Waste Heat Recovery Unit Catalyst for VOC Oxidation

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Solution Overview

Problem

Hydrocarbon processing facilities face challenges in efficiently removing volatile organic compounds (VOCs) from effluent gas streams and ensuring adequate buoyancy for gas dispersal, as existing abatement technologies are energy-intensive and lack sufficient heat for effective VOC oxidation and buoyancy.

Innovation Solution

A method involving a waste heat recovery unit (WHRU) with a catalyst bed, where the effluent gas stream containing CO2 and VOCs is mixed with hot turbine exhaust gas to achieve oxidation of VOCs and increase gas temperature for improved buoyancy, utilizing an oxidation catalyst such as palladium or platinum on support materials like titania or zeolite.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If dedicated abatement facilities are used to oxidize VOCs, then VOC removal efficiency is improved, but energy demand and space demand increase

Engineering Contradiction:

ImproveVOC removal efficiencyVSAvoidenergy demand

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

The patent combines the VOC abatement function with the waste heat recovery function into a single integrated unit. The catalytic oxidizer is integrated within the waste heat recovery unit, allowing simultaneous VOC oxidation and heat recovery from turbine exhaust, thereby eliminating the need for separate dedicated abatement facilities and reducing both energy demand and space requirements

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The waste heat recovery unit is designed to perform multiple functions: it recovers heat from turbine exhaust for power generation and simultaneously serves as a catalytic oxidizer for VOC abatement. This multi-functionality allows a single piece of equipment to address both energy recovery and environmental compliance needs

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Use of energy by moving object

If effluent gas is released at ambient temperature, then energy consumption is reduced, but gas buoyancy and dispersal capability deteriorate

Engineering Contradiction:

Improveenergy consumptionVSAvoidgas dispersal capability

Core Design Contradiction:

Use of energy by moving objectVSEase of operation

Solution Approach 1:

The patent converts the hot turbine exhaust gas, which would otherwise be a waste product requiring cooling, into a beneficial heat source for heating the CO2 effluent stream. This eliminates the need for additional energy input while ensuring the released gas has sufficient temperature for adequate buoyancy and dispersal

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Use of energy by moving object

If effluent gas is released at ambient temperature, then energy consumption is reduced, but gas buoyancy deteriorates causing gas to slump back down

Engineering Contradiction:

Improveenergy consumptionVSAvoidgas temperature

Core Design Contradiction:

Use of energy by moving objectVSTemperature

Solution Approach 1:

The heating function is merged with the waste heat recovery process. The CO2 effluent stream is heated by exchanging heat with the hot turbine exhaust gas within the integrated unit, thereby achieving the necessary temperature elevation for buoyancy without requiring separate heating facilities or additional energy input

Inventive Principle:

Principle #5Merging (Combining)

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 approach effectively oxidizes VOCs and enhances gas buoyancy, reducing energy demand by leveraging existing heat from turbine exhaust, allowing for efficient VOC abatement and safe dispersal without additional heating facilities.

Implementation Method 1

a catalyst bed comprising an oxidation catalyst... effecting oxidation of the at least one VOC in the second gas stream

Methodology Applied

Scientific EffectCatalytic oxidation: Catalysis

Implementation Method 2

oxidation of the at least one VOC in the second gas stream

Methodology Applied

Scientific EffectOxidation: Oxidation

Implementation Method 3

the WHRU comprises at least one bank of heat exchange tubes... mixing the first gas stream and a turbine exhaust gas within a waste heat recovery unit (WHRU)

Methodology Applied

Scientific EffectHeat exchange: Heat Exchanger

Data Source

PatentUS11529585B2Thermal oxidation of volatile organic compounds using a catalyst layer within a waste heat recovery unit

Publication Date: 2022.12.20 KELLOGG BROWN & ROOT INC

AI summary

Methods and systems for treating volatile organic compounds (VOCs) generated in a hydrocarbon treating process are disclosed. An effluent stream containing the VOCs, as well as carbon dioxide (CO2) is combined with hot exhaust gas from a turbine and provided to a waste heat recovery unit (WHRU). The WHRU is adapted to contain a catalyst bed containing oxidation catalyst capable of effecting the oxidation of the VOCs. The temperature of the catalyzing reaction can be tailored based on the position of the catalyst bed within the temperature gradient of the WHRU. The methods and systems described herein solve the problem of effecting the removal of VOCs from the effluent. Heating the CO2-containing effluent in the WHRU also lend buoyancy to the effluent, thereby facilitating its dispersal upon release.