Oxidizable Catalyst Separation Using Stacked Screens
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Solution Overview
Problem
Refineries incur unnecessary costs in disposing of industrial waste as they do not efficiently segregate hazardous and non-hazardous components of catalyst and inert support materials, leading to equal treatment and processing expenses for both.
Innovation Solution
A system and method using an enclosure with stacked screens and inert gas to separate oxidizable catalyst material from inert support media, allowing for the inert media to be disposed of as non-hazardous waste and the catalyst for reclamation or disposal, while minimizing oxidation risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If catalyst material is mixed with inert support media and disposed of together, then disposal process is simplified, but disposal cost increases due to hazardous waste classification
Solution Approach 1:
The patent applies segmentation by separating the catalyst material from the inert support media into distinct streams. The catalyst material is classified as hazardous waste requiring special disposal, while the inert support media is classified as non-hazardous waste allowing cheaper disposal methods. This segmentation resolves the contradiction by enabling simplified disposal processes for each stream while reducing overall disposal costs through differentiated treatment.
Solution Approach 2:
The patent extracts the catalyst material from the mixed waste stream and isolates it for separate handling. By taking out the hazardous catalyst material from the mixture, the system can dispose of the remaining inert support media at lower cost while properly managing the hazardous component through specialized disposal pathways, thereby reducing overall disposal expenses.
2Ease of operation
If catalyst material is exposed to air during handling, then processing is easier, but oxidation reaction occurs reducing catalyst effectiveness
Solution Approach 1:
The patent applies the inert atmosphere principle by using nitrogen gas to create an inert environment during catalyst material handling and disposal operations. This prevents oxygen from the air from contacting the catalyst material, thereby avoiding oxidation reactions that would reduce catalyst effectiveness. The system maintains catalyst reliability while enabling straightforward processing operations under controlled atmospheric conditions.
Solution Approach 2:
The patent implements preliminary anti-action by pre-saturating the catalyst material with nitrogen gas before disposal operations begin. This preliminary step creates a protective inert atmosphere that prevents oxidation from occurring during subsequent handling and disposal processes, thereby preserving catalyst effectiveness while maintaining operational ease.
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
Enables cost reduction by segregating hazardous and non-hazardous waste components, reducing disposal costs and enabling reuse of catalyst materials.
Implementation Method 1
Inert gas is supplied to the enclosure to displace oxygen within the enclosure so as to limit oxidation of the oxidizable catalyst material
Implementation Method 2
a plurality of stacked screens within the enclosure, the stacked screens having openings that decrease in size from a top of the stack to a bottom of the stack
Data Source
AI summary
A method for disposing of a mixture of oxidizable catalyst material and inert support media. The method comprises introducing inert gas into an enclosure. The enclosure contains a plurality of stacked screens, the stacked screens have openings that decrease in size from a top of the stack to a bottom of the stack. The method also comprises introducing the mixture to an uppermost one of the plurality of stacked screens; moving the plurality of stacked screens to cause the oxidizable catalyst material to separate from and migrate to a location beneath the inert support media; conveying the separated inert support media to a location outside the enclosure for disposal as non-hazardous waste; and conveying the separated oxidizable catalyst material to a location outside the enclosure for at least one of reclamation, or thermal destruction.