Molecular filters for selective removal and recycling of gaseous aerosols.

Abstract

The present invention relates to a system and method for reducing harmful contaminants from exhaust gases that includes a molecular filter media composition and method for making the same. The filter media provides air purification by absorbing emissions from the exhaust gases and recycling the contaminants through chemical interaction between the filter media surface and a regenerant. The sorbent composition of the filter media maintains its integrity even at high process temperatures.

Description

[Technical field]

[0001] The present invention relates to a system and method for removing hazardous compounds from toxic gases. In particular, the present invention relates to chemisorption systems and regenerable molecular filters. [Background technology]

[0002] Air pollution is one of the most debated issues of our time, and new regulations on air pollutant emissions are forcing companies to control their emissions. The large amounts of toxic and corrosive gases used in industry have led to problems with gas leakage in storage and flow systems. The use of toxic and corrosive gases in the chemical and semiconductor industries has led to similar regulations on gas cylinders and flow systems. Scrubbers are one of the primary devices for controlling gaseous emissions, especially acid gases. Dry scrubbing systems are used to remove pollutants and contaminants in exhaust gases without producing wet sludge. Dry scrubbing systems combine selected chemical reagents with the exhaust gases at a very high rate, neutralizing the pollutants in the gas. The operation is carried out in three steps: gas cooling, reagent injection, and filtering. Gas cooling systems cool the exhaust gases to facilitate the removal of pollutants, using evaporative coolers. Once the gas has cooled considerably, reagent injection can begin. However, the neutralized pollutants continue to remain as part of the dry scrubbing stream. Please refer to the following documents. US-20150182945-A1 relates to a dry scrubbing media composition, preparation method and method of use. The composition includes activated alumina and magnesium oxide. Optionally, activated carbon and other impregnants such as hydroxides of Group 1A metals are included. The composition shows improved efficiency and ability to remove compounds such as hydrogen sulfide from air streams. However, when the sorbent is used, it must be sent to a landfill. US-5482536-A relates to an apparatus for containing and removing toxic or corrosive gases from a leaking pipe or cylinder. A gas passage is attached at one end to the leak in the pipe or cylinder and at the other end to an air-operated exhaust device. The air-operated exhaust device, by the input of a non-flammable purge gas, creates an exhaust flow from the leak to a drum attached to the air-operated exhaust device. The drum contains a scrubbing medium which, when in contact with the leaking gas, purifies or removes harmful components and releases the purified air to the atmosphere. WO-2005025733 relates to a dry scrubbing system for treating effluent from an upstream wastewater production process. The dry scrubbing system accommodates operation in a process window with wide variations in process conditions (e.g., flow rate and / or concentration) of scrubbable gas species in the effluent. In the dry scrubbing system, multiple scrubbing media are used, each scrubbing media being optimal in a regime of the operating window to ensure at least a predetermined removal level of scrubbable gas species throughout the operating window. US-20180169578-A1 relates to a particular embodiment, where gaseous phosphorus in wastewater is removed by the use of potassium hydroxide as an active removal agent.The present invention relates to a process for removing mercury from flue gas from a combustion plant, the process comprising providing a carbon-based sorbent, producing an aqueous suspension comprising the sorbent, introducing the suspension into a flue gas stream from the combustion plant into a dry gas phase of the flue gas that is unsaturated with water vapor, loading mercury onto the sorbent over a predetermined reaction pathway, removing the mercury-loaded sorbent from the flue gas stream, and reclamation or regeneration of the mercury-loaded sorbent. Despite the widespread use of activated carbon and zeolites in exhaust gas treatment, it is clear that their durability is limited. None of the compositions described to date have effectively resolved the issues surrounding the effectiveness and renewability of dry scrubbers. To counter such claims, reusable and robust platforms and materials to reduce pollutants and provide clean air in the atmosphere have become the need of the hour. The molecular filter media of the present invention is a filter powder or pellet with an extremely high surface area to reduce the concentration of toxic pollutants, and is a cost-effective technology that works for difficult-to-remove pollutants. Furthermore, this technology focuses on the circular economy of using pollutants as raw materials for the next step. For example, hydrogen sulfide gas can be reused for other sulfide salts. The information disclosed in the Background section of this disclosure is intended to enhance understanding of the general background of the invention and should not be construed as an admission or in any way suggesting that this information forms prior art already known to those of skill in the art.

[0003] SUMMARY OF THE PRESENT EMBODIMENT It is a primary object of the present invention to provide a molecular filter composition, a method for its preparation, and a system for removing pollutants from exhaust gases. Another object of the present invention is to provide a molecular filter composition having improved efficiency and capacity for removing toxic gas compounds from areas such as oil refineries and reservoirs, sewage treatment plants, hospital morgues, animal housing rooms, pulp and paper mills, and the like. Summary of the Invention

