Clay-Based Adsorbent for High-Capacity HCl Removal
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Solution Overview
Problem
Existing adsorbents for removing inorganic chlorides, particularly HCl, from hydrocarbon streams have limited chloride adsorption capacity and tend to catalyze the formation of 'Green Oil', leading to operational issues and high costs due to the use of expensive materials like zinc compounds.
Innovation Solution
A non-alumina and non-zinc composite adsorbent comprising sodium carbonate, sodium bicarbonate, and a low-cost clay material like attapulgite, with an alkali metal promoter, which achieves a chloride adsorption capacity three times higher than existing adsorbents and minimizes 'Green Oil' formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If zinc compounds are used as active material in adsorbents, then chloride adsorption capacity is improved, but manufacturing cost increases significantly
Solution Approach 1:
The patent replaces expensive zinc compounds with cheaper alternatives such as activated alumina, metal oxides, and zeolites. The adsorbent formulation uses cost-effective materials like sodium carbonate, sodium bicarbonate, and clay binders instead of costly zinc-based active materials, achieving comparable chloride removal capacity at reduced manufacturing cost
Solution Approach 2:
The patent employs composite adsorbent formulations combining multiple inexpensive materials (activated alumina, metal oxides, zeolites, clay binders) to achieve synergistic effects that match or exceed the performance of zinc compound-based adsorbents while significantly reducing manufacturing costs
2Quantity of substance
If activated alumina is used for HCl removal, then chloride adsorption capacity is improved, but tendency to catalyze Green Oil formation increases
Solution Approach 1:
The patent modifies the surface properties of alumina-based adsorbents through impregnation with alkaline earth metal salts or promotion with phosphate and organic amine compounds. This creates localized basic sites on the alumina surface that enhance chloride adsorption while suppressing the acid-catalyzed polymerization reactions that lead to Green Oil formation
Solution Approach 2:
The patent alters the chemical composition and surface properties of the adsorbent by incorporating promoters such as phosphate and organic amines. These modifications change the surface chemistry parameters of alumina, reducing its acid catalytic activity and thereby minimizing Green Oil formation while maintaining effective HCl removal capacity
3Productivity
If adsorbent capacity is increased to handle higher chloride loads, then productivity is improved, but structural integrity deteriorates due to moisture exposure
Solution Approach 1:
The patent utilizes porous refractory inorganic materials such as kieselguhr as the adsorbent matrix. These materials provide high surface area and pore volume for efficient chloride adsorption while maintaining mechanical strength and structural integrity even when exposed to moisture and operating conditions, enabling high capacity utilization without compromising structural stability
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 adsorbent effectively removes HCl with a capacity of up to 40 wt. % and maintains structural integrity, reducing operational issues and costs by using cost-effective materials while preventing 'Green Oil' formation.
Implementation Method 1
The adsorbent effectively removes HCl with a capacity of up to 40 wt. %
Implementation Method 2
with an alkali metal promoter, which achieves a chloride adsorption capacity three times higher than existing adsorbents
Data Source
AI summary
The present invention discloses an adsorbent composition for removing halogen-containing contaminants such as hydrogen chloride from gas streams and a process for its formation. The adsorbent composition comprises an active metal component and a carrier or binder. The active metal component is selected from the group consisting of sodium, potassium, magnesium, calcium and barium and the carrier/binder is selected from a group of clay materials like sepiolite, montmorillonite, kaolin or attapulgite.