Method for purifying industrial gases and purification unit

Abstract

The invention relates to industrial technologies focused on cleaning gases generated during the combustion of fossil fuels, municipal and industrial waste, tires, polymers, and other chemical substances. Particular attention is given to the removal of oxidized particles and harmful gases produced in combustion and production processes in sectors such as metallurgy, energy, construction, and chemical industries.

Description

[0001] DESCRIPTION

[0002] METHOD FOR PURIFYING INDUSTRIAL GASES AND PURIFICATION UNIT

[0003] Technical Field

[0004] The invention relates to a purification method developed to reduce the concentration of gases and oxidized particles released into the air stream during the combustion of fossil fuels, domestic and industrial waste, tires, polymers, and other chemical substances, as well as a purification unit operating based on this method.

[0005] The invention specifically pertains to a purification method and purification unit developed for the removal of oxidized particles and harmful gases generated during combustion and production processes in industries such as metallurgy, energy, construction, and chemical sectors. It enables the conversion of oxides and elemental substances in the air stream into their original components and water, followed by the removal of elemental substances from the air stream. This invention contributes to environmental protection and the improvement of ecological conditions in industrial regions.

[0006] State of the Art

[0007] Environmental pollution is increasing due to anthropogenic contaminants released into the air and water as a result of industrial activities in developed nations. The primary sources of such pollutants are particles generated during the combustion of hydrocarbon fuels in power plants, as well as in smelting, internal combustion engines, and other industrial processes. These pollutants include oxides of carbon, sulfur, nitrogen, lead, zinc, and other elements. For example, coal containing impurities such as lead and zinc oxidizes along with carbon when burned. Sulfur and nitrogen oxides are formed during the combustion of fuels containing sulfur and nitrogen compounds, contributing to the formation of acid rain and posing a significant environmental challenge.

[0008] Various methods have been developed to clean emissions generated during the combustion of hydrocarbon fuels in power plants, combustion processes, industrial processes, and internal combustion engines. For instance, coal-fired power plants commonly use washing processes with calcium compounds, which react with sulfur oxides to form gypsum. However, such processes produce significant amounts of waste, leading to disposal challenges. To reduce the need for washing, low-sulfur coal is used, which increases electricity production costs.

[0009] Alternatively, lowering the operating temperature of the power plant can reduce sulfur oxide emissions, but this results in losses in the thermal efficiency of the coal. Another method involves the use of electrostatic separators to enhance the efficiency of particle removal. In this approach, ionizers are employed to charge the particles, which are then collected in the electrostatic separator.

[0010] Industrial gas purification systems are a critical technology for cleaning and filtering gases generated in industrial facilities. These systems prevent the release of pollutants into the atmosphere, thereby reducing environmental pollution and protecting workers' health. They typically include filters, electrostatic precipitators, absorption columns, and catalytic converters. These systems capture contaminants in gases and release purified air. Industrial gas purification systems are designed based on the type of gas, level of contamination, and the specific needs of the facility. Their implementation not only ensures compliance with environmental regulations and legal requirements but also reduces costs. Such systems enhance the competitiveness of industrial enterprises and promote long-term environmental sustainability.

[0011] Extensive research has been conducted to effectively purify industrial waste gases. One such study is the invention described in patent application W02007 / 037768, titled "A System and Method for Obtaining Fuel from Waste Materials." This invention pertains to a system and process developed to produce heat, power, combustible gases, and chemicals from segregated or unsegregated Municipal Solid Waste (MSW), industrial waste, wastewater treatment plant sludge, leather industry waste, agricultural residues, and similar materials. More specifically, the invention relates to a system and method for producing heat, power, combustible gases, and chemicals from solid waste. It involves steps such as raw material preparation, gasification, synthesis gas purification, energy generation, and optionally the production of valuable chemicals alongside by-products.

[0012] Another study is the invention described in patent application EP1501622B1 , titled "Method and Apparatus for Processing Gas Emitted from a Waste Treatment System." This invention pertains to the purification of gas emitted from industrial or hazardous waste treatment systems. Previous particle control approaches have faced significant challenges, such as failing to reduce emissions to acceptable levels, high construction and operational costs, and low energy efficiency. Therefore, there is a pressing need to develop new industrial gas purification methods that address these shortcomings and meet contemporary requirements.

