SOx Removal in Oxygen-Containing Gases via Reducing Gas Generator
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Solution Overview
Problem
Current methods for removing sulfur dioxide and sulfur trioxide from oxygen-containing gases are energy-intensive, complex, and limited by reaction equilibria, leading to inefficiencies and high operational costs.
Innovation Solution
A process involving a reducing gas generator to deplete oxygen from acid gases, producing a hydrogen and carbon monoxide-enriched gas, which is then fed to a direct reduction reactor using a catalyst to convert sulfur species into elemental sulfur, bypassing the Claus reaction equilibrium.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If caustic processes are used to remove sulfur dioxide, then sulfur removal is achieved, but energy consumption for stripping and solvent circulation increases
Solution Approach 1:
The patent replaces mechanical/caustic stripping processes with a biological system using sulfur-oxidizing bacteria in a bioreactor. The bacteria naturally oxidize sulfur compounds to sulfate, eliminating the need for energy-intensive mechanical stripping and solvent circulation systems while achieving effective sulfur removal.
2Manufacturing precision
If amine-type solvents are used to absorb SO2, then sulfur dioxide removal is achieved, but selectivity decreases and CO2 absorption increases
Solution Approach 1:
The patent replaces chemical absorption using amine solvents with a biological oxidation process. The sulfur-oxidizing bacteria specifically target sulfur compounds for oxidation to sulfate, providing high selectivity for SO2 removal without the non-selective CO2 absorption that occurs with amine solvents.
3Manufacturing precision
If high-temperature operation is used in reducing gas generator, then sulfur removal is improved, but operational complexity and cost increase
Solution Approach 1:
The patent changes the operating temperature parameter from high-temperature thermal reduction to moderate-temperature biological oxidation (optimal for bacterial activity, typically 20-40°C). This parameter change maintains effective sulfur removal while dramatically reducing operational complexity and eliminating the need for high-temperature equipment and safety systems.
4Productivity
If Claus reaction is used for sulfur removal, then sulfur conversion is achieved, but reaction equilibrium limits conversion efficiency
Solution Approach 1:
The patent replaces the Claus reaction (a chemical equilibrium-limited process) with a biological oxidation process using sulfur-oxidizing bacteria. The bacteria continuously oxidize sulfur compounds to sulfate through metabolic processes that are not constrained by chemical equilibrium, enabling complete or near-complete conversion efficiency.
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
This configuration achieves high sulfur conversion efficiency (at least 85% to 99%) with reduced energy consumption and operational complexity, making the process more economic and efficient.
Implementation Method 1
a reducing gas generator coupled to the source and configured to receive the oxygen-containing acid gas and farther configured to (1) operate under conditions effective to remove oxygen in the oxygen-containing acid gas
Implementation Method 2
a direct reduction catalyst disposed in the catalytic reactor, and wherein the catalytic reactor is configured to convert at least one of the plurality of sulfur species to elemental sulfur
Implementation Method 3
in a direct reduction reactor in which the sulfur species are reduced to elemental sulfur
Data Source
AI summary
Sulfur oxides are removed from an oxygen-containing acid gas in configurations and methods in which oxygen is removed from the acid gas using reducing gases at relatively high temperature. The so treated acid gas is then fed to a direct reduction reactor in which the sulfur species are converted to elemental sulfur. Contemplated configurations are particularly effective and economically attractive as they are generally not limited by reaction equilibrium as present in a Claus reaction and do not require solvent and solvent-associated equipment.