[0004] The present invention seeks to overcome the problems encountered in the prior art and discloses a system and renewable molecular media for removing harmful pollutants from exhaust gases, as well as a method for preparing the same. The compositions include activated inert media components that contain high surface area and are often impregnated with reactive materials that effectively capture and neutralize gaseous pollutants. Optionally, activated carbon and other impregnating agents are included in the compositions. The compositions exhibit increased efficiency and capacity for removing toxic gaseous compounds from areas such as oil refineries and reservoirs, sewage treatment plants, hospital morgues, animal housing rooms, and pulp and paper mills. In one embodiment of the present invention, the present invention discloses a method for removing contaminants from a gas effluent, comprising providing the gas effluent in a reaction chamber. In one embodiment, a dry or semi-dry molecular filter media is provided in a reaction chamber to capture and neutralize gaseous pollutants from a gas effluent to produce a purified gas, where the filter media comprises 30-85% by weight of an activated substrate and 15-25% by weight of an active reagent, and provides at least one gas outlet for releasing the purified gas. Upon saturation of the active sites of the filter media with the pollutants, the filter media is recharged by flushing the reaction chamber with a regenerant comprising at least one or more liquid, gas or solid particles dispersed in a liquid. After recharging the filter media, the regenerant is recirculated and the filter media is reused to purify the toxic gas emissions, making them safe for environmental release, and to reuse the pollutants in the by-products. In another embodiment of the present invention, the activated substrate is at least one of, but not limited to, carbon, metal oxides, metal carbides, ceramics, porcelain, clay, porous glass, mixed metal oxides consisting of binary, ternary, quaternary in terms of the number of different metal cations present, and combinations thereof. In one embodiment, metal oxides can function as solid catalysts both as active phases and supports. Metal oxides are utilized for both their acid-base and redox properties. In a preferred embodiment of the invention, the activating agent is at least one of, but not limited to, a reducing agent such as metabisulfite, a permanganate, an oxidizing agent, an organic acid, a salt of trisodium citrate and other acids and bases, metal salts of iron, silver, zinc, palladium, and combinations thereof. In one embodiment, the regenerant is an aqueous solution of an activating agent dispersed in a liquid, the activating agent being one or more solid particles, liquids, or gases such as air, oxygen, hydrogen, ozone, etc. In an exemplary embodiment, the present invention discloses a rechargeable filter media composition for removing harmful components from gaseous emissions, comprising 30-85% by weight of an activated substrate and 15-25% by weight of an active agent. In an embodiment, the active agent is an active ingredient for promoting the reaction of adsorption of the toxic components and their neutralization. In one embodiment of the present invention, the present invention discloses a process for making molecular filter media, which includes the steps of mixing activated beads in water for at least 10 minutes, then decanting the water and washing / rinsing the activated beads with distilled water to remove impurities; incubating the washed and activated beads at 60°C for at least 1 hour to obtain a high surface area activated substrate; taking at least 5% wt / vol of activator and optionally mixing with at least 10-20% wt / vol of metal oxide powder to obtain an active reagent, adding distilled water as required to dry the mixture, and finally impregnating the high surface area activated substrate with the active reagent in a ratio of 1:1 to 5:1; extruding the mixture into pellets and spheronizing it to obtain molecular filter media. In another embodiment of the invention, the drying is by at least one of air drying, heat drying and blow drying. In one embodiment, the filter media is formed as high surface area carbon or high surface area metal oxide pellets impregnated with an active agent that adsorbs pollutants in the exhaust gas. In an exemplary embodiment of the present invention, the present invention discloses a system for removing toxic components from a gas effluent comprising at least one gas inlet in a reaction chamber having a gas passage for drawing the gas effluent into the reaction chamber. In one embodiment, the reaction chamber is filled with a molecular filter media for capturing and neutralizing toxic components from the gas effluent to produce a cleaned gas, and provides at least one gas outlet for releasing the cleaned gas to the environment. Further, at least an inlet is provided for adding a regenerant to the reaction chamber to recharge the filter media, and at least an outlet at one end of the reaction chamber is provided for removing the regenerant, which recycles the contaminants. In yet another embodiment of the present invention, the filter media removes contaminants by at least one of capture and neutralization, catalysis and redox conversion. In another embodiment, the regenerant recycles the contaminant species into salts for use as feedstocks in industries by at least one of thermal evaporation, membrane technology, osmosis, reverse osmosis and combinations thereof, including but not limited to. In an exemplary embodiment, the present invention discloses a regenerant for recharging filter media that consists of an aqueous solution containing an activator and a gas, such as air, oxygen, hydrogen, or ozone. In an embodiment, the activator is one or more liquids, gases, or solid particles dispersed in the liquid. In another embodiment, the active components in the regenerant are at least one or more liquid, gaseous or solid particles, such as, but not limited to, NaOH, oxidizers, potassium bicarbonate, palladium and combinations thereof. In one embodiment, the activity is recharged into the filter media composition by at least one mechanism selected from neutralization, catalysis or redox conversion. In one embodiment of the present invention, the present invention discloses an efficient