Segregating Oxidizable Catalyst Material Using Stacked Screens

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Solution Overview

Problem

The petrochemical refinement industry incurs unnecessary costs due to the lack of efficient separation of hazardous and non-hazardous components in industrial waste, leading to equal processing and transportation expenses for both, despite inert support materials being non-hazardous.

Innovation Solution

A system and method utilizing an enclosure with stacked screens and inert gas to separate oxidizable catalyst material from inert support media, allowing the inert support media to be disposed of as non-hazardous waste and the catalyst material to be conveyed for reclamation, thermal destruction, or disposal, while maintaining an inert gas environment to prevent oxidation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If catalyst material and inert support media are not separated, then processing and transportation costs are reduced (simpler process), but disposal costs increase due to hazardous waste classification

Engineering Contradiction:

Improveseparation process complexityVSAvoiddisposal cost

Core Design Contradiction:

Device complexityVSLoss of energy

Solution Approach 1:

The invention segments the industrial waste stream into hazardous (catalyst material) and non-hazardous (inert support media) components using stacked screens with different aperture sizes. This segmentation allows each component to be disposed of according to its appropriate classification, reducing disposal costs while maintaining process simplicity through automated gravity-based separation.

Inventive Principle:

Principle #1Segmentation

2Reliability

If inert support media is classified as hazardous waste, then disposal compliance is ensured, but disposal costs increase unnecessarily

Engineering Contradiction:

Improvedisposal complianceVSAvoiddisposal cost

Core Design Contradiction:

ReliabilityVSLoss of energy

Solution Approach 1:

The invention extracts the inert support media from the hazardous waste stream using stacked screens that allow non-hazardous materials to pass through while retaining hazardous catalyst material. This extraction enables the inert support media to be disposed of as non-hazardous waste, reducing disposal costs while maintaining compliance through proper identification and separation of waste streams.

Inventive Principle:

Principle #2Taking out (Extraction)

3Ease of operation

If catalyst material is exposed to air during processing, then handling is simplified, but oxidation reactions occur reducing catalyst effectiveness

Engineering Contradiction:

Improvehandling simplicityVSAvoidoxidation reaction

Core Design Contradiction:

Ease of operationVSObject-generated harmful factors

Solution Approach 1:

The invention creates an inert atmosphere within the enclosed stacking screen system by using nitrogen or other inert gases to displace oxygen. This prevents oxidation reactions of the catalyst material during handling and processing, while the enclosed design with inert gas maintains simplicity through automated operation and eliminates the need for complex protective measures.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

4Productivity

If all catalyst material is replaced at once, then unit down time is optimized, but waste material accumulation increases

Engineering Contradiction:

Improveunit throughputVSAvoidwaste material volume

Core Design Contradiction:

ProductivityVSQuantity of substance

Solution Approach 1:

The invention segments the waste material into hazardous and non-hazardous components during the catalyst replacement process. By separating inert support media from catalyst material using stacked screens, the system enables efficient unit down time while reducing waste material accumulation through proper classification and separate handling of the two waste streams.

Inventive Principle:

Principle #1Segmentation

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

This approach reduces the premium on hazardous waste management by enabling the separation and proper disposal of inert support media as non-hazardous waste, potentially lowering overall disposal costs and allowing for the reuse or recycling of catalyst materials.

Implementation Method 1

inert gas inlet associated with the enclosure for conveying the inert gas to the enclosure to displace oxygen within the enclosure and thereby limit oxidation of the oxidizable catalyst material

Methodology Applied

Scientific EffectInert gas displacement: Physical Containment

Implementation Method 2

a plurality of stacked screens disposed within the enclosure, the stacked screens having openings that decrease in size from a top of the stack to a bottom of the stack

Methodology Applied

Scientific EffectScreen separation: Filter (physical)

Implementation Method 3

at least one motor for moving the stacked screens to cause the oxidizable catalyst material to separate from and migrate to a location beneath the inert support media

Methodology Applied

Scientific EffectMechanical vibration: Vibration

Data Source

PatentUS11767975B2Systems and methods for segregating and grinding oxidizable catalyst material

Publication Date: 2023.09.26 THE MAITLAND

AI summary

A method of disposing of a mixture of oxidizable catalyst material and inert support media. The method comprises introducing inert gas into an enclosure; introducing the mixture into the enclosure; separating the oxidizable catalyst material and the inert support media within the enclosure; maintaining an inert gas environment around the oxidizable catalyst material during separating; exporting the separated inert support media from the enclosure; and grinding the separated oxidizable catalyst material into a powder for disposal as hazardous waste via incineration.