Sorbent Mill Deagglomeration for Mercury Adsorption
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Solution Overview
Problem
Current methods for removing gaseous pollutants, particularly elemental mercury and mercury compounds, from coal-fired power plant flue gases are inefficient and costly due to low surface area to mass ratio of sorbent particles and high energy requirements for deagglomeration, and are less effective compared to waste incinerators.
Innovation Solution
A system utilizing superheated steam to deagglomerate and comminute carbonaceous sorbent particles into finer sizes, increasing their surface area and dispersibility within the flue gas, without relying on compressed air, thereby enhancing adsorption efficiency and reducing operational costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If carbonaceous sorbent particles are used to adsorb mercury vapor, then mercury removal is achieved, but the low surface area to mass ratio of larger particles limits adsorption efficiency
Solution Approach 1:
The patent segments the carbonaceous sorbent into extremely fine particles with mean size of 0.5-5 microns, breaking down larger particles to dramatically increase the total surface area available for mercury adsorption while maintaining adequate removal efficiency
2Ease of operation
If compressed air is used to inject and disperse sorbent particles, then particle dispersion is improved, but energy consumption and operational costs increase significantly
Solution Approach 1:
The patent employs the flue gas flow itself to transport and disperse the sorbent particles through the injection system, eliminating the need for external compressed air systems and associated energy consumption while achieving adequate particle distribution
Solution Approach 2:
The patent utilizes the existing gas flow dynamics of the flue gas to achieve particle dispersion and transport, leveraging the natural pneumatic environment rather than introducing additional compressed gas systems
3Productivity
If smaller sorbent particles are used to increase surface area, then adsorption efficiency improves, but storage, handling, and transport become extremely difficult
Solution Approach 1:
The patent performs sorbent particle generation and sizing within the flue gas stream itself, converting larger particles to fine particles in-situ rather than requiring storage and handling of pre-ground fine particles, thus avoiding the associated operational difficulties
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 improved mercury and mercury compound removal efficiency by increasing the surface area of sorbent particles and reducing energy consumption, making the process more cost-effective and efficient compared to traditional methods.
Implementation Method 1
processing the superheated steam to provide dry, high quality superheated steam of the proper pressure, temperature that is below a predetermined moisture content; providing the processed steam to a sorbent mill to process the sorbent to deagglomerate it and to break the particles of the powdered sorbent into a greater number of smaller particles
Implementation Method 2
break the particles of the powdered sorbent into a greater number of smaller particles
Implementation Method 3
injecting the processed sorbent into contact with the flue gas to adsorb mercury and mercury compounds
Data Source
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AI summary
A system for removing gaseous pollutants, such as mercury from flue gases of a solid- fueled furnace (17), includes a sorbent mill (34) that receives superheated steam and a sorbent (28), such as activated carbon, in a partially agglomerated state, that processes the sorbent (28) by de-agglomerating and comminuting the sorbent (28). An educator (35) transports the processed sorbent (28) to a distributor (36) that injects it into the flue gases at a contact location having a temperature between 500º F and 900º F, whereupon the sorbent (28) adsorbs mercury from the flue gas. A particle collection device (24) removes the processed sorbent (28) having adsorbed mercury, from the flue gas.