and inexpensive method for filtering harmful, toxic or malodorous compounds from air or gas streams. In another embodiment of the present invention, the present invention discloses an adsorbent composition that maintains its integrity at high process temperatures. In accordance with the present invention, there is provided a process for producing a molecular filter media comprising: (a) Mix 30-85% by final weight of activated beads in approximately twice the volume of water for at least 10 minutes; (b) Decant the water and wash / rinse the activated beads with distilled water to remove impurities; (c) incubating the washed and activated beads at a temperature of 60°C for at least 1 hour to obtain a high surface area activated substrate; (d) taking at least 5% wt / vol of an activator and optionally mixing with at least 10-20% wt / vol of a metal oxide powder; (e) adding distilled water to the mixture (from step (d)); (f) drying the mixture (of step (e)) to obtain an active agent, where the active agent is an active ingredient for promoting the reaction of adsorption and neutralization of the toxic ingredient; (g) impregnating the resulting high surface area activated substrate (from step (c)) with the resulting activating reagent (from step (f)) in a ratio of 1:1-5:1 to obtain an impregnation mixture; and (h) The impregnated mixture (of step g) is extruded into pellets and spheronized to produce a molecular filter media. According to the present invention there is also provided a method for removing pollutants from a gas effluent comprising: - providing a gaseous exhaust into the reaction chamber; - providing a dry or semi-dry molecular filter media within a reaction chamber for capturing and neutralizing gaseous contaminants from a gas effluent to produce a purified gas, the filter media comprising 30-85% by weight of an activated substrate and 15-25% by weight of an active reagent; - providing at least one gas outlet for releasing the purified gas; - upon saturation of the active sites of the filter media by the contaminants, recharging the reaction chamber by flushing it with a regenerant comprising at least one or more liquid, gas or solid particles dispersed in a liquid; and - After recharging the filter media, the regenerant is recirculated, the filter media is reused for purification of toxic gas emissions, making it safe for environmental release, and the pollutants are recycled into by-products. There is also provided in accordance with the present invention a rechargeable filter media composition for removing harmful constituents from gas effluent, comprising: - 30-85% by weight of activated substrate; - 15-25% by weight of an active agent, which is an active ingredient for promoting the reaction of adsorption of harmful components and their neutralization. According to the present invention there is also provided a system for removing toxic constituents from a gas effluent comprising: - at least one gas inlet in the reaction chamber having a gas passage for drawing the gas effluent into the reaction chamber, said reaction chamber being filled with a molecular filter media for capturing and neutralizing toxic components from the gas effluent to produce a purified gas; - at least one gas outlet for releasing the purified gas into the environment; - at least one inlet for adding a regenerant to the reaction chamber to recharge the filter media, and at least one outlet for removing the regenerant from at least one outlet at one end of the reaction chamber; Regenerators reuse pollutants; the filter media removes contaminants by at least one of capture and neutralization, catalysis, and redox conversion; and A regenerator recycles the contaminants into salt by at least one of thermal evaporation, membrane technology, osmosis, reverse osmosis, and combinations thereof, for use as an industrial feedstock. In at least one embodiment, the drying is by at least one of air drying, heat drying, and blow drying. In at least one embodiment, the regenerant is an aqueous formulation containing about 4-10% active agent that flushes gases and by-products out of the molecular filter and returns the active agent to the molecular filter in preparation for the next cycle. In at least one embodiment, the regenerant comprises an activator, a gas such as air, oxygen, hydrogen, ozone, and an aqueous solution having one or more liquids, gases, or solid particles dispersed therein. In at least one embodiment, the active agent is at least one of a reducing agent such as metabisulfite, a permanganate, an oxidizing agent, organic acid salts of trisodium citrate and other acids and bases, metal salts of iron, silver, zinc, palladium, and combinations thereof. In at least one embodiment, the active component in the regenerant is at least one or more liquids, gases, or solid particles, such as NaOH, oxidizers, potassium bicarbonate, palladium, and combinations thereof. In at least one embodiment, the activated substrate is at least one of carbon, metal oxides, metal carbides, ceramics, porcelains, clays, porous glasses, mixed metal oxides consisting of binary, ternary and quaternary with respect to the number of different metal cations present, and combinations thereof. In at least one embodiment, the filter media is formed as high surface area carbon or high surface area metal oxide pellets impregnated with an active agent that adsorbs pollutants in the exhaust gas. In at least one embodiment, the filter media is a palladium coated substrate for removing carbon monoxide from exhaust gases and converting it to CO2 as a by-product, which is captured by the regenerant NaOH and converted to carbonate, resulting in a by-product that is recycled for industrial use through the use of catalysis and neutralization reactions. In at least one embodiment, the filter media is an oxidizer having a permanganate coated substrate for removing ethylene from decaying produce and converting it to carbon dioxide as a by-product, the by-product forming a blanket on the produce, and a regenerator is an oxidizer for replenishing the media. In at least one embodiment, the filter media is a metabisulfite coated substrate for removing oxygen from produce. These and other objects, features and advantages of the present invention will become apparent after a review of the following detailed description of the disclosed embodiments and the appended claims.