[0013] Brief Description of the Invention

[0014] This invention relates to a method for purifying industrial gases that eliminates all the shortcomings of existing solutions and offers additional advantages. The method is designed to process gases containing oxidized particles generated during the combustion of fossil fuels, waste materials, tires, polymers, and other chemical substances. It facilitates the conversion of oxides and elemental substances into water and the removal of elemental substances from the air stream.

[0015] The primary objective of the invention is to process air streams containing combustion products, transforming them into elemental substances and water.

[0016] An additional objective is the removal of elemental substances from the air, resulting in a significantly improved and purified air stream while providing the opportunity to recover valuable elemental substances when necessary.

[0017] Another objective is to treat emissions from coal-fired power plants using a device with low energy consumption to enhance efficiency. This approach allows for the recovery of carbon from flue gases for reuse as fuel, significantly increasing the power plant’s efficiency.

[0018] Furthermore, the invention aims to enable the use of previously prohibited waste incinerators due to high air purification efficiency, thereby facilitating better control of air pollution.

[0019] An additional purpose is to reduce the size of landfill areas through combustion and proper processing, extending the usability of landfill sites. This reduces the closure time of landfills and prolongs their operational lifespan.

[0020] The structural and characteristic features of the invention, along with all its advantages, will be more clearly understood through the detailed description provided below, which references the accompanying figures. Therefore, the evaluation of the invention should consider these figures and detailed explanations. Brief Description of the Figures

[0021] To fully understand the configuration of the present invention and its advantages in conjunction with auxiliary components, it should be evaluated together with the figures described below.

[0022] Figure 1 : Shows a schematic overall view of the gas purification unit,

[0023] Figure 2: Shows a schematic cross-sectional view of the gas purification unit,

[0024] Figure 3: Shows a schematic overall view of the gas purification unit in a disassembled state,

[0025] Figure 4a: Shows a schematic overall view of the bushing bearings and the body in a disassembled state,

[0026] Figure 4b: Shows a schematic overall view of the assembly configuration of the injector positioning device,

[0027] Figure 4c: Shows a schematic overall view of the body and the suspension bushing assembly configuration,

[0028] Figure 4d: Shows a schematic overall view of the assembly configuration of the forked pin,

[0029] Figure 4e: Shows a schematic overall view of how the unit’s position is adjusted.

[0030] Reference Numbers

[0031] 100. Gas purification unit

[0032] 101. Body

[0033] 102. Conical hopper

[0034] 103. Upper water pocket

[0035] 104. Lower water pocket 126. Injector positioning rod

[0036] 127. Support leg

[0037] 128. Band

[0038] 129. Stabilizing diagonal

[0039] 130. Upper strut

[0040] 131. Adjustment bolt

[0041] 132. Support bolt

[0042] 133. Arm

[0043] 134. Holder arm

[0044] 135. Injector insulator

[0045] 136. Support insulator bolt

[0046] 137. Sleeve assembly

[0047] 138. Upper disc

[0048] 139. Suspension

[0049] 140. Fixator

[0050] 141. Keyed pin

[0051] 142. Ring

[0052] 143. Insulator

[0053] Detailed Description of the Invention

[0054] In this detailed description, the industrial gas purification unit (100) and purification method developed for treating process gases emitted from black and non-ferrous metallurgy facilities, chemical and petrochemical plants, construction industries, as well as energy and fuel industry installations, are explained purely as an example for better understanding and without imposing any limiting effect.

[0055] The gas purification unit (100), as shown in Figure 1 , is used in industrial settings, production workshops, and other facilities to purify fugitive emissions of harmful substances, dispose of wastes through incineration, and eliminate atmospheric emissions of pollutants from liquid- fueled boilers in industries using hydrocarbon fuels for technological purposes. It cleans an airflow containing oxidized compounds and / or particles that include carbon, sulfur, iron, and other elements. The mentioned gas purification unit (100) has a conical structure that ensures proper gas flow direction. The gas purification unit (100) comprises: a body (101) forming a conical hopper (102) in its central portion, An upper water pocket (103) positioned at the upper section of the body (101), A lower water pocket (104) positioned at the lower section of the body (101), A support ring (105) placed at the upper portion of the body (101) in communication with the upper water pocket (103) to support it, A lower gas channel (106) installed inside the body (101) at the lower part of the conical hopper (102), An inlet water manifold (107) connected to the upper water pocket (103), A cover (108), Two drain pipes (109) connected to the lower water pocket (104), and An injector (110) positioned at the very top of the body (101), covering the conical hopper (102). The mentioned injector (110) is made of a dielectric material and has a three-dimensional hollow form. Corrosion-resistant, sharp metal electrodes (111 ) are arranged on the exterior surface of the injector (110). These sharp metal electrodes (111) are electrically interconnected and connected to a connector (112) for attachment to a high-voltage power supply (125). The injector (110) is connected to the injector positioning rod (126) via high-voltage insulators (115). The injector suspension frame (113) is attached to the support ring (105) through high-voltage insulators (116) and struts (117). This entire structure is mounted on a frame (118).

