Collection Enhanced Materials for FCC Unit Emission Control
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Solution Overview
Problem
Current methods for reducing SOx emissions in fluid catalytic cracking (FCC) units increase PM emissions and operational costs, and rely on expensive ammonia injection or increased ESP power, which are not environmentally sustainable in the long term.
Innovation Solution
The development of collection enhanced materials (CEM) and down stream additives (DSA) that include low electrical resistivity components and magnetic susceptibility increasing components, which are introduced into the gaseous exhaust stream to enhance PM collection and reduce emissions by improving the efficiency of particle removal devices like ESPs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-generated harmful factors
If ammonia injection or increased ESP power is used to reduce SOx emissions, then SOx emissions are reduced, but PM emissions and operational costs increase
Solution Approach 1:
The patent changes the electrical resistivity parameter of the catalyst particles by introducing conductive materials (carbon black, metal oxides, graphite) to reduce PM escape. This parameter change allows the ESP to operate more efficiently at lower power levels while maintaining PM collection effectiveness, thereby resolving the contradiction between SOx reduction and PM emission control
Solution Approach 2:
The patent creates composite catalyst particles by combining traditional cracking catalyst materials with conductive materials (carbon black, metal oxides, or graphite). This composite structure provides both the catalytic function for SOx reduction and the electrical conductivity needed for effective PM collection in the ESP, eliminating the need for ammonia injection or excessive power consumption
2Object-generated harmful factors
If ammonia injection or increased ESP power is used to reduce SOx emissions, then SOx emissions are reduced, but operational costs increase
Solution Approach 1:
The patent changes the electrical resistivity parameter of the catalyst particles by introducing conductive materials (carbon black, metal oxides, graphite) to reduce PM escape. This parameter change allows the ESP to operate more efficiently at lower power levels while maintaining PM collection effectiveness, thereby resolving the contradiction between SOx reduction and PM emission control
Solution Approach 2:
The patent uses inexpensive conductive materials (carbon black, metal oxides, graphite) that can be easily incorporated into the catalyst formulation. These materials are cost-effective alternatives to expensive ammonia injection systems and reduce the operational costs associated with high-power ESP operation
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
These materials effectively reduce PM escape into the atmosphere while maintaining or reducing SOx emissions, thereby meeting EPA regulations without increasing operational costs or environmental impact.
Implementation Method 1
collection enhanced materials (CEM) and down stream additives (DSA) that include low electrical resistivity components
Implementation Method 2
magnetic susceptibility increasing components
Implementation Method 3
electrostatic precipitators (ESP)
Implementation Method 4
electrostatic precipitators (ESP)...absorbing PM
Data Source
AI summary
Collection enhanced materials, flue gas additives, and methods of making the enhanced materials and flue gas additives are provided. In one embodiment, a down stream addition system configured to control material passing through a metering device from a vessel to a gaseous exhaust path extending between a unit and an exhaust flue of the unit is provided. In alternative embodiments, methods are provided for introducing at least one of a flue gas additive and a collection enhanced material to a gaseous exhaust stream exiting a unit; exposing and removing at least a portion of at least one a of flue gas additive and a collection enhanced material from a gaseous exhaust stream exiting a unit prior to entering an exhaust flue; and recycling at least a portion of material removed a from a gaseous exhaust stream exiting a unit back to the gaseous exhaust stream without passing through the unit.