[0005] Since this is a patent document, general broad rules of interpretation should be applied when reading it. Everything described and shown in this document is an example of the subject matter of the claims appended below. The specific structural and functional details disclosed herein are merely for the purpose of illustrating how to make and use the examples. Several different embodiments and methods not specifically disclosed herein may be included within the scope of the claims. Thus, the claims may be embodied in many alternative forms and should not be interpreted as being limited to only the examples described herein. The terms "comprises," "comprising," or other variations thereof, as used in this disclosure, are intended to cover a non-exclusive inclusion, such that a device, apparatus, system, assembly, or method consisting of a list of components or a sequence of steps, does not include only those components or steps, but may include other components or steps not expressly listed or inherent to such apparatus, assembly, or device. In other words, one or more elements or steps in a system or device or process proceeded by "comprises a" or "comprising" does not, without more constraints, exclude the presence of other elements or additional elements or additional steps in the system or device or process, as the case may be. Rather, an exclusive modifier such as "only" or "single" may preclude the presence or addition of other subjects in the modifier. The use of permissive terms such as "may" or "can" reflects optionality such that the modifier is not necessarily present, while the absence of a permissive term does not reflect compulsion. In listing items in the exemplary embodiments, conjunctions and inclusive terms such as "and," "together," and "or" include, without excluding, all combinations of one or more of the listed items. The use of "etc." is defined as "et cetera" and indicates the inclusion of all other elements belonging to the same group of the preceding item in any "and / or" combination(s). The modifiers "first," "second," "another," and the like may be used herein to describe various items, but do not limit the modified items to any order. These terms are used only to distinguish one element from another. When there is an ordinal number such as "second" or higher, there must simply be that many elements, without necessarily any difference or other relationship between those elements. When an element is referred to as being "connected," "coupled," "on," "attached," "fixed," or otherwise related to another element, it may be directly connected to the other element, or there may be intervening elements present. In contrast, when an element is referred to as being "directly connected" or "directly coupled" to another element, there are no intervening elements present. Other words used to describe the relationship between elements should be interpreted similarly (e.g., "between" vs. "directly between," "adjacent" vs. "directly adjacent," etc.). As used herein, singular forms such as "a", "an" and "the" are intended to include both the singular and the plural unless the context expressly dictates otherwise. An indefinite article such as "a" or "an" introduces or refers to any modified term, whether previously introduced or not, and a definite article such as "the" refers to the same term previously introduced. Relative terms such as "approximately", "more than" and terms of degree such as "approximately" or "substantially" reflect a 10% variation in the modified value or the full range of imprecision that achieves the functionality of the modified term when understood by one of ordinary skill in the art in the technical context. Precision and non-variation are expressed by opposing terms such as "exactly". The inventors have recognized that, although available processes for reducing contaminants are widely used, they are not sufficiently reduced and the operating costs are very high. Furthermore, the operating costs are high because the filter media is consumed during the process. Therefore, there remains a need for a new and original regenerative filter media method in such applications that is not only environmentally friendly but also economical and provides excellent results for removing contaminants. To overcome these problems, the inventors have developed the exemplary embodiments and methods described below to address these and other problems recognized by the inventors with unique solutions enabled by the exemplary embodiments. In one embodiment, the present invention relates to a system and method for reducing harmful pollutants from exhaust gases that includes a molecular filter media composition and method for making the same. The filter media provides air purification and odor control by absorbing and adsorbing odors and destroying collected odors through chemical interactions on the surface of the filter media. The system consists of a regenerative molecular filter in a packed bed structure. Corrosive gases flow through it and contaminants are selectively captured and filtered by the molecular media. When the active sites of the filter media become saturated with contaminants / pollutants from the exhaust gas, a regenerant flows in, removing the captured contaminants and replenishing the active materials in the molecular filter. The regenerant recycles and converts the contaminants into salt, which can be utilized as a by-product in other industries. In one embodiment, the filter for CO2 removal works with NaOH solution in the regenerant, and the by-product of the reaction is sodium carbonate. In one embodiment, the molecular media composition described herein comprises activated alumina and a metal carbonate. In one embodiment, the molecular filter media further comprises powdered activated carbon. In another embodiment, the molecular filter media is impregnated with a reducing agent, such as metabisulfite. In one embodiment, the molecular filter media compositions provided herein have an enhanced ability to adsorb certain undesirable compounds with greater efficiency than currently available media. Additionally, the molecular filter media compositions described herein enjoy increased physical strength. In one embodiment, extremely high surface area carbons are used. Activated carbon, powdered carbon, and beech black are referred to herein as "high surface area carbons." The size range of the powder is largely a matter of choice, but when producing pellets of filter media, several parameters are necessary to ensure that uniform pellets are achieved during rolling. In one embodiment, the carbon is sized to pass 85% through a 40×80 mesh screen. It has been noted that the rate of adsorption varies with the surface area of ​​the activated carbon used. Thus, a high surface area, preferably 500 to 2000 m 2 / g surface area, most preferably 1000-1200 m 2 It is important to employ an activated carbon having a surface area of ​​1 / g. In one embodiment of the present invention, the present invention discloses a method for removing contaminants from a gaseous effluent, comprising providing the gaseous effluent in a reaction chamber. In an embodiment, the reaction chamber includes a dry or semi-dry molecular filter medium for capturing and neutralizing gaseous contaminants from the gaseous effluent to produce a purified gas, the filter medium including 30-85% by weight of an activated substrate and 15-25% by weight of an active reagent, and providing at least one gas outlet for releasing the purified gas. Upon saturation of the active sites of the filter medium with contaminants, the filter medium is recharged by flushing the reaction chamber with a regenerant including at least one or more liquid, gaseous or solid particles dispersed in a liquid. After recharging the filter medium, the regenerant is recirculated and the filter medium is reused to purify the toxic gaseous effluent, making it safe for environmental release, and to reuse the contaminants in the by-products. In another embodiment of the present invention, the activated substrate is at least one of, but not limited to, carbon, metal oxides, metal carbides, ceramics, porcelain, clay, porous glass, mixed metal oxides consisting of binary, ternary, quaternary in terms of the number of different metal cations present, and combinations thereof. In one embodiment, metal oxides can function as solid catalysts both as active phases and supports. Metal oxides are utilized for both their acid-base and redox properties. In a preferred embodiment of the present invention, the active agent is at least one of, but not limited to, a reducing agent such as metabisulfite, permanganate, an oxidizing agent, trisodium citrate and other organic acid salts of acids and bases, metal salts of iron, silver, zinc, palladium, and combinations thereof. In one embodiment, the regenerant is an aqueous solution containing an activator consisting of one or more solid particles, liquids, or gases, such as air, oxygen, hydrogen, ozone, etc., dispersed in a liquid. In an exemplary embodiment, the present invention discloses a rechargeable filter media composition for removing harmful components from gaseous emissions, comprising 30-85% by weight of an activated substrate and 15-25% by weight of an active agent. In an embodiment, the active agent is an active ingredient for promoting the reaction of adsorption of the toxic components and their neutralization. In another embodiment of the present invention, the activating substrate is at least one of, but is not limited to, carbon, metal oxides, metal