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Highly attrition resistant and dry regenerable sorbents for carbon dioxide capture

  • US 8,110,523 B2
  • Filed: 11/27/2007
  • Issued: 02/07/2012
  • Est. Priority Date: 01/04/2005
  • Status: Active Grant
First Claim
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1. A method for preparing a dry regenerable sorbent for carbon dioxide capture from flue gas produced by fossil fuel-fired power plants including industrial boilers before being released to atmosphere or from fuel gas stream produced by conversion of fossil fuel, by dry regenerable sorbent technology,wherein the method comprises the steps of:

  • 1) sequentially or simultaneously adding solid raw materials of the sorbent to water with stirring using a mixer or homogenizer to form a mixture;

    2) adding a dispersant to the mixture such that the solid raw materials are well mixed with and dispersed in the water without agglomeration and adding a defoamer to the mixture to remove bubbles or prevent the formulation of bubbles during the stirring and homogenization;

    3) wet-comminuting using at least one mill selected from roller mills, ball mills, attrition mills, vibratory mills, planetary mills and bead mills and homogenizing to obtain a well-dispersed colloidal slurry;

    4) controlling a concentration of the slurry within the range of 15˜

    50 wt %;

    5) sieving an impurity impeding the dispersion and stability of the slurry and obstructing or plugging the spray of slurry from a nozzle or an atomizer;

    6) forming the slurry to produce sorbent particles using a spray dryer; and

    7) pre-drying and calcining the sorbent particles to prepare the final sorbent, wherein the sorbent comprises;

    solid raw materials comprising;

    10˜

    60 wt % of an active component selected from carbonates or bicarbonates of sodium or potassium;

    15˜

    40 wt % of a support selected from solid porous non-metallic materials hydrophilic and capable of imparting a required specific surface area to the sorbent; and

    10˜

    60 wt % of an inorganic binder selected from cement-like, clay-like, and ceramic-like binders capable of imparting mechanical strength to the sorbent, wherein the total weight of the solid raw materials is 100 wt %, and wherein the purity of active component is 98% or higher, and wherein the sorbent has a spherical shape, a specific surface area of 20 m2/g or more, and a porosity of 30% or more, bulk density of 0.4 g/ml or more, a carbon dioxide sorption capacity of 3% or more, a utilization efficiency of 7% or more, an attrition index (Al) of 90% or less, an average particle size of 60˜

    160 μ

    m, and a particle size distribution of 40˜

    300 μ

    m, and wherein the sorbent is used to capture and separate carbon dioxide in a fluidized-bed or transport absorber and a fluidized-bed or transport regenerator at a temperature range of 40˜

    200°

    C.

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