Spent Chromia/Alumina Catalyst as Cement Raw Material
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Solution Overview
Problem
The disposal of spent hydrocarbon dehydrogenation catalysts, which often contain toxic components, poses environmental and health risks due to landfilling, requiring costly long-term maintenance and inefficient land use.
Innovation Solution
Processing spent hydrocarbon dehydrogenation catalysts to produce cement, utilizing them as a raw material and incorporating reducing agents to reduce toxic metal ions, thereby eliminating the need for landfill disposal and meeting environmental standards.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If spent catalysts are disposed via landfilling, then the disposal process is simple, but it causes environmental pollution, requires long-term maintenance, and wastes land resources
Solution Approach 1:
The patent converts the harmful spent catalyst waste into a beneficial raw material for cement production. The spent catalyst, which would otherwise be disposed of in landfills, is processed and used as a substitute for traditional cement raw materials like clay and shale, thereby eliminating environmental pollution while maintaining disposal simplicity through a standardized processing flow
2Ease of manufacture
If spent catalysts are disposed via landfilling, then the disposal method is straightforward, but it incurs high long-term maintenance and surveillance costs
Solution Approach 1:
The patent implements a recovery approach where spent catalysts are collected, processed through calcination and grinding, and recovered as valuable raw materials for cement production. This eliminates the need for long-term landfill maintenance while maintaining operational simplicity through established cement industry infrastructure
3Device complexity
If spent catalysts are disposed via landfilling, then the disposal process requires minimal processing, but it results in inefficient land use
Solution Approach 1:
The patent makes the spent catalyst serve multiple functions: it acts as both a waste disposal solution and a valuable raw material source for cement production. The processed catalyst can replace traditional raw materials in cement manufacturing, thereby reducing landfill land requirements while maintaining minimal processing complexity through integration with existing cement production facilities
4Ease of manufacture
If spent catalysts containing toxic components are disposed via landfilling, then the disposal is straightforward, but it poses significant environmental and health risks
Solution Approach 1:
The patent converts toxic spent catalyst waste into a beneficial cement raw material through a processing sequence including calcination at high temperatures and grinding. The calcination process stabilizes toxic components, and the final cement product meets environmental standards, thereby eliminating toxic release risks while maintaining disposal straightforwardness through integrated processing
Solution Approach 2:
The patent applies parameter changes by subjecting spent catalysts to high-temperature calcination (typically 800-1200°C) and controlled grinding processes. These parameter changes transform the physical and chemical properties of the catalyst, stabilizing toxic components and creating a safe, environmentally compliant cement raw material that eliminates harmful factor release
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 method reuses spent catalysts, reducing land usage and environmental impact, while producing cement that meets health and environmental requirements, eliminating the need for long-term maintenance and surveillance of landfill sites.
Implementation Method 1
the disclosed method can use a reducing agent to reduce toxic metal ions such as Cr6+
Implementation Method 2
processing a spent hydrocarbon dehydrogenation catalyst comprising alumina to produce a processed raw material
Data Source
AI summary
Methods of producing cement using a spent hydrocarbon dehydrogenation catalyst are disclosed. A spent hydrocarbon dehydrogenation catalyst comprising alumina is processed to produce a processed raw material. The processed raw material is then used as a component for producing the cement. Compositions of cement including the processed raw material are disclosed.