carbides, ceramics, porcelain, clay, porous glass, mixed metal oxides consisting of binary, ternary and quaternary with respect to the number of different metal cations present, and combinations thereof. In one embodiment, the activating agent is at least one of, but is not limited to, metabisulfite, permanganate, oxidizing agents, organic acid salts of trisodium citrate and other acids and bases, reducing agents such as metal salts of iron, silver, zinc, palladium, and combinations thereof. In one embodiment of the present invention, the present invention comprises mixing the activated beads in water for at least 10 minutes, then decanting the water and washing / rinsing the activated beads with distilled water to remove impurities; and incubating the washed activated beads at a temperature of 60° C. for at least 1 hour to obtain a high surface area activated substrate, taking at least 5% wt / vol of an activator and optionally mixing with at least 10-20% wt / vol of metal oxide powder to obtain an active reagent, and adding distilled water as necessary to dry the mixture; finally, impregnating the high surface area activated substrate with the active reagent in a ratio of 1:1 to 5:1; and extruding and spheronizing the mixture into pellets to obtain molecular filter media. In another embodiment of the invention, the drying is by at least one of air drying, heat drying and blow drying. In one embodiment, the filter media is formed as high surface area carbon or high surface area metal oxide pellets impregnated with an active agent that adsorbs pollutants in the exhaust gas. In an exemplary embodiment of the invention, the present invention discloses a system for removing toxic components from a gas effluent, comprising at least one gas inlet in a reaction chamber having a gas passage for drawing the gas effluent into the reaction chamber. In one embodiment, the reaction chamber is filled with a molecular filter media for capturing and neutralizing toxic components from the gas effluent to produce a cleaned gas, and provides at least one gas outlet for releasing the cleaned gas to the environment. Further, at least an inlet is provided for adding a regenerant to the reaction chamber to recharge the filter media, and at least an outlet at one end of the reaction chamber is provided for removing the regenerant, which recycles the contaminants. In yet another embodiment of the present invention, the filter media removes contaminants by at least one of capture and neutralization, catalysis and redox conversion. In another embodiment, the regenerant recycles the contaminant species into salts for use as feedstocks in industries by at least one of thermal evaporation, membrane technology, osmosis, reverse osmosis and combinations thereof, including but not limited to. In yet another embodiment of the present invention, the filter media is a palladium coated substrate for removing carbon monoxide from exhaust gas and converting it to CO2 as a by-product, which is captured by regenerant NaOH and converted to carbonate, resulting in the by-product being recycled for industrial use by the use of catalytic and neutralization reactions. In a preferred embodiment, the filter media is an oxidizer such as a permanganate coated substrate for removing ethylene from decaying vegetables and converting it to carbon dioxide as a by-product, which also forms a blanket on the produce, and the regenerant used is an oxidizer to replenish the media. In another embodiment, the filter media is a metabisulfite coated substrate for removing oxygen from produce. In an exemplary embodiment, the present invention discloses a regenerant for recharging filter media that consists of an aqueous solution containing an activator and a gas, such as air, oxygen, hydrogen, or ozone. In an embodiment, the activator is one or more liquids, gases, or solid particles dispersed in the liquid. In another embodiment, the active components in the regenerant are at least one or more liquid, gaseous or solid particles, such as, but not limited to, NaOH, oxidizers, potassium bicarbonate, palladium and combinations thereof. In one embodiment, the activity is recharged into the filter media composition by at least one mechanism selected from neutralization, catalysis or redox conversion. The molecular filter media compositions provided herein utilize a chemisorption process to remove chlorine and sulfur dioxide by absorption, adsorption and chemical reaction. The chlorine or sulfur dioxide is captured within the filter media where irreversible chemical reactions occur, converting the gases to harmless solids and salts, which are then concentrated in a regenerant. In one embodiment, the filter media contacts the effluent gas stream with a solid material that functions to chemisorb or react with the undesirable constituents and affect their removal. In another embodiment, the molecular filter media described herein concentrates and completely contains harmful contaminants, is passive in operation, has no moving parts, and operates on demand, making it a safe and preferred mode of filtration and purification. The regenerant for the molecular filter can be wet or dry (ozone, hydrogen gas, etc.). In another embodiment, the molecular filter media is prepared or manufactured by extrusion to form a solid structure. Extrusion is a manufacturing process used to create elongated objects of a certain cross-sectional shape. The material or mixture is extruded and / or drawn through a die of the desired profile shape. The die can have a variety of shapes and diameters. The plasticity and shape retention of the extruded material can be changed or improved by the use of a binder. The binder is not particularly limited, and various binders used in manufacturing molded products by extrusion molding or injection molding can be used. Specific examples include various alcohols, celluloses such as methyl cellulose and ethyl cellulose, starches, vinyl resins, various waxes, thermoplastic polyolefins such as polyethylene and polypropylene, polyacetate vinyl compounds, and the like. In one embodiment, the binder includes, but is not limited to, starch adhesives, organic binders, clay, feldspar, and the like. Undesirable airborne compounds, including chlorine and sulfur-containing compounds, ammonia, formaldehyde, urea, carbon monoxide, nitrogen oxides, mercaptans, amines, and ethylene, occur in many environments, most of which are primarily responsible for the presence of unpleasant odors, irritating or toxic gases. In another embodiment, the system is used for other applications such as food preservation. In the case of food preservation, the removal of oxygen by a reducing agent such as sodium metabisulfite helps preserve the food and slow microbial metabolism. Other possible reducing agents are ferrous carbonate and ascorbic acid. The reducing agent can be stored in an external tank and introduced to the filter to "recharge" the media, allowing for continuous processing. Oxidizing agents such as permanganate also help to break down ethylene, a "spoilage" gas in foods, and coat the food with the resulting gas, slowing the spoilage process. Selective removal of sulfides is also important, apart from chemical removal - ozone can be used to oxidize substances with the medium. By actively passing ozone or other reactive gases with the medium, industrially relevant substances can be obtained. The idea is that gaseous waste is a misplaced resource. Furthermore, it can be absorbed into liquid or gel-like media. For example, sulfur dioxide (SO2), a colorless gas, can be oxidized with ozone to sulfur trioxide, which in the presence of water is easily converted to sulfuric acid, which is used for industrial applications. Health effects of exposure to high concentrations of SO2 include breathing disorders, respiratory diseases, changes in the lung's defenses, and aggravation of respiratory and cardiovascular diseases. Therefore, the removal of sulfur dioxide is extremely important. Radioactivity removal is also important in nuclear facilities, where a mixture of potassium hydroxide and potassium iodide serves this purpose. Our formulation also contains a mixture of sodium hydroxide and magnesium chloride. As clean energy from nuclear reactors becomes more important, the safety of the process requires the deployment of an absorbent medium around the reactor in case a leak is detected. In one embodiment, the system is directed to the removal of pollutants, particularly those controlling hydrogen sulfide (H2S) gas emissions from municipal wastewater treatment plants; including ammonia (NH3) from animal care and daycare centers, formaldehyde (HCHO) from hospital mortuaries, urea (CH4N2O) from toilet exhaust and the paper industry to soften cellulose, nitrogen oxides such as carbon monoxide (CO), nitrogen dioxide (NO2), nitric oxide (NO), and nitrous oxide (N2O), mercaptans and amines such as methyl mercaptan (CH3SH), butyl mercaptan (C4H9SH), and methylamine (CH5N), and other undesirable gases found in sewer odors. The combination of ozonation and smart material media helps in the oxidation of ethylene. Absorbents with oxidizing agents or reducing agents such as sodium metabisulfite are also important. In one embodiment, the regenerable molecular filter media of the present invention has a high total adsorption capacity for compounds of interest, a high efficiency for removing compounds from air or gas streams, and a high light-off temperature (non-flammable). The sorbent composition is intended to absorb many undesirable gaseous compounds present in household air. EXAMPLES

