Sorbent Preparation via Copper Sulphide Coating
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Solution Overview
Problem
Existing methods for preparing copper sorbents require a separate sulphiding step, which is inefficient and adds complexity, whereas there is a need for a method to efficiently remove heavy metals like mercury and arsenic from fluid streams without this additional step.
Innovation Solution
A method involving the mixing of an inert particulate support material with binders, shaping into agglomerates, coating with a copper sulphide and binder mixture, and drying to form a sorbent that can directly remove heavy metals from fluid streams, eliminating the need for a separate sulphiding step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a separate sulphiding step is used to convert copper compound to copper sulphide, then the sorbent can effectively remove heavy metals, but the process complexity and manufacturing time increase
Solution Approach 1:
The patent combines the sulphiding step with the coating step by using copper sulphide as the coating material directly. Instead of applying a copper compound layer and then separately sulphiding it, the invention applies a pre-prepared copper sulphide coating mixture containing particulate copper sulphide and binders onto the support material in one operation, thereby merging two previously separate process steps into one.
Solution Approach 2:
The copper sulphide is prepared in advance as a coating mixture with binders before the coating application. This preliminary preparation of the copper sulphide coating mixture allows the sulphiding to be completed before the coating step, eliminating the need for a separate sulphiding step during the sorbent manufacturing process.
2Reliability
If a separate sulphiding step is employed, then copper compound can be converted to copper sulphide, but the manufacturing time and process steps increase
Solution Approach 1:
The patent combines the sulphiding step with the coating step by using copper sulphide as the coating material directly. Instead of applying a copper compound layer and then separately sulphiding it, the invention applies a pre-prepared copper sulphide coating mixture containing particulate copper sulphide and binders onto the support material in one operation, thereby merging two previously separate process steps into one.
3Reliability
If copper compound layer is applied and then sulphided separately, then copper sulphide sorbent is formed, but the process requires additional equipment and operational steps
Solution Approach 1:
The patent combines the sulphiding step with the coating step by using copper sulphide as the coating material directly. Instead of applying a copper compound layer and then separately sulphiding it, the invention applies a pre-prepared copper sulphide coating mixture containing particulate copper sulphide and binders onto the support material in one operation, thereby merging two previously separate process steps into one.
4Reliability
If conventional pelleted compositions are used, then copper sorbent can be formed, but the attrition resistance and physical properties are insufficient
Solution Approach 1:
The patent uses a composite structure consisting of a support material core coated with a copper sulphide-containing coating mixture. The coating mixture comprises particulate copper sulphide and binders, creating a composite material that combines the structural properties of the support material with the heavy metal capture capability of copper sulphide, thereby improving attrition resistance and overall sorbent performance.
Solution Approach 2:
The patent applies copper sulphide coating specifically to the surface of the support material particles, creating a layered structure where the core provides mechanical strength and the surface coating provides heavy metal capture functionality. This local differentiation of material properties optimizes both structural integrity and sorbent performance.
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 produces a sorbent that effectively captures heavy metals, such as mercury and arsenic, from fluid streams, offering improved efficiency and simplicity by integrating the sulphiding process, with enhanced physical properties and attrition resistance.
Implementation Method 1
coating the agglomerates with a coating mixture powder comprising a particulate copper sulphide and one or more binders to form a coated agglomerate
Implementation Method 2
drying the coated agglomerate to form a dried sorbent
Implementation Method 3
The dried sorbent may be used to treat both liquid and gaseous fluid streams containing heavy metals
Implementation Method 4
By 'sorbent' we include absorbent and adsorbent
Data Source
AI summary
A method is described for preparing a sorbent comprising the steps of:(i) mixing together an inert particulate support material and one or more binders to form a support mixture,(ii) shaping the support mixture by granulation in a granulator to form agglomerates,(iii) coating the agglomerates with a coating mixture powder comprising a particulate copper sulphide and one or more binders to form a coated agglomerate, and(iv) drying the coated agglomerate to form a dried sorbent.