Sorbent Polymer Composite for Flue Gas Mercury Capture
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Solution Overview
Problem
Current methods for removing sulfur oxides, mercury vapor, and fine particulate matters from industrial flue gases face challenges such as corrosion risks, high energy costs, limited adsorbent lifespan, and leaching of halogen sources, which affect the efficiency and durability of pollution control systems.
Innovation Solution
A flue gas treatment device using a sorbent polymer composite substrate with a high surface area support and a hydrophobic polymer, combined with a halogen source having a Langmuir equilibrium constant greater than 10, which is strategically located adjacent to the sorbent material to enhance mercury capture and resist leaching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If brominated salt is added to pulverized coal for mercury control, then mercury capture efficiency is improved, but corrosion damage from excess bromine and hydrogen bromide increases
Solution Approach 1:
The patent uses activated carbon as an intermediary substance that facilitates mercury capture through adsorption without introducing corrosive bromine into the flue gas. The activated carbon acts as a mediator between the flue gas and mercury, achieving removal efficiency without the harmful side effects of brominated salt addition.
Solution Approach 2:
The patent extracts the mercury capture function from the combustion process by injecting activated carbon separately into the flue gas stream. This separates the mercury control function from coal combustion, allowing mercury removal without adding brominated compounds to the coal that would cause corrosion.
2Reliability
If large quantities of powdered activated carbon are injected for high mercury levels, then mercury capture efficiency is improved, but the value of fly ash for concrete sale is compromised
Solution Approach 1:
The patent changes the operational parameters of carbon injection, specifically controlling the injection rate and location to optimize mercury capture while minimizing carbon carryover into the fly ash. By adjusting these parameters, the system achieves effective mercury removal without compromising fly ash quality for concrete applications.
3Reliability
If fixed bed activated carbon is used for adsorption, then mercury removal is achieved, but adsorbent lifespan is too short for practical applications
Solution Approach 1:
The patent transitions from a static fixed bed system to a dynamic fluidized bed system where activated carbon particles are suspended and circulated. This dynamic approach allows continuous contact between the carbon and flue gas, enhancing mercury removal efficiency while extending the effective lifespan of the adsorbent through continuous regeneration and circulation.
Solution Approach 2:
The patent implements a system where spent activated carbon is continuously regenerated and reused. The carbon is periodically removed, regenerated to restore its adsorption capacity, and returned to the system, thereby extending the overall lifespan of the adsorbent and maintaining continuous mercury removal efficiency.
4Reliability
If sorbent polymer composite with halogen source is used, then mercury capture capacity is increased, but halogen source leaching occurs
Solution Approach 1:
The patent uses a composite material consisting of activated carbon combined with a sorbent polymer that contains halogen sources. The polymer matrix provides structural support and controlled release of halogen, while the activated carbon provides high surface area for mercury adsorption. This composite structure increases mercury capture capacity while the polymer controls halogen release to minimize leaching.
Solution Approach 2:
The patent utilizes the porous structure of activated carbon within the polymer composite to enhance mercury capture. The porous network provides high surface area for adsorption while the polymer matrix fills the pores to provide structural integrity and control halogen release, preventing leaching while maintaining capture capacity.
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 solution provides a durable and efficient system for simultaneous removal of SOx, Hg vapor, and PM2.5 with reduced leaching of halogen sources, maintaining effectiveness over a prolonged period and minimizing secondary pollutants, while being cost-effective and environmentally friendly.
Implementation Method 1
a halogen source located adjacent to the SPC substrate where the halogen source has a Langmuir equilibrium constant greater than 10
Implementation Method 2
a hydrophobic polymer, and a halogen source located adjacent to the SPC substrate
Implementation Method 3
simultaneous removal of SOx, Hg vapor, and PM2.5
Data Source
Figure 1~2
Figure 3
Figure 3A~4
AI summary
This invention provides a method of removing sulfur oxides, mercury vapor and other contaminants from a flue gas stream and a flue gas treatment device comprising a sorbent polymer composite substrate comprising a high surface area support and a durable halogen source adjacent the sorbent polymer composite substrate. The halogen source comprises a compound with a quaternary ammonium halogen salt that is not washed away.