CZTS Sorbent Recycling for Mercury Removal
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Solution Overview
Problem
Current industrial emission control systems are ineffective in capturing and removing mercury and other hazardous contaminants from coal-fired power plant emissions, particularly due to the conversion of mercury into nano-sized vapor particles that slip through filter systems, and existing methods are inefficient, costly, or impractical for large-scale commercial use.
Innovation Solution
A reverse venturi shaped fluidized bed apparatus with a mass of reactive material containing amalgam forming metals, such as copper, zinc, and tin, that chemically binds contaminants, combined with a sorbent recycling subsystem to optimize sorbent performance and extend its lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional filter systems are used to remove contaminants from emissions, then the system structure is simple, but mercury vapor particles slip through and contamination removal is ineffective
Solution Approach 1:
The invention changes the chemical state of mercury vapor by introducing amalgam-forming metals (zinc, copper, tin) that chemically bind with mercury to form solid amalgams. This parameter change from vapor phase to solid-bound phase enables effective capture that physical filters cannot achieve
Solution Approach 2:
The invention uses composite sorbent materials combining amalgam-forming metals with support matrices (activated carbon, alumina, silica gel, or ceramic beads). This composite structure provides both the chemical reactivity needed to capture mercury vapor and the physical structure for practical deployment in emission control systems
2Reliability
If sorbent materials are used to capture mercury, then contaminant removal effectiveness improves, but sorbent performance degrades over time and requires replacement
Solution Approach 1:
The invention implements a sorbent regeneration system where spent sorbent is periodically removed, thermally treated to desorb captured mercury, and returned to service. This recovering process restores sorbent capture capability, extending operational lifespan and reducing material replacement frequency
Solution Approach 2:
The invention maintains continuous contaminant removal effectiveness through a circulation system that continuously regenerates sorbent materials. Multiple sorbent beds operate in sequence with one being regenerated while others are actively capturing contaminants, ensuring uninterrupted effective action
3Reliability
If more sorbent material is used to improve capture efficiency, then contaminant removal improves, but operational cost increases
Solution Approach 1:
By recovering and regenerating sorbent materials through thermal desorption and reactivation, the system reduces the need to continuously purchase and replace spent sorbent. This recovers the investment in sorbent material and significantly reduces ongoing operational costs while maintaining high removal efficiency
Solution Approach 2:
The sorbent regeneration system uses the energy already present in the flue gas stream or waste heat from the process to drive the desorption and regeneration of sorbent materials. This self-service approach minimizes additional energy input requirements and reduces operational costs
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 achieves significant removal of hazardous contaminants, including mercury, from both gaseous and non-gaseous emissions, enabling industries to meet stringent regulations and potentially avoid increased costs associated with reclassifying fly ash as a hazardous material.
Implementation Method 1
a mass of reactive material containing amalgam forming metals, such as copper, zinc, and tin, that chemically binds contaminants
Implementation Method 2
A reverse venturi shaped fluidized bed apparatus with a mass of reactive material
Data Source
AI summary
An emissions control system including a fluidized bed apparatus containing a reactive sorbent material is disclosed for gaseous and non-gaseous contaminated emissions. The reactive sorbent material may be CZTS, CZTS-Alloy, or a CZTS-Mixture sorbent material. The fluidized bed apparatus is configured with one or more closed loop sorbent recycling subsystems. The sorbent recycling subsystems include the capability to separate sorbents from each other, separate contaminates from sorbents for disposal and/or recycling, clean and/or rejuvenate sorbents for return to the fluidized bed apparatus, dispose of spent and exhausted sorbents, and replace the spent and exhausted sorbents with new sorbent to maintain consistent sorbent function in the fluidized bed apparatus. Monitoring sensors provide information useful in a method for establishing and maintaining consistent process parameter controls.