Method of adsorbing metals and organic compounds from vaporous streams

• US 20020198097A1
• Filed: 03/29/2001
• Published: 12/26/2002
• Est. Priority Date: 03/29/2001
• Status: Active Grant

• Current Assignee: Merck & Co., Inc.
• Original Assignee: Merck & Co., Inc.
• Inventors: El-Shoubary, Youssef, Maes, Rudy
• Granted Patent: US 6,558,642 B2
• Time in Patent Office: Days
• US Class Current: 502/56
• CPC Class Codes: B01D 53/10 with dispersed adsorbents
• CPC Class Codes: B01D 53/64 Heavy metals or compounds thereof, e.g. mercury
• CPC Class Codes: B01D 53/70 Organic halogen compounds
• CPC Class Codes: B01D 53/72 Organic compounds not provided for in groups B01D53/48 - B01D53/70, e.g. hydrocarbons
• CPC Class Codes: B01J 20/0222 Compounds of Mn, Re
• CPC Class Codes: B01J 20/0237 Compounds of Cu
• CPC Class Codes: B01J 20/0266 Compounds of S
• CPC Class Codes: B01J 20/0288 Halides of compounds other than those provided for in B01J20/046
• CPC Class Codes: B01J 20/04 comprising compounds of alkali metals, alkaline earth metals or magnesium
• CPC Class Codes: B01J 20/041 Oxides or hydroxides
• CPC Class Codes: B01J 20/046 containing halogens, e.g. halides
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/3204 Inorganic carriers, supports or substrates
• CPC Class Codes: B01J 20/3236 containing metal, other than zeolites, e.g. oxides, hydroxides, sulphides or salts
• CPC Class Codes: B01J 2220/42 Materials comprising a mixture of inorganic materials materials coated or impregnated on a carrier B01J20/32
• CPC Class Codes: B01J 2220/4825 Polysaccharides or cellulose materials, e.g. starch, chitin, sawdust, wood, straw, cotton
• CPC Class Codes: B01J 2220/4881 Residues from shells, e.g. eggshells, mollusk shells
• CPC Class Codes: C22B 3/24 by adsorption on solid substances, e.g. by extraction with solid resins
• CPC Class Codes: C22B 43/00 Obtaining mercury
• CPC Class Codes: Y02C 20/40 of CO2
• CPC Class Codes: Y02P 10/146 : Perfluorocarbons [PFC]; Hydrofluorocarbons [HFC]; Sulfur hexafluoride [SF6]
• CPC Class Codes: Y02P 10/20 : Recycling
• CPC Class Codes: Y10S 95/90 : Solid sorbent

Abstract

A method and adsorption powder useful for the removal of mercury and other metals, as well as furans, dioxins and other organic compounds from high temperature and high moisture gaseous streams. The method utilizes an adsorption powder characterized as containing a carbon-based powder and an effective amount of cupric chloride suitable to remove metals and organic compounds. The powder may contain calcium hydroxide, sulfur, potassium permanganate, potassium iodide, and combinations thereof.

Claims

1. A method of removing metals and organic compounds from a gaseous stream using the adsorption powder, the powder characterized as containing a carbon-based powder and an effective amount of cupric chloride suitable for removing metals and organic compounds from vaporous streams, wherein the method comprises the steps of:

a) placing a solid phase metals- and organic compounds-containing material into a cleaner;

b) heating the cleaner containing the solid phase material to form gaseous and solid components of the material, wherein the metals are vaporized and contained in the gaseous component and the organic compound are reduced to elemental gases;

c) transferring the gaseous component to an exhaust cleaning unit/afterburner, and transferring the solid component to a cooling unit;

d) heating the exhaust cleaning unit/afterburner containing the gaseous component to combust the organic compounds to elemental oxides;

e) cooling the exhaust cleaning unit/afterburner containing the gaseous component;

f) adding the adsorption powder to the exhaust cleaning unit/afterburner to adsorb the metal;

g) transferring the powder-containing gaseous component to a baghouse; and

h) releasing the substantially mercury-free gaseous component of said sample to the atmosphere,

wherein the metals are selected from the group consisting of mercury, lead, nickel, zinc, copper, arsenic and cadmium, and the organic compounds are selected from the group consisting of dioxins and furans.

2. The method according to claim 1, wherein the adsorption powder of step f) is a carbon-based powder selected from the group consisting of coal carbons, wood carbon, activated carbon, fruit pits, graphite carbon, coconut shell carbon, peat carbons, petroleum cokes, synthetic polymers, and combinations thereof.