[0056] The contaminated air or flue gas is pumped into the upper flue gas channel (119) of the gas purification unit (100) by the flue gas air supply device (122) with a locking mechanism, as shown in Figure 2. The aforementioned injector (110) passes between the tips of the sharp metal electrodes (111 ) and the water electrode (120), then enters the lower gas channel (106), and is released into the atmosphere by the purified gas exhaust fan (123). The water electrode (120) is formed by the water flowing down from the upper water pocket (103) into the body (101) and serves as a collector for removed foreign substances. The water containing settled contaminants accumulates in the lower water pocket (104) and then flows by gravity into the recycled water preparation and treatment unit (124), where it is filtered and fed back into the upper water pocket (103) of the industrial gas purification unit (100) for reuse. The sharp metal electrodes (111) of the injector (110) receive electric current from the high-voltage power supply (125) through the connector (112), with a voltage of 30-80 kV and a current of up to 7 mA, supplied via a ballast resistor. The distance between the tips of the sharp metal electrodes (111 ) and the water electrode (120) in the operating zone is adjusted using the linear positioning rod (114). The purified gas exhaust fan (123) is connected to the lower gas channel (106) located at the lower part of the body (101).

[0057] In Figure 4a, the sleeve assembly (137) with prefabricated bushing bearings is fastened to the body (101 ) using fasteners (121) positioned 30 mm from the edge via the linear positioning rod (114). In Figure 4b, the fixed, bushed linear positioning rod (114) is placed into the hole of the upper disc (138) and secured with fasteners (121). By aligning the 12.5 mm holes on the linear positioning rod (114) and the bushing, the retractable body of the linear positioning rod (114) is inserted into the suspension (140). Subsequently, as shown in Figure 4c, the fixator (141 ) is inserted into the hole at the lower end of the linear positioning rod (114) and secured with a keyed pin (142). After fastening, the ends of the keyed pin (142) are bent.

[0058] The assembled structure shown in Figure 4d is then mounted to the injector suspension frame (113) and fixed to the lower ring (143) with fasteners (121 ). Insulators (144) are attached to the injector suspension frame (113) via fasteners (121 ). As shown in Figure 4e, the support insulator bolts (136) are connected to the lower holes of the insulators (144).

[0059] After assembling the gas purification unit (100), as shown in Figure 4f, the lower adjustment bolts (131 ) are used to set the horizontal level of the upper edge of the conical hopper (102) overflow. The upper adjustment bolts (131) are used to adjust the vertical position of the injector suspension frame (113). Once the adjustment bolts (131 ) are loosened and the upper disc (138) is shifted relative to the injector suspension frame (113), the distance between the sharp metal electrodes (111) and the conical hopper (102) is measured. The injector (110) and the body (101) are then aligned, and the previously loosened fasteners (121) are re-tightened.

[0060] In one preferred embodiment of the invention, the gas purification unit (100) is used to clean air streams containing pollutants generated from the combustion of fossil fuels, waste, and other materials, as well as to remove oxides and elemental substances.

[0061] In another preferred embodiment of the invention, the gas purification unit (100) is employed to clean emissions from coal-fired power plants by recovering carbon from plant emissions and reusing it as fuel. In yet another preferred embodiment of the invention, the gas purification unit (100) is used in waste incinerators by burning waste and cleaning the incinerator’s emissions, thereby producing elemental materials that occupy significantly less space than the original unburned waste, effectively reducing the requirements for landfill space.

[0062] In another preferred embodiment of the invention, the gas purification unit (100) is utilized so that the burned material, from which elemental substances have been recovered, and which now occupies a much smaller volume, can be reburied in the landfill after processing to reclaim these elemental materials.

[0063] In another preferred embodiment, the gas purification unit (100) is used for the production of valuable elemental materials, such as fullerenes.

