Catalyst Mixture for Waste Gas Treatment
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Solution Overview
Problem
Existing catalyst systems, such as the Sulfacid® and Kombisorbon® processes, are less efficient at higher concentrations of SO2, heavy metals, and dioxins/furans in waste gases, and require more catalyst to achieve optimal removal, which is not feasible.
Innovation Solution
A catalyst mixture comprising 95% to 30% vol. of activated carbon catalyst combined with 5% to 70% vol. of filler materials like plastic, alumina, metal, or ceramic, which enhances pollutant removal efficiency and facilitates easier regeneration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If more activated carbon catalyst is used to remove pollutants at higher concentrations, then pollutant removal efficiency should improve, but the process becomes less efficient and regeneration time increases
Solution Approach 1:
The patent applies composite materials by combining activated carbon catalyst particles with inert filler materials (such as ceramic spheres, plastic beads, or metal shot) to create a hybrid catalyst bed. This composite structure maintains the pollutant-removing functionality of activated carbon while the inert filler provides structural support, improves gas flow distribution, and prevents catalyst clumping. The result is enhanced removal efficiency for SO2, heavy metals, and dioxins at higher concentrations, with reduced regeneration time due to better mass transfer and reduced catalyst deactivation.
2Quantity of substance
If activated carbon catalyst is used alone, then it can remove pollutants through adsorption, but it becomes saturated quickly and requires frequent regeneration
Solution Approach 1:
The patent implements continuity of useful action by creating a catalyst system where activated carbon particles work in conjunction with inert filler materials that maintain optimal gas flow and prevent channeling. This ensures continuous effective contact between pollutants and catalyst surfaces, maximizing the utilization of adsorption capacity throughout the service life. The inert filler prevents localized saturation and maintains uniform reaction conditions, extending the operational duration before regeneration is required.
3Reliability
If high concentration of pollutants is present in waste gas, then more catalyst is needed to achieve optimal removal, but this increases system complexity and cost
Solution Approach 1:
The patent applies parameter changes by modifying the physical and chemical properties of the catalyst bed through the addition of inert filler materials. This changes the bed density, porosity, surface area distribution, and gas flow characteristics, allowing the system to handle higher pollutant concentrations more effectively. The parameter optimization occurs at the material composition level rather than requiring complex system redesign, thus improving removal efficiency while minimizing increased complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The catalyst mixture achieves more complete removal of pollutants at higher concentrations and reduces regeneration time by up to 40%, demonstrating improved performance and efficiency compared to standalone activated carbon catalysts.
Implementation Method 1
The Kombisorbon® process allows removing ionic mercury known as Hg2+ through adsorption as HgCl2 on the activated carbon catalyst, to remove elemental mercury known as Hg0 by forming with the sulfur on the carbon mercuric sulfide known as HgS
Implementation Method 2
The SO2 is converted to sulfuric acid by wet catalysis in the presence of oxygen and water
Data Source
AI summary
A catalyst comprises a mixture of 95% vol. to 30% vol. of an activated carbon catalyst and from 5% vol. to 70% vol. of a filler material as well as a configuration of such a catalyst for the removal of SO2, heavy metals and/or dioxins form waste gas and liquids.