3. The method according to claim 2, wherein the effective amount of cupric chloride is from about 1 to about 45 weight percent.

4. The method according to claim 3, wherein the cupric chloride is selected from the group consisting of cupric(II)chloride, cupric(III)chloride, and cupric(IV)chloride.

5. The method according to claim 4, wherein the powder further comprises one or more components selected from the group consisting of calcium hydroxide, sulfur, potassium permanganate, potassium iodide.

6. The method according to claim 5, wherein the adsorption powder comprises from about 10 to about 60 weight percent of carbon, from about 10 to about 70 weight percent of calcium hydroxide, and from about 1 to about 45 weight percent of cupric(II)chloride.

7. The method according to claim 6, wherein the adsorption powder comprises from about 30 to about 50 weight percent of carbon, from about 50 to about 70 weight percent of calcium hydroxide, and from about 2 to about 10 weight percent of cupric(II)chloride.

8. The method according to claim 7, wherein the adsorption powder comprises about 40 weight percent of carbon, about 60 weight percent of calcium hydroxide, and about 5 weight percent of cupric(II)chloride.

9. The method according to claim 5, wherein the adsorption powder comprises from about 30 to about 50 weight percent of carbon, from about 45 to about 70 weight percent of calcium hydroxide, from about 1 to about 10 weight percent of sulfur, and from about 1 to about 15 weight percent of cupric(II)chloride.

10. The method according to claim 9, wherein the adsorption powder comprises from about 35 to about 45 weight percent of carbon, from about 50 to about 65 weight percent of calcium hydroxide, from about 2 to about 8 weight percent of sulfur, and from about 4 to about 12 weight percent of cupric(II)chloride.

11. The method according to claim 10, wherein the adsorption powder comprises about 38 weight percent of carbon, about 58 weight percent of calcium hydroxide, about 4 weight percent of sulfur, and from about 5 to about 10 weight percent of cupric(II)chloride.

12. The method according to claim 5, wherein the adsorption powder comprises from about 25 to about 45 weight percent of carbon, from about 40 to about 60 weight percent of calcium hydroxide, from about 2 to about 10 weight percent of sulfur, from about 5 to about 15 weight percent of potassium permanganate impregnated onto a carbon substrate, and from about 1 to about 15 weight percent of cupric(II)chloride.

13. The method according to claim 12, wherein the adsorption powder comprises from about 30 to about 40 weight percent of carbon, from about 45 to about 55 weight percent of calcium hydroxide, from about 3 to about 8 weight percent of sulfur, from about 7 to about 12 weight percent of potassium permanganate impregnated onto a carbon substrate, and from about 2 to about 10 weight percent of cupric(II)chloride.

14. The method according to claim 13, wherein the adsorption powder comprises about 345 weight percent of carbon, about 52 weight percent of calcium hydroxide, about 4 weight percent of sulfur, about 10 weight percent of potassium permanganate impregnated onto a carbon substrate, and about 5 weight percent of cupric(II)chloride.

15. The method according to claim 5, wherein the adsorption powder comprises from about 25 to about 45 weight percent of carbon, from about 45 to about 60 weight percent of calcium hydroxide, from about 5 to about 50 weight percent of potassium iodide impregnated on to a carbon substrate, and from about 5 to about 45 weight percent of cupric(II)chloride.

16. The method according to claim 15, wherein the adsorption powder comprises from about 35 to about 40 weight percent of carbon, from about 50 to about 55 weight percent of calcium hydroxide, from about 10 to about 35 weight percent of potassium iodide impregnated on to a carbon substrate, and from about 8 to about 15 weight percent of cupric(II)chloride.

17. The method according to claim 16, wherein the adsorption powder comprises about 38 weight percent of carbon, about 52 weight percent of calcium hydroxide, about 10 weight percent of potassium iodide impregnated on to a carbon substrate, and from about 10 weight percent of cupric(ll)chloride.

18. The method according to claim 5, wherein the adsorption powder comprises from about 25 to about 45 weight percent of carbon, from about 40 to about 60 weight percent of calcium hydroxide, from about 2 to about 15 weight percent of potassium iodide impregnated onto a carbon substrate, and from about 1 to about 15 weight percent of cupric chloride.

19. The method according to claim 18, wherein the adsorption powder comprises from about 30 to about 40 weight percent of carbon, from about 40 to about 60 weight percent of calcium hydroxide, from about 2 to about 12 weight percent of potassium iodide impregnated onto a carbon substrate, and from about 1 to about 15 weight percent of cupric chloride.

