Exhaust Catalyst Regeneration via Segmented Crushing
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Solution Overview
Problem
Existing methods for regenerating exhaust gas treatment catalysts contaminated with fly ash reduce catalyst component volumes, lower denitration performance, and lead to sulfur dioxide oxidation, causing corrosion and performance degradation.
Innovation Solution
A method involving crushing the catalyst to separate coarse pieces from fine ash particles, followed by pulverization and recalcination, effectively removing ash and maintaining catalyst component volumes, preventing poisoning and sulfur dioxide oxidation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the catalyst is pulverized and reground to remove fly ash, then the catalyst can be reused, but the catalyst component volume per unit is reduced and denitration performance deteriorates
Solution Approach 1:
The catalyst is crushed into coarse pieces (retaining 50-90% of original volume) and separated from fine ash particles through screening. This segmentation allows selective removal of ash while preserving catalyst structure and volume, avoiding complete pulverization and maintaining sufficient catalyst component concentration for effective denitration.
2Reliability
If fly ash is completely removed from the catalyst, then denitration performance is maintained, but the regeneration process becomes more complex
Solution Approach 1:
The harmful fly ash particles are extracted from the catalyst through crushing and screening processes. By removing only the ash contamination while preserving the catalyst honeycomb structure and active components, the process achieves performance restoration without requiring complete catalyst replacement or overly complex regeneration procedures.
3Duration of action of moving object
If the catalyst is used for a long period, then operational flexibility is improved, but fly ash accumulates and blocks the holes reducing performance
Solution Approach 1:
The catalyst is periodically subjected to crushing and screening treatments before complete ash accumulation blocks the honeycomb holes. This preliminary regeneration action removes accumulated ash and restores hole accessibility, maintaining denitration performance throughout the extended service life without requiring catalyst replacement.
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 method restores denitration performance to levels equivalent to new catalysts, reduces corrosion, and minimizes water usage and environmental impact.
Implementation Method 1
crushing the catalyst to separate coarse pieces from fine ash particles
Implementation Method 2
molded into a honeycomb shape so as to have multiple holes, and calcined
Data Source
Figure 1
Figure 2
AI summary
Provided is a method of regenerating an exhaust gas treatment catalyst 11 having ash adhered to a surface thereof. The method includes a crushing step (S1) in which the exhaust gas treatment catalyst (11) is crushed such that 70 to 95 wt% of the whole exhaust gas treatment catalyst (11) becomes coarse pieces (12) having a size exceeding a threshold size (S) (any value in a range of 0.105 to 1.0 mm); a separating step (S2) in which the fragments obtained by crushing the exhaust gas treatment catalyst (11) are separated into the coarse pieces (12) having a size exceeding threshold size (S) and fine particles (13) having a size not larger than the threshold size (S); a pulverizing step (S3) in which the coarse pieces (12) thus separated are pulverized to a fine powder having an average particle diameter of not larger than 0.1 mm; a kneading step (S4) and a molding step (S5) in which the fine powder is kneaded with other raw materials and molded into an exhaust gas treatment catalyst; and a drying step (S6) and a calcining step (S7) in which the molded precursor is dried and calcined to thus obtain a regenerated exhaust gas treatment catalyst (14).