Movable Silo and Converter for Spent Catalyst Recovery
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Solution Overview
Problem
The processing and disposal of spent catalysts from the Claus process are inefficient and environmentally unfriendly, with existing methods primarily involving landfill disposal despite economic and environmental pressures to reduce waste.
Innovation Solution
A catalyst converter and movable storage silo system that uses layers of ceramic and aluminum balls, along with a stainless steel wire mesh conveyor belt, to separate and transport spent catalysts, enabling their use as an additive in cement manufacturing instead of landfill disposal.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spent catalyst is disposed of in landfills, then disposal is simple and requires minimal processing, but environmental harm increases and economic value is lost
Solution Approach 1:
The patent recovers valuable metals (alumina, silica, calcium oxide) from spent Claus catalyst instead of discarding them in landfills. The converter processes the spent catalyst to extract and recover these materials, transforming waste into reusable resources for cement manufacturing and other applications, thereby eliminating environmental harm while maintaining ease of disposal through automated processing
Solution Approach 2:
The invention converts the harmful waste product (spent catalyst) into a beneficial resource. The spent catalyst, which would otherwise cause environmental pollution, is processed to recover valuable materials that can be used as additives in cement manufacturing, turning an environmental problem into an economic and environmental solution
2Object-affected harmful factors
If spent catalyst is processed to recover materials, then environmental benefit increases and economic value is recovered, but processing complexity increases
Solution Approach 1:
The converter is divided into distinct functional sections: a first chamber for initial processing and material separation, and a second chamber for further processing and recovery. This segmentation allows complex processing to be broken down into manageable stages, reducing overall system complexity while achieving comprehensive material recovery and environmental benefits
Solution Approach 2:
The patent introduces intermediate processing steps and components, such as the conveyor belt system that transports material between chambers, and the dust removal subsystem that intermediates between the converter and environmental release. These intermediaries manage complexity by handling specific functions in isolated modules
3Productivity
If spent catalyst is transported to cement plants, then utilization efficiency increases, but transportation logistics become more complex
Solution Approach 1:
The patent employs a movable silo mounted on a vehicle that can be dynamically positioned and transported to different locations, including cement plants. This dynamic transportation system allows the processing unit to move closer to utilization sites, reducing transportation logistics complexity while maintaining high utilization efficiency of the recovered catalyst materials
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 processes and transports spent catalysts, allowing for their utilization in cement production, thereby reducing waste and environmental impact while maintaining cement strength comparable to conventional materials.
Implementation Method 1
The first layer of balls is configured to retain from below spent catalyst resulting from operation of an industrial process
Implementation Method 2
The second layer of balls is configured to retain from above the spent catalyst
Implementation Method 3
The conveyor belt is configured to separate the spent catalyst from dust. The wire mesh can include a plurality of apertures configured to pass particles of the spent catalyst smaller than the apertures
Data Source
AI summary
A system and method use a converter and a movable storage silo for receiving, processing, and transporting spent catalysts. The spent catalysts can be utilized in the manufacture of cement instead of being disposed in landfills. A hydraulic sub-system remove dusts from the spent catalyst prior to storage in the silo.