20. The method according to claim 19, wherein the adsorption powder comprises about 35 weight percent of carbon, about 55 weight percent of calcium hydroxide, about 5 of potassium iodide impregnated onto a carbon substrate, and about 5 weight percent of cupric(II)chloride.

21. The method according to claim 19, wherein the adsorption powder comprises about 35 weight percent of carbon, about 50 weight percent of calcium hydroxide, about 10 of potassium iodide impregnated onto a carbon substrate, and about 5 weight percent of cupric(III)chloride.

22. The method according to claim 19, wherein the adsorption powder comprises about 35 weight percent of carbon, about 50 weight percent of calcium hydroxide, about 10 of potassium iodide impregnated onto a carbon substrate, and about 5 weight percent of cupric(IV)chloride.

23. A method of removing metals and organic compounds from a gaseous stream using the adsorption powder, wherein the powder comprises from about 30 to about 40 weight percent of carbon, from about 40 to about 60 weight percent of calcium hydroxide, from about 1 to about 10 weight percent of sulfur, from about 5 to about 15 weight percent of potassium permanganate, and from about 1 to about 15 weight percent of cupric(II)chloride, wherein the method comprises the steps of:

a) placing a solid phase metals- and organic compounds-containing material into a rotary kiln/drum;

b) heating the kiln/drum containing the solid phase material to a temperature of from about 325°

to about 900°

F. to form gaseous and solid components of the material, wherein the metals are vaporized and contained in the gaseous component and the organic compound are reduced to elemental gases;

c) transferring the gaseous component to an exhaust cleaning unit/afterburner, and transferring the solid component to a cooling unit;

d) heating the exhaust cleaning unit/afterburner containing the gaseous component to combust the organic compounds to elemental oxides;

e) cooling the exhaust cleaning unit/afterburner containing the gaseous component;

f) adding the adsorption powder to the exhaust cleaning unit/afterburner to adsorb the metal;

g) transferring the powder-containing gaseous component to a baghouse; and

h) releasing the substantially mercury-free gaseous component of said sample to the atmosphere,

wherein the metals are selected from the group consisting of mercury, lead, nickel, zinc, copper, arsenic and cadmium, and the organic compounds are selected from the group consisting of dioxins and furans.

24. A method of removing metals and organic compounds from a gaseous stream using the adsorption powder, wherein the powder comprises from about 25 to about 45 weight percent of carbon, from about 45 to about 60 weight percent of calcium hydroxide, from about 30 to about 50 weight percent of potassium iodide impregnated on to a carbon substrate, and from about 5 to about 15 weight percent of cupric(II)chloride, wherein the method comprises the steps of:

a) placing a solid phase metals- and organic compounds-containing material into a rotary kiln/drum;

b) heating the kiln/drum containing the solid phase material to a temperature of from about 325°

to about 900°

F. to form gaseous and solid components of the material, wherein the metals are vaporized and contained in the gaseous component and the organic compound are reduced to elemental gases;

c) transferring the gaseous component to an exhaust cleaning unit/afterburner, and transferring the solid component to a cooling unit;

d) heating the exhaust cleaning unit/afterburner containing the gaseous component to combust the organic compounds to elemental oxides;

e) cooling the exhaust cleaning unit/afterburner containing the gaseous component;

f) adding the adsorption powder to the exhaust cleaning unit/afterburner to adsorb the metal;

g) transferring the powder-containing gaseous component to a baghouse; and

h) releasing the substantially mercury-free gaseous component of said sample to the atmosphere,

wherein the metals are selected from the group consisting of mercury, lead, nickel, zinc, copper, arsenic and cadmium, and the organic compounds are selected from the group consisting of dioxins and furans.

25. A method of removing metals and organic compounds from a gaseous stream using the adsorption powder, wherein the powder comprises from about 25 to about 45 weight percent of carbon, from about 40 to about 60 weight percent of calcium hydroxide, from about 2 to about 15 weight percent of potassium iodide impregnated onto a carbon substrate, and from about 1 to about 15 weight percent of cupric chloride, wherein the method comprises the steps of:

a) placing a solid phase metals- and organic compounds-containing material into a rotary kiln/drum;

b) heating the kiln/drum containing the solid phase material to a temperature of from about 325°

to about 900°

F. to form gaseous and solid components of the material, wherein the metals are vaporized and contained in the gaseous component and the organic compound are reduced to elemental gases;

c) transferring the gaseous component to an exhaust cleaning unit/afterburner, and transferring the solid component to a cooling unit;

to combust the organic compounds to elemental oxides;

e) cooling the exhaust cleaning unit/afterburner containing the gaseous component;

f) adding the adsorption powder to the exhaust cleaning unit/afterburner to adsorb the metal;

g) transferring the powder-containing gaseous component to a baghouse; and

h) releasing the substantially mercury-free gaseous component of said sample to the atmosphere,

wherein the metals are selected from the group consisting of mercury, lead, nickel, zinc, copper, arsenic and cadmium, and the organic compounds are selected from the group consisting of dioxins and furans.