[0006] Example 1: Media for removal of SOx and NOx: The filter media was manufactured according to the scheme including: active substrate, alumina and zeolite powder; and active agent is mixed in a separate vessel with at least 6% wt / vol active agent such as KMnO4 and at least 10-20 wt / vol zeolite powder, adding distilled water to the mixture as required, and then drying the composition by air drying / heat drying / blowing drying, which is the active agent; and impregnating the substrate with the active agent in a ratio of 1:1 to 5:1, heating to 350°C, extruding, spheronizing and pelletizing. Furthermore, the regenerant of this SOx, NOx reduction filter media is bleach, peroxide, ozone gas, oxygen gas. Example 2: Medium for removing chlorine-containing acid gas: The active substrate was coarse activated carbon and zeolite powder, and the active agent was prepared by mixing at least 4% wt / vol of an activator such as NaOH with at least 10-20% wt / vol of zeolite powder in a separate beaker, adding distilled water as required, and drying by air drying / heat drying / blowing; the active agent was impregnated into the substrate in a ratio of 1:1 to 5:1, heated to 350°C, extruded, spheronized, and pelletized. Furthermore, the regenerant for these acid gas reducing filter media was 4% NaOH in water. Example 3: Ammonia removal medium: The active substrate was coarse activated carbon and zeolite powder, and the active reagent was prepared by mixing at least 4%-85% wt / vol of an activator such as phosphoric acid with at least 10%-20% wt / vol of zeolite powder in a separate beaker, adding distilled water as necessary, and drying by air drying / heat drying / blowing, which was the active reagent: the substrate was impregnated with the activator in a ratio of 1:1 to 5:1, heated to 350°C, extruded, spheronized and pelletized. Furthermore, the regenerant for these acid gas downflow filter media was 4%-85% phosphoric acid in water. Example 4: Media for removing radioactive materials: The filter media was prepared by mixing the active substrate (here coarse activated carbon and zeolite powder), the active agent (at least 4% wt / vol KOH, 4% wt / vol KI, and at least 10-20% wt / vol zeolite powder) in a separate flask, adding distilled water as necessary, and drying by air drying / heat drying / blowing, which was the active agent: the substrate was impregnated with the active agent in a ratio of 1:1 to 5:1, heated to 350°C, extruded, spheronized, and pelletized. Furthermore, the regenerant for these acid gas reducing filter media was KOH and KI in water. Example 5: Media for removing heavy metals such as As and Pb from air and water: The filter media is made of an active substrate (here, iron oxide ceramic and crude activated carbon (30%+70% ratio); the active agent is mixed with at least 10-20% wt / vol of zeolite powder in a separate beaker, such as iron hydroxide agent at least 4% wt / vol, and distilled water is added as needed, and then the composition is dried by air drying / heat drying / blowing drying, which is the active agent; the substrate is impregnated with the active agent in a ratio of 1:1 to 5:1, heated to 350°C, extruded, spheronized and pelletized. Furthermore, the regenerant for these acid gas descending filter media is finely dispersed iron powder / dissolved iron salt in water, and flowed with compressed gas as needed. Example 6: Media for removing bacteria and viruses: The active substrate was coarse activated carbon and zeolite powder, and the active agent was a mixture of at least 4% wt / vol of three metals selected from silver, zinc, and copper with at least 10-20% wt / vol of zeolite powder in a separate beaker, with distilled water added as necessary, and dried by air drying, heat drying, or blow drying, which was the active agent: the substrate was impregnated with the active agent in a ratio of 1:1 to 5:1, heated to 350 °C, extruded, spheronized, and pelletized. Furthermore, the regenerant for these acid gas reducing filter media was an aqueous formulation of silver, zinc, and copper dissolved in water. Example 7: Media for removing 20% ​​by weight of H2S, 10% by weight of SOx, and 10% by weight of chlorine: The filter media was an active substrate of alumina balls and zeolite powder; the active agent was a mixture of at least 32% wt / vol of an active agent such as potassium bicarbonate and at least 10-20% wt / vol of zeolite powder in a separate bead, adding distilled water as required, and then drying the composition by air drying / heat drying / blowing; the active agent was impregnated into the substrate in a ratio of 1:1 to 5:1, heated to 350°C, extruded, spheronized, and pelletized. Furthermore, the regenerant for these acid gas reducing filter media was potassium bicarbonate in water. Experiments showed that they adsorbed a total of 20% of H2S. Example 8: Medium for removing NOx, carbon monoxide, and hydrocarbons: The filter media was manufactured according to the following scheme: the active substrate was coarse activated carbon and metal oxide powder; the active agent was mixed in a separate vessel with at least 0.1% wt / vol of an activator such as palladium and at least 10-20% wt / vol of zeolite powder, adding distilled water as necessary, and then drying the composition by air drying / heat drying / blowing, which was the active agent; the substrate was impregnated with the activator in a ratio of 1:1 to 5:1, heated to 350°C, extruded, spheronized and pelletized. Furthermore, the regenerant of these acid gas reducing filter media was palladium activator in water. Example 9: Fish oil removal medium: The activator is prepared by mixing at least 5-10% wt / vol of an activator such as trisodium citrate with at least 10-20% wt / vol of ceramic powder in a separate container, adding distilled water as necessary, and then drying the composition by air drying / heat drying / blowing; the activator is impregnated into a substrate in a ratio of 1:1 to 5:1, heated to 350°C, extruded, spheronized, and pelletized. Furthermore, the regenerant for these acid gas reducing filter media was an aqueous solution containing the activator, or a gas such as air, oxygen, hydrogen, or ozone. Example 10: Medium for removing ethylene and controlling the quality of fruits and vegetables: For this, the filter medium is an oxidizing agent, such as a permanganate-coated substrate, which removes ethylene from the decaying vegetables and converts it into carbon dioxide as a by-product. This is to remove exogenous food spoilage gases from the atmosphere, which accumulate during post-harvest storage and have detrimental effects on the vegetables. Measurements of fruit pH, decomposition of ascorbic acid during storage and antioxidant capacity proved the effectiveness of the described medium. Technical Advantages

