected to oil removal treatment in the fluidized bed gasifier to produce combustible gas and oil-removed material, the heat generated after the combustible gas is fully combusted in the secondary combustion chamber enters the rotary kiln to realize the calcination process of the mixture of the oil-removed material and the alkaline material, and sodiumized material is generated.

3. The oil-containing spent catalyst gasification deoiling roasting method and apparatus according to claim 1, characterized by, The fuel of the ignition burner and the supplementary combustion burner is selected from one of natural gas, coal gas, coal powder, fuel oil, biomass fuel and other combustible materials with a heat value of more than 3000 Kcal / kg.

4. The oil-containing spent catalyst gasification deoiling roasting method and apparatus according to claim 1, characterized by, The air preheating device recovers the waste heat of the flue gas to heat the air, and the hot air is sent into the fluidized bed gasifier as primary air and into the secondary combustion chamber as secondary air.

5. The oil-containing spent catalyst gasification deoiling roasting method and apparatus according to claim 1, characterized by, The excess air coefficient of the primary air supplied by the fluidized bed gasifier is less than 1.

0.

6. The oil-containing waste catalyst gasification and deoiling roasting method and device, adopt the oil-containing waste catalyst gasification and deoiling roasting method and device as any one of claims 1-5, characterized in that, The method comprises the following steps: S1, the oil-containing waste catalyst is sent into the fluidized bed gasifier from the feed inlet, and the waste catalyst serves as the fluidized bed material; S2, the ignition burner uses ignition fuel to heat the bed material temperature of the fluidized bed gasifier to 650-750℃, and the oil and carbon, hydrogen and sulfur compounds carried by the oil-containing waste catalyst are ignited, and the insufficient combustion of the oil-containing waste catalyst in the oxygen-deficient environment with the excess air coefficient of the primary air of the fluidized bed gasifier less than 1.0 produces combustible gas such as CO, and the combustible gas is discharged from the upper part of the fluidized bed gasifier to the secondary combustion chamber; S3, the oil-containing waste catalyst becomes oil-removed material and is discharged from the bottom of the fluidized bed gasifier, sent into the mixed feed device through the oil-removed material conveying device, mixed with the alkaline material in the mixed feed device and then put into the rotary kiln; S4, the supplementary combustion burner puts in a part of supplementary combustion fuel, and the combustible gas is completely combusted with the aid of the secondary air, and the heat generated by the combustion calcines the oil-removed material and the alkaline material in the rotary kiln to generate sodiumized material. The sodiumized material is sent to the subsequent treatment process, which is not within the scope of the present application; S5, waste heat recovery and flue gas treatment: S5.1, the high-temperature flue gas from the rotary kiln outlet enters the waste heat boiler to recover a part of waste heat; S5.2, the flue gas from the waste heat boiler outlet enters the air preheater to recover a part of waste heat, and the discharged hot air is sent into the fluidized bed gasifier as primary air and into the secondary combustion chamber as secondary air; S5.3, the flue gas with reduced temperature enters the quench tower for temperature adjustment, and the flue gas temperature at the outlet of the quench tower should be within the allowable range of the dust collector; S5.4, the flue gas at the outlet of the quench tower enters the dust collector for dust removal treatment; S5.5, the flue gas recirculation fan extracts a part of the recirculated flue gas from the flue duct at the outlet of the dust collector and sends it into the fluidized bed gasifier again; S5.6, the remaining flue gas in the flue duct at the outlet of the dust collector enters the acid removal tower for acid removal treatment after passing through the flue gas reheater; S5.7, the flue gas after the acid removal treatment passes through the flue gas reheater, the induced draft fan and the chimney in sequence and is discharged.

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