26. A method of removing metals and organic compounds from a gaseous stream using the adsorption powder, wherein the powder comprises about 35 weight percent of carbon, about 55 weight percent of calcium hydroxide, about 5 of potassium iodide impregnated onto a carbon substrate, and about 5 weight percent of cupric(lI)chloride, wherein the method comprises the steps of:

a) placing a solid phase metals- and organic compounds-containing material into a rotary kiln/drum;

b) heating the kiln/drum containing the solid phase material to a temperature of from about 325°

to about 900°

F. to form gaseous and solid components of the material, wherein the metals are vaporized and contained in the gaseous component and the organic compound are reduced to elemental gases;

c) transferring the gaseous component to an exhaust cleaning unit/afterburner, and transferring the solid component to a cooling unit;

d) heating the exhaust cleaning unit/afterburner containing the gaseous component to combust the organic compounds to elemental oxides;

e) cooling the exhaust cleaning unit/afterburner containing the gaseous component;

f) adding the adsorption powder to the exhaust cleaning unit/afterburner to adsorb the metal;

g) transferring the powder-containing gaseous component to a baghouse; and

h) releasing the substantially mercury-free gaseous component of said sample to the atmosphere,

wherein the metals are selected from the group consisting of mercury, lead, nickel, zinc, copper, arsenic and cadmium, and the organic compounds are selected from the group consisting of dioxins and furans.

27. A method of removing metals and organic compounds from a gaseous stream using the adsorption powder, wherein the powder comprises about 35 weight percent of carbon, about 50 weight percent of calcium hydroxide, about 10 of potassium iodide impregnated onto a carbon substrate, and about 5 weight percent of cupric(III)chloride, wherein the method comprises the steps of:

a) placing a solid phase metals- and organic compounds-containing material into a rotary kiln/drum;

b) heating the kiln/drum containing the solid phase material to a temperature of from about 325°

to about 900°

F. to form gaseous and solid components of the material, wherein the metals are vaporized and contained in the gaseous component and the organic compound are reduced to elemental gases;

c) transferring the gaseous component to an exhaust cleaning unit/afterburner, and transferring the solid component to a cooling unit;

d) heating the exhaust cleaning unit/afterburner containing the gaseous component to combust the organic compounds to elemental oxides;

e) cooling the exhaust cleaning unit/afterburner containing the gaseous component;

f) adding the adsorption powder to the exhaust cleaning unit/afterburner to adsorb the metal;

g) transferring the powder-containing gaseous component to a baghouse; and

h) releasing the substantially mercury-free gaseous component of said sample to the atmosphere,

wherein the metals are selected from the group consisting of mercury, lead, nickel, zinc, copper, arsenic and cadmium, and the organic compounds are selected from the group consisting of dioxins and furans.

28. A method of removing metals and organic compounds from a gaseous stream using the adsorption powder, wherein the powder comprises about 35 weight percent of carbon, about 50 weight percent of calcium hydroxide, about 10 of potassium iodide impregnated onto a carbon substrate, and about 5 weight percent of cupric(IV)chloride, wherein the method comprises the steps of:

a) placing a solid phase metals- and organic compounds-containing material into a rotary kiln/drum;

b) heating the kiln/drum containing the solid phase material to a temperature of from about 325°

to about 900°

F. to form gaseous and solid components of the material, wherein the metals are vaporized and contained in the gaseous component and the organic compound are reduced to elemental gases;

c) transferring the gaseous component to an exhaust cleaning unit/afterburner, and transferring the solid component to a cooling unit;

d) heating the exhaust cleaning unit/afterburner containing the gaseous component to combust the organic compounds to elemental oxides;

e) cooling the exhaust cleaning unit/afterburner containing the gaseous component;

f) adding the adsorption powder to the exhaust cleaning unit/afterburner to adsorb the metal;

g) transferring the powder-containing gaseous component to a baghouse; and

h) releasing the substantially mercury-free gaseous component of said sample to the atmosphere,

wherein the metals are selected from the group consisting of mercury, lead, nickel, zinc and cadmium, and the organic compounds are selected from the group consisting of dioxins and furans.