Cement Clinker Mercury Removal With Mobile Segmented Sorbent Beds
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Solution Overview
Problem
Existing mercury removal systems for cement clinker production are costly and prone to operational issues such as spontaneous combustion, requiring complex equipment and high maintenance, while existing fixed-bed and moving-bed adsorbers are inefficient and costly.
Innovation Solution
A system using a mobile container with multiple fixed beds of carbon-containing or mineral sorbents, arranged immobile within, allows for efficient mercury separation by distributing sorbents across containers to manage temperature and reduce fire risk, with a compact design that minimizes equipment complexity and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a moving-bed adsorber is used to remove mercury from flue gases, then mercury separation efficiency is improved, but device complexity and operational reliability deteriorate due to spontaneous combustion of activated carbon
Solution Approach 1:
The system divides the sorbent into multiple separate containers (first container, second container, third container) within the mobile container, each holding a portion of the total sorbent mass. This segmentation prevents spontaneous combustion by limiting the amount of sorbent in each container and allows independent replacement of individual containers without shutting down the entire system.
Solution Approach 2:
The system enables dynamic replacement of sorbent containers while the mobile container remains in operation. The control system can redirect flue gases through operational containers while non-operational containers are replaced, providing operational flexibility and continuous mercury removal capability.
2Reliability
If a fixed-bed adsorber with large-volume sorbent is used, then mercury separation efficiency is improved, but fire safety deteriorates due to spontaneous combustion risk
Solution Approach 1:
The total sorbent volume is divided across multiple smaller containers (first, second, and third containers) within the mobile container. Each container holds a fraction of the total sorbent mass, reducing the risk of spontaneous combustion while maintaining overall separation efficiency through the combined capacity of all containers.
Solution Approach 2:
The system positions containers at different locations within the mobile container, with the first container in a first location, second container in a second location, and third container in a third location. This spatial distribution improves heat dissipation and reduces localized overheating risks while maintaining effective mercury contact.
3Productivity
If sorbent replacement is performed in traditional systems, then sorbent regeneration is achieved, but system downtime increases due to shutdown requirements
Solution Approach 1:
The system allows dynamic replacement of individual sorbent containers while the mobile container remains operational. The control system redirects flue gases through operational containers during the replacement process, enabling continuous mercury removal and eliminating the need for complete system shutdowns.
Solution Approach 2:
Empty containers are prepared in advance and can be quickly exchanged with used containers. The mobile container is designed with quick-connect mechanisms and lifting devices that enable rapid container replacement, minimizing the time required for sorbent regeneration activities.
4Productivity
If a mobile container with multiple containers is used, then sorbent replacement efficiency is improved, but device complexity increases due to multiple components
Solution Approach 1:
Multiple sorbent containers (first, second, and third containers) are integrated within a single mobile container structure that includes a unified support structure, lifting device, and connection to the flue gas system. This merging allows coordinated replacement of all containers simultaneously while maintaining a manageable single-unit structure.
Solution Approach 2:
The mobile container includes a lifting device that enables self-service replacement of sorbent containers without requiring complex external handling equipment. The containers are designed to be easily detached and reattached, allowing rapid sorbent replacement by operational personnel.
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 system effectively separates mercury from flue gases with reduced operational risks and maintenance costs, enabling efficient sorbent replacement without system downtime, and enhances separation efficiency through series and parallel connections of containers.
Implementation Method 1
separating the volatile component, in particular mercury, from flue gases with the aid of a fixed bed adsorber
Data Source
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AI summary
The invention relates to an installation, in particular a cement clinker installation (1), and to a method for depositing a volatile component, in particular mercury, from flue gases, comprising: a mobile container (7) having a feed (7A) and a discharge (7B) for the flue gases, wherein several containers (8), each filled with a solid bed (9) of a sorbent, in particular a carbon-containing and/or mineral sorbent, are arranged in the mobile container (22).