[0064] In the industrial gas purification method developed for treating process gases discharged from ferrous and non-ferrous metallurgy facilities, chemical and petrochemical plants, the construction industry, as well as energy and fuel industry installations — the subject of this invention — the behavior of carbon dioxide (CO2) gas discharges is as follows:

[0065] The main discharge products from CO2 are 02, CO, and CO2. The degree of CO2 dissociation at the discharge outlet can reach up to 60%. Significant concentrations of O (oxygen) atoms are present in the discharge region; [O] / [O2] » 0.1. Under similar conditions, mass spectrometric studies of the discharge show that C3O2 and C2O concentrations are small compared to those of 02, CO, and CO2.

[0066] The dissociation of CO2, CO, and 02 occurs during collisions with electrons, resulting from the excitation of unstable and pre-dissociative electronic states, and also during collisions with electronically excited, metastable CO(aA3P) molecules. In the reaction CO + CO(aA3P) — > CO2 + C, “hot” carbon atoms (with excess translational energy) are formed, with concentrations not exceeding 10A12 cm-3. An important depletion pathway for these hot C (carbon) atoms is the reaction CO2 + C — > 2CO.

[0067] The depletion of oxygen atoms primarily occurs via recombination at the walls, resulting in the formation of 02 and CO2. Reaction (I) may occur at the glass (water) walls of the discharge tube and on metal electrodes.

[0068] Reaction I: O — > 1 02

[0069] CO2 formation reactions can also occur on the glass (water) surface. Reaction II: O(st.) + CO — > CO2 and O + CO(st.) — > CO2

[0070] In a discharge, the main processes for the formation of 02 and C02 are heterogeneous recombinations according to Reaction I and Reaction II, respectively. When water vapor is added to the initial C02, OH radicals form in the discharge. These radicals participate in the reactions OH + O — > 02 + H and OH + CO — > C02 + H, leading to the production of 02 and C02.

[0071] The reaction continues as follows:

[0072] H20 = OH’ + H+

[0073] H++ e~ = H

[0074] 40H“ - 4e~ = 02 + 2H2O

[0075] 6H + S02 = H2S + 2H2O

[0076] S02 + 2H2S = 3Sj + 2H2O

[0077] Alternatively:

[0078] S02 + 4H = Si + 2H2O

[0079] Similarly, according to the existing mechanism, carbon dioxide can be reduced:

[0080] 4H + C02 = Cl + 2H2O

[0081] C02 + 8H = CH4 + 2H2O

[0082] CH4 + C02 = 2C1 + 2H2O

[0083] The method of the invention can be used for various purposes, such as reducing oxides in an airflow containing pollutants generated by the combustion of fossil fuels, waste, and other materials into elemental substances and water, and subsequently removing the elemental material from the airflow. Additionally, the method can be employed to improve the efficiency of coal-fired power plants by recovering carbon from the plant emissions and reusing the recovered carbon as fuel. Furthermore, the method can be applied to extracted landfill material that has been incinerated and processed to recover elemental matter, which is then returned to a storage area in a much smaller volume of reclaimed elemental material.

Claims

CLAIMS1. An industrial gas purification method for reducing oxides present in an airflow containing oxidized particles, as well as pollutants generated by the combustion of fossil fuels, waste, tires, polymers, and other chemicals, into elemental substances and water, and for removing the elemental substances from the airflow, characterized by the following steps:- introducing an airflow containing carbon compounds into a reactor space and passing it upward through a reaction region, thereby causing interaction with sharp metal electrode tips (1 11 ) protruding from the outer surface of an injector (1 10);- electrically isolating the electrode and the conical hopper reactor from each other;- supplying electrical potential to the sharp metal electrodes (11 1 );- dissociating CO2, CO, and O2 through collisions with electrons resulting from the excitation of unstable and pre-dissociative electronic states, as well as collisions with electronically excited, metastable CO(a3P) molecules;- adding water vapor to the initial CO2 to form OH radicals within the discharge, wherein the OH radicals participate in OH + O — > O2 + H and OH + CO — > CO2 + H reactions, thereby forming O2 and CO2.

2. The method according to claim 1 , characterized by the step of cooling the air flow by at least about 60°C using any conventional method, when utilized to directly process a high- temperature air flow.

3. The method according to claim 1 , characterized by the step of accelerating the air entering the gap between the injector (110) and the reactor to enhance the interaction between point electrodes and oxidized particles, as a result of the interaction between oxidized particles and the injector’s tubular electrodes.

