METHODS FOR THE MANUFACTURE OF A SORBENT COMPOSITION HAVING A CATALYST COMPONENT

• US 20180028971A1
• Filed: 10/10/2017
• Published: 02/01/2018
• Est. Priority Date: 05/30/2014
• Status: Active Grant

• Current Assignee: ARQ Solutions LLC
• Original Assignee: ADA Carbon Solutions, LLC (Advanced Emissions Solutions, Inc.)
• Inventors: Huston, Robert B., Cayton, Roger H., Wong, Joseph M., Lowring, Jacob B.
• Granted Patent: US 10,456,745 B2
• Time in Patent Office: Days
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/304 Linear dimensions, e.g. particle shape, diameter
• CPC Class Codes: B01D 2253/306 Surface area, e.g. BET-specific surface
• CPC Class Codes: B01D 2253/308 Pore size
• CPC Class Codes: B01D 2253/31 Pore size distribution
• CPC Class Codes: B01D 2253/311 Porosity, e.g. pore volume
• CPC Class Codes: B01D 2255/202 Alkali metals
• CPC Class Codes: B01D 2255/2022 Potassium
• CPC Class Codes: B01D 2255/2025 Lithium
• CPC Class Codes: B01D 2255/2027 Sodium
• CPC Class Codes: B01D 2255/204 Alkaline earth metals
• CPC Class Codes: B01D 2255/2042 Barium
• CPC Class Codes: B01D 2255/2045 Calcium
• CPC Class Codes: B01D 2255/2047 Magnesium
• CPC Class Codes: B01D 2255/2061 Yttrium
• CPC Class Codes: B01D 2255/2065 Cerium
• CPC Class Codes: B01D 2255/20723 Vanadium
• CPC Class Codes: B01D 2255/2073 Manganese
• CPC Class Codes: B01D 2255/20738 Iron
• CPC Class Codes: B01D 2255/20761 Copper
• CPC Class Codes: B01D 2255/20792 : Zinc
• CPC Class Codes: B01D 2257/602 : Mercury or mercury compounds
• CPC Class Codes: B01D 2258/0283 : Flue gases
• CPC Class Codes: B01D 53/64 : Heavy metals or compounds thereof, e.g. mercury
• CPC Class Codes: B01D 53/83 : with moving reactants
• CPC Class Codes: B01D 53/8665 : Removing heavy metals or compounds thereof, e.g. mercury
• CPC Class Codes: B01J 20/20 : comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/28016 : Particle form
• CPC Class Codes: B01J 20/28061 : being in the range 100-500 m2/g
• CPC Class Codes: B01J 20/28071 : being less than 0.5 ml/g
• CPC Class Codes: B01J 21/18 : Carbon
• CPC Class Codes: B01J 27/053 : Sulfates
• CPC Class Codes: B01J 27/055 : with alkali metals, copper, gold or silver
• CPC Class Codes: B01J 27/122 : of copper
• CPC Class Codes: B01J 27/128 : with iron group metals or platinum group metals
• CPC Class Codes: B01J 35/31 : Density
• CPC Class Codes: B01J 35/40 : characterised by dimensions, e.g. grain size in a colloidal state B01J35/23; crystallite size B01J35/77
• CPC Class Codes: B01J 35/615 : 100-500 m2/g
• CPC Class Codes: B01J 35/633 : less than 0.5 ml/g
• CPC Class Codes: B01J 37/0201 : Impregnation

Abstract

A sorbent composition that is useful for injection into a flue gas stream of a coal burning furnace to efficiently remove mercury from the flue gas stream. The sorbent composition may include a sorbent with an associated ancillary catalyst component that is a catalytic metal, a precursor to a catalytic metal, a catalytic metal compound or a precursor to a catalytic metal compound. Alternatively, a catalytic metal or metal compound, or their precursors, may be admixed with the coal feedstock prior to or during combustion in the furnace, or may be independently injected into a flue gas stream. A catalytic promoter may also be used to enhance the performance of the catalytic metal or metal compound.

Claims

1. A method for the manufacture of a sorbent composition comprising the step of:

dispersing an ancillary catalyst component comprising a metal with a solid sorbent, the solid sorbent having a surface area of at least about 350 m2/g and pore volume of at least about 0.20 cc/g.

2. The method recited in claim 1, wherein the solid sorbent is a carbonaceous sorbent.

3. The method recited in claim 2, wherein the solid sorbent comprises powdered activated carbon.

4. The method recited in claim 1, wherein the ancillary catalyst component and the solid sorbent form an admixture.

5. The method recited in claim 4, wherein the dispersing step comprises dry admixing the solid sorbent and the ancillary catalyst component or a precursor to the ancillary catalyst component.

6. The method recited in claim 1, wherein the ancillary catalyst component is deposited upon the solid sorbent.

7. The method recited in claim 1, further comprising the step of:

combining, before the dispersing step, a halogen with the ancillary catalyst component.

8. The method recited in claim 7, wherein the dispersing step comprises contacting the solid sorbent with a metal or metal-containing compound in a gas phase to deposit the ancillary catalyst component or a precursor to the ancillary catalyst component onto the solid sorbent.

9. The method recited in claim 7, wherein the dispersing step comprises contacting the solid sorbent with a metal or metal-containing compound in a liquid phase to deposit the ancillary catalyst component or a precursor to the ancillary catalyst component onto the solid sorbent.

10. The method recited in claim 9, wherein the ancillary catalyst component or precursor to the ancillary catalyst component is at least partially solubilized in the liquid phase.

11. The method recited in claim 1, further comprising the step of dispersing a catalytic promoter with the solid sorbent and the ancillary catalyst component.

12. The method recited in claim 11, wherein the catalytic promoter comprises a metal selected from the group consisting of metals from Group I, Group II, and Group III elements.

13. The method recited in claim 12, wherein the catalytic promoter comprises a metal selected from the group consisting of metals from Group I and Group II elements.

14. The method recited in claim 13, wherein the catalytic promoter comprises a metal selected from the group consisting of Li, Na, K, Mg, Ca, Ba and Al.

15. The method recited in any of claim 1, wherein the flue gas stream contains acid gases in a concentration of at least about 3 ppm.