[0007] · Filter media can be disposed of in landfills, eliminating the need for professional disposal and associated costs. -It is also non-toxic and poses no risk before or after the reaction. -The filter media operates effectively at room temperature. The filter media provides improved chlorine and sulfur dioxide removal over media currently known in the art, while providing the benefits of a wet scrubbing system and enhanced removal of corrosive gases. · The regenerant dissolves important salts to form value-added products that can be used in the same or different industrial processes. Compared to wet scrubbers, which have a very low capture efficiency of corrosive gases and where a small amount of salt is mixed in a large amount of water (90% or more), the salt content here is very high, leading to efficient recovery of salt. · Molecular filter media are adsorbent compositions that maintain their integrity at high process temperatures.

Claims

1. 1. A process for producing a molecular filter media, comprising: (a) mixing 30-85% by final weight of activated beads with approximately twice the amount of water for at least 10 minutes; (b) decanting the water and washing / rinsing the activated beads with distilled water to remove impurities; (c) incubating the washed and activated beads at a temperature of 60° C. for at least 1 hour to obtain a high surface area activated substrate; (d) taking at least 5% wt / vol of an activator and optionally mixing with at least 10-20% wt / vol of a metal oxide powder; (e) adding distilled water to the mixture (of step (d)); (f) drying the mixture (of step (e)) to obtain an active agent, wherein said active agent is an active ingredient for promoting the reaction of adsorption and neutralization of toxic ingredients; (g) impregnating the high surface area activated substrate (from step (c)) with the activating reagent (from step (f)) in a ratio of 1:1 to 5:1 to obtain an impregnation mixture; and (h) extruding and spheronizing the impregnated mixture (of step g) into pellets to produce the molecular filter media; This includes:

2. 10. The process for producing the molecular filter media of claim 1, wherein drying is by at least one of air drying, heat drying, and blow drying.

3. 10. The process for producing a molecular filter media according to claim 1, wherein the regenerant is an aqueous formulation containing about 4 to 10% active agent that flushes gas and molecular filter by-products and returns the active agent to the molecular filter in preparation for the next cycle.

4. 10. The process for producing a molecular filter media of claim 1, wherein the regenerant is an aqueous solution containing an activator and / or a gas, such as air, oxygen, hydrogen and / or ozone, in which one or more liquid, gas or solid particles are dispersed.

5. 2. The process for producing a molecular filter media of claim 1, wherein the active agent is at least one of a reducing agent such as metabisulfite, permanganate, an oxidizing agent, an organic acid salt of trisodium citrate and other acids and bases, a metal salt of iron, silver, zinc, palladium, and combinations thereof.

6. 10. The process for producing a molecular filter media according to claim 1, wherein the active component of the regenerant is at least one or more liquids, gases or solid particles, such as NaOH, an oxidizer, potassium bicarbonate, palladium and combinations thereof.

7. 2. The process for producing a molecular filter media of claim 1, wherein the activated substrate is at least one of carbon, metal oxide, metal carbide, ceramic, porcelain, clay, porous glass, mixed metal oxides consisting of binary, ternary, and quaternary with respect to the number of different metal cations present, and combinations thereof.

8. 10. The process for manufacturing a molecular filter media according to claim 1, wherein the filter media is formed as high surface area carbon or high surface area metal oxide pellets impregnated with an active agent that adsorbs pollutants in exhaust gases.

9. 10. The process for producing a molecular filter media according to claim 1, wherein the filter media removes carbon monoxide from exhaust gases and produces CO as a by-product. 2 wherein the by-product is captured by a regenerant NaOH and converted to carbonate, resulting in the by-product being recycled for industrial use by using catalytic reactions and neutralization reactions.

10. 10. The process of claim 1 for producing a molecular filter media, wherein the filter media is an oxidizer having a permanganate coated substrate for removing ethylene from decaying produce and converting it to carbon dioxide as a by-product, the by-product forming a blanket on the produce, and the regenerant is an oxidizer for replenishing the media.

11. 10. The process for making a molecular filter media according to claim 1, wherein the filter media is a metabisulfite coated substrate for removing oxygen from produce.

12. 1. A method for removing pollutants from a gas exhaust comprising: - providing a gaseous exhaust into the reaction chamber; - providing a dry or semi-dry molecular filter medium in said reaction chamber for capturing and neutralizing gaseous contaminants from the gas effluent and producing a purified gas, said filter medium comprising 30-85% by weight of an activated substrate and 15-25% by weight of an active reagent; - providing at least one gas outlet for releasing said purified gas; - upon saturation of the active sites of the filter media by the contaminants, recharging the reaction chamber by flushing it with a regenerant comprising at least one or more liquids, gases or solid particles dispersed in a liquid; and - Recharging the filter media, then recirculating the regenerant, reusing the filter media for purification of toxic gas emissions, making it safe for environmental release, and recycling pollutants into by-products; This includes:

13. 13. The method for removing contaminants from a gas effluent according to claim 12, wherein drying is performed by at least one of air drying, heat drying and blow drying.

14. 13. The method of removing contaminants from a gaseous exhaust as described in claim 12, wherein the regenerant is an aqueous formulation containing about 4-10% active agent that flushes the gas and by-products out of the molecular filter and returns active agent to the molecular filter in preparation for the next cycle.

15. 13. A method for removing pollutants from a gas effluent as described in claim 12, wherein the regenerant is an aqueous solution containing an activator and / or a gas, such as air, oxygen, hydrogen and / or ozone, in which one or more liquid, gas or solid particles are dispersed.

16. 13. The method for removing pollutants from a gas effluent as set forth in claim 12, wherein the active reagent is at least one of a reducing agent such as metabisulfite, permanganate, an oxidizing agent, an organic acid salt of trisodium citrate and other acids and bases, a metal salt of iron, silver, zinc, palladium, and combinations thereof.

17. 13. The method for removing pollutants from a gas effluent as described in claim 12, wherein the active component of the regenerant is at least one or more liquids, gases or solid particles, such as NaOH, an oxidant, potassium bicarbonate, palladium and combinations thereof.

18. 13. The method for removing pollutants from a gas exhaust according to claim 12, wherein the activated substrate is at least one of carbon, metal oxides, metal carbides, ceramics, porcelain, clay, porous glass, mixed metal oxides consisting of binary, ternary, quaternary with respect to the number of different metal cations present, and combinations thereof.

19. 13. The method for removing pollutants from a gas exhaust as recited in claim 12, wherein the filter media is formed as high surface area carbon or high surface area metal oxide pellets impregnated with an active agent that adsorbs pollutants in the exhaust gas.