4. An industrial gas purification unit (100), developed for the purification of process gases emitted from ferrous and non-ferrous metallurgy facilities, chemical and petrochemical plants, the construction industry, and energy and fuel industry installations, characterized by comprising: a body (101 ) forming a conical hopper (102) in its central section,- an upper water pocket (103) positioned at the upper part of the body (101), into which filtered water is transferred for reuse,- a lower water pocket (104) positioned at the lower part of the body (101), where water containing settled contaminants is collected,- a support ring (105) placed at the upper portion of the body (101 ) and in communication with the upper water pocket (103) to support it,- a lower gas channel (106) connected in such a way that it remains inside the body (101 ) at the lower portion of the conical hopper (102),- an inlet water manifold (107) connected to the upper water pocket (103),- two drain pipes (109) connected to the lower water pocket (104),- an injector (110) made of dielectric material, positioned at the very top of the body (101) and covering the conical hopper (102),- corrosion-resistant, sharp-tipped metal electrodes (111) arranged on the outer surface of the injector (110), electrically interconnected and connected to a connector (112) for a high-voltage power supply (125),- a water electrode (120) formed by the downward flow of water from the upper water pocket (103) into the body (101), passing between the tips of the sharp metal electrodes (111) and serving as a collector for removed foreign substances,- a recycled water preparation and treatment unit (124) into which the water collected in the lower water pocket (104) flows by gravity for filtration.

5. The gas purification unit (100) according to claim 4, characterized by having a conical structure that ensures proper gas flow direction.

6. The gas purification unit (100) according to claim 4, characterized by comprising an injector positioning rod (126) to which the injector (110) is connected.

7. The gas purification unit (100) according to claim 4, characterized by comprising high- voltage insulators (115) that connect the injector (110) to the injector positioning rod (126).

8. The gas purification unit (100) according to claim 4, characterized by comprising an injector suspension frame (113) attached to the support ring (105) via high-voltage insulators (116) and struts (117), on which insulators (144) are mounted.

9. The gas purification unit (100) according to claim 4, characterized by comprising a flue gas air supply device (122) with a locking mechanism for introducing contaminated air or flue gas into the gas purification unit (100).

10. The gas purification unit (100) according to claim 4, characterized by comprising an upper flue gas channel (119) through which contaminated air or flue gas is pumped by the flue gas air supply device (122) with a locking mechanism.

11. The gas purification unit (100) according to claim 4, characterized by comprising a purified gas exhaust fan (123) that releases the cleaned air or flue gas into the atmosphere after it passes through the lower gas channel (106).

12. The gas purification unit (100) according to claim 4, characterized by comprising a linear positioning rod (114) for adjusting the distance between the tips of the sharp metal electrodes (111) and the water electrode (120).

13. The gas purification unit (100) according to claim 4, characterized by comprising a support frame mounted on a foundation via a support leg (127), a band (128), and a stabilizing diagonal (129), using flattened fasteners (121).

14. The gas purification unit (100) according to claim 4, characterized by comprising an adjustment bolt (131) threaded into the upper holes of the support frame, used to set the horizontal level of the upper edge of the conical hopper (102) overflow and the vertical position of the injector suspension frame (113).

15. The gas purification unit (100) according to claim 4, characterized by comprising support bolts (132) inserted through the holes of the support ring’s (143) bushings.

16. The gas purification unit (100) according to claim 4, characterized by comprising an upper strut (130) connected to the threaded section of the support bolts (132), with its upper holes interfacing with the adjustment bolts (131).

17. The gas purification unit (100) according to claim 4, characterized by comprising a stabilizing diagonal (129) aligned with the holes above the injector insulators (135) after the injector (110) is removed.

18. The gas purification unit (100) according to claim 4, characterized by comprising an arm (133) that connects the support leg (127) to the body (101 ), onto which the upper strut (130) is attached.

19. The gas purification unit (100) according to claim 4, characterized by comprising a suspension (140) in which the retractable body of the linear positioning rod (114) is placed.

20. The gas purification unit (100) according to claim 4, characterized by comprising a fixator (141) inserted into the hole located at the lower portion of the linear positioning rod (114).

21. The gas purification unit (100) according to claim 4, characterized by comprising a keyed pin (142), whose ends are bent after insertion, to secure the fixator (141).

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