Refractory Brick from Spent Claus Catalyst
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Solution Overview
Problem
Spent Claus catalysts, produced in large quantities due to frequent replacement in gas processing plants, are considered waste and pose environmental hazards due to their deactivation and sulfur-containing impurities, which reduce sulfur recovery and cause air pollution.
Innovation Solution
A method of producing refractory bricks by heating spent Claus catalysts, reducing their particle size, mixing with cement, forming a castable mixture, casting in a mold, curing, and drying to create a durable and thermally stable refractory brick.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If spent Claus catalyst is disposed of as waste, then environmental pollution is caused, but disposal costs and environmental compliance burden increase
Solution Approach 1:
The patent converts the harmful spent catalyst waste into a beneficial refractory brick material. The spent catalyst, which would otherwise be disposed of as hazardous waste, is processed through heating and particle size reduction to create a valuable construction material for high-temperature applications, thereby eliminating environmental pollution while recovering material value
Solution Approach 2:
The patent applies thermal treatment (heating to 400-850°C) and mechanical processing (particle size reduction to 0.15-0.425mm) to transform the spent catalyst from a waste state into a usable refractory material. These parameter changes in temperature and particle size enable the catalyst to meet the specifications for refractory brick production
2Ease of manufacture
If spent Claus catalyst is reused directly without processing, then production cost is reduced, but the catalyst lacks the required physical properties for refractory applications
Solution Approach 1:
The patent performs preliminary processing of the spent catalyst before it can be used as refractory material. The heating treatment at 400-850°C and particle size reduction to 0.15-0.425mm are conducted in advance to prepare the catalyst with the appropriate physical properties, ensuring it meets refractory application requirements before incorporation into the brick matrix
Solution Approach 2:
The patent creates a composite refractory material by combining processed spent catalyst particles with cement and optionally aggregate. This composite approach allows the spent catalyst to contribute its alumina content and refractory properties while the cement matrix provides binding and structural integrity, achieving both cost-effectiveness and mechanical strength
3Productivity
If Claus catalyst is used with high surface area and low density, then sulfur conversion activity is improved, but the catalyst deactivates faster due to coke deposition and sulfur accumulation
Solution Approach 1:
The patent converts the deactivated catalyst, which has lost its sulfur conversion activity due to coke and sulfur accumulation, into a valuable refractory material. The thermal processing at 400-850°C removes the deactivating deposits while the alumina structure remains intact, transforming a failed catalyst into a durable construction material for high-temperature applications
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 effectively utilizes spent Claus catalysts as a valuable resource, reducing environmental pollution by converting waste into a high-strength refractory material suitable for furnace linings and other high-temperature applications.
Implementation Method 1
heating a spent Claus catalyst
Implementation Method 2
reducing a particle size of the catalyst
Data Source
AI summary
A method of producing refractory brick includes heating a spent Claus catalyst, reducing a particle size of the catalyst, dry mixing the catalyst with cement to form a dry mixture, adding water to the dry mixture to form a castable mixture, casting the castable mixture in a mold, curing the mold, and drying the mold to form the refractory brick.