20. 13. The method of removing pollutants from a gas exhaust as recited in claim 12, wherein the filter media removes carbon monoxide from the exhaust gas and CO as a by-product. 2 wherein the by-product is captured by a regenerant NaOH and converted to carbonate, resulting in the by-product being recycled for industrial use by using catalytic reactions and neutralization reactions.

21. 13. The method for removing contaminants from a gaseous emission as described in claim 12, wherein the filter media is an oxidizer having a permanganate coated substrate for removing ethylene from decaying produce and converting it to carbon dioxide as a by-product, the by-product forming a blanket on the produce, and the regenerant is an oxidizer for replenishing the media.

22. 13. The method for removing contaminants from a gaseous exhaust according to claim 12, wherein the filter media is a metabisulfite coated substrate for removing oxygen from produce.

23. 1. A rechargeable filter media composition for removing harmful constituents from a gaseous emission comprising: - 30-85% by weight of an activating substrate; and - 15-25% by weight of active agents for promoting the adsorption of harmful components and their neutralization reactions; Equipped with.

24. 24. The rechargeable filter media composition of claim 23, wherein the regenerant is an aqueous formulation containing about 4-10% active agent that flushes the gas and by-products out of the molecular filter and returns active agent to the molecular filter in preparation for the next cycle.

25. 24. The rechargeable filter media composition of claim 23, wherein the regenerant is an aqueous solution containing an activator and / or a gas, such as air, oxygen, hydrogen and / or ozone, in which one or more liquid, gas or solid particles are dispersed.

26. 24. The rechargeable filter media composition of claim 23, wherein the active agent is at least one of a reducing agent such as metabisulfite, permanganate, an oxidizing agent, an organic acid salt of trisodium citrate and other acids and bases, a metal salt of iron, silver, zinc, palladium, and combinations thereof.

27. 24. The rechargeable filter media composition of claim 23, wherein the regenerant active ingredient is at least one or more liquids, gases, or solid particles, such as NaOH, oxidizers, potassium bicarbonate, palladium, and combinations thereof.

28. 24. The rechargeable filter media composition of claim 23, wherein the activated substrate is at least one of carbon, metal oxide, metal carbide, ceramic, porcelain, clay, porous glass, mixed metal oxides consisting of binary, ternary, quaternary with respect to the number of different metal cations present, and combinations thereof.

29. 24. The rechargeable filter media composition of claim 23, wherein the filter media is formed as high surface area carbon or high surface area metal oxide pellets impregnated with an active agent that adsorbs pollutants in exhaust gases.

30. 24. The rechargeable filter media composition of claim 23, wherein the filter media removes carbon monoxide from exhaust gases and produces CO as a by-product. 2 wherein the by-product is captured by a regenerant NaOH and converted to carbonate, resulting in the by-product being recycled for industrial use by using catalytic reactions and neutralization reactions.

31. 24. The rechargeable filter media composition of claim 23, wherein the filter media is an oxidizer having a permanganate coated substrate for removing ethylene from decaying produce and converting it to carbon dioxide as a by-product, the by-product forming a blanket on the produce, and the regenerant is an oxidizer for replenishing the media.

32. 24. The rechargeable filter media composition of claim 23, wherein the filter media is a metabisulfite coated substrate for removing oxygen from produce.

33. 1. A system for removing toxic components from a gas effluent, comprising: - at least one gas inlet in the reaction chamber having a gas passage for drawing a gas effluent into the reaction chamber, said reaction chamber being filled with a molecular filter media for capturing and neutralizing said toxic components from said gas effluent to produce a purified gas; - at least one gas outlet for releasing the purified gas into the environment; - at least one inlet for adding a regenerant to the reaction chamber to recharge the filter media and removing the regenerant from at least one outlet at one end of the reaction chamber; o the regenerant recycles the contaminants; o the filter media removes the contaminants by at least one of capture and neutralization, catalysis, and redox conversion; and o The regenerator recycles the contaminated material into salt by at least one of thermal evaporation, membrane technology, osmosis, reverse osmosis, and combinations thereof, for use as industrial raw material.

34. 34. The rechargeable filter media composition of claim 33, wherein the regenerant is an aqueous formulation containing about 4-10% active agent that flushes the gas and by-products out of the molecular filter and returns active agent to the molecular filter in preparation for the next cycle.

35. 34. The rechargeable filter media composition of claim 33, wherein the regenerant is an aqueous solution containing an activator and / or a gas, such as air, oxygen, hydrogen and / or ozone, in which one or more liquid, gas, or solid particles are dispersed.

36. 34. The rechargeable filter media composition of claim 33, wherein the active agent is at least one of a reducing agent such as metabisulfite, permanganate, an oxidizing agent, an organic acid salt of trisodium citrate and other acids and bases, a metal salt of iron, silver, zinc, palladium, and combinations thereof.

37. 34. The rechargeable filter media composition of claim 33, wherein the regenerant active ingredient is at least one or more liquids, gases, or solid particles, such as NaOH, oxidizers, potassium bicarbonate, palladium, and combinations thereof.

38. 34. The rechargeable filter media composition of claim 33, wherein the activated substrate is at least one of carbon, metal oxide, metal carbide, ceramic, porcelain, clay, porous glass, mixed metal oxides consisting of binary, ternary, quaternary with respect to the number of different metal cations present, and combinations thereof.

39. 34. The rechargeable filter media composition of claim 33, wherein the filter media is formed as high surface area carbon or high surface area metal oxide pellets impregnated with an active agent that adsorbs pollutants in exhaust gases.

40. 34. The rechargeable filter media composition of claim 33, wherein the filter media removes carbon monoxide from exhaust gases and produces CO as a by-product. 2 wherein the by-product is captured by a regenerant NaOH and converted to carbonate, resulting in the by-product being recycled for industrial use by using catalytic reactions and neutralization reactions.

41. 34. The rechargeable filter media composition of claim 33, wherein the filter media is an oxidizer having a permanganate coated substrate for removing ethylene from decaying produce and converting it to carbon dioxide as a by-product, the by-product forming a blanket on the produce, and the regenerant is an oxidizer for replenishing the media.

42. 34. The rechargeable filter media composition of claim 33, wherein the filter media is a metabisulfite coated substrate for removing oxygen from produce.