Clean coal stack

• US 9,919,269 B2
• Filed: 03/11/2016
• Issued: 03/20/2018
• Est. Priority Date: 03/15/2013
• Status: Expired due to Fees

• Current Assignee: 3 D Clean Coal Emissions Stack, LLC
• Original Assignee: 3 D Clean Coal Emissions Stack, LLC
• Inventors: Davidson, James Gary
• Primary Examiner(s): Vanoy, Timothy C
• Application Number:
  US15/067,569
• Publication Number:
  US 20160199780A1
• Time in Patent Office: 739 Days
• CPC Class Codes: B01D 2255/50 Zeolites
• CPC Class Codes: B01D 2257/502 Carbon monoxide
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2257/602 Mercury or mercury compounds
• CPC Class Codes: B01D 2258/0283 Flue gases
• CPC Class Codes: B01D 53/261 by adsorption
• CPC Class Codes: B01D 53/32 by electrical effects other than those provided for in group B01D61/00
• CPC Class Codes: B01D 53/8609 Sulfur oxides
• CPC Class Codes: B01D 53/8628 Processes characterised by a specific catalyst
• CPC Class Codes: B01D 53/8637 Simultaneously removing sulfur oxides and nitrogen oxides
• CPC Class Codes: B01D 53/864 Removing carbon monoxide or hydrocarbons
• CPC Class Codes: B01D 53/8665 Removing heavy metals or compounds thereof, e.g. mercury
• CPC Class Codes: B01D 53/869 Multiple step processes
• CPC Class Codes: B01D 53/8693 After-treatment of removed components
• CPC Class Codes: B01D 53/885 Devices in general for catalytic purification of waste gases
• CPC Class Codes: C05C 5/00 Fertilisers containing other nitrates
• CPC Class Codes: C05D 9/00 Other inorganic fertilisers
• CPC Class Codes: F23J 15/02 of purifiers, e.g. for removing noxious material traps for solid residues F23J3/04
• CPC Class Codes: F23J 2219/10 Catalytic reduction devices
• CPC Class Codes: Y02E 20/32 Direct CO2 mitigation
• CPC Class Codes: Y02P 20/151 : Reduction of greenhouse gas [GHG] emissions, e.g. CO2

Abstract

A method and apparatus for cleaning and recycling stack gas from coal-fired power plants, from natural or propane burning heating plants, or from cement kilns by using renewable catalysts of zeolite to separate pollutants into recyclable and reusable materials. The method reduces from the stack gas carbon monoxide (CO), carbon dioxide (CO₂), nitrogen oxide (NOx), sulfur oxide (SOx) as well as halogens such as chloride and fluorides and trace metals particularly, mercury, lead, and zinc.

Claims

1. Apparatus for drying and cleaning stack gases comprising:

(a) a first catalytic flow-through bed comprised of natural calcium zeolite with a porosity of a total surface area of not greater than 1200 m²/g adapted to reduce carbon oxides present in an exhaust stack;

(b) a second catalytic flow-through bed comprised of a blend of natural sodium zeolite and natural calcium zeolite of a porosity with a total surface area of not greater than 1200 m²/g adapted to reduce sulfur oxides present in the exhaust stack downstream of the first bed;

(c) a third catalytic flow-through bed comprised of natural calcium zeolite with a porosity of a total surface area not greater than 1200 m²/g adapted to reduce nitrogen oxides present in the exhaust stack downstream of the second bed;

(d) a pair of electrodes adapted to be positioned inline in the gas flow upstream of the first catalytic flow-through bed, the electrodes insulated from containment of the gas flow, with a DC voltage applied between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow through the catalytic flow-through beds;

(e) the exhaust stack adapted to provide a gas flow, the gas flow selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln, sequentially past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed, each catalytic bed collecting residuals and providing stack gases exiting the third catalytic flow-through bed with at least 70% reduction in carbon oxides, sulfur oxides, and nitrogen oxides; and

(f) wherein the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed are each adapted to be periodically purged with nitrogen such that residuals collected in the first catalytic flow-through bed, the second catalytic flow-through bed, and/or the third catalytic flow-through bed can be removed and each catalytic flow-through bed prepared for reuse.

2. The apparatus as set forth in claim 1 where the pair of electrodes in the gas flow upstream of the first catalytic flow-through bed are insulated from containment of the gas flow with the voltage applied between the electrodes of less than 34 volts to ionize water vapor in the gas flow and reduce moisture content of the gas flow in the first catalytic flow-through bed.

3. The apparatus as set forth in claim 1 where in addition a venturi is positioned in the gas flow downstream of the third catalytic flow-through bed to stabilize gas flow through the beds.

4. The apparatus as set forth in claim 1 where the pair of electrodes are positioned in the gas flow downstream of a baghouse.

5. The apparatus as set forth in claim 1 where the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed are each positioned between screens, the screens each between 150 and 250 mesh.

6. The apparatus as set forth in claim 1 where the second catalytic flow-through bed is comprised of the blend of natural sodium zeolite and natural calcium zeolite of between 25% and 75%.

7. The apparatus as set forth in claim 1 where the exhaust stack is adapted to exit gases from the third catalytic flow-through bed having at least 80% reduction in sulfur oxides, nitrogen oxides, and carbon oxides compared to the stack gases delivered to the pair of electrodes.

8. The apparatus as set forth in claim 1 where the exhaust stack is adapted to exit gases from the third catalytic flow-through bed having at least 90% reduction in carbon oxides, sulfur oxides, and nitrogen oxides compared to the stack gases delivered to the pair of electrodes.

9. The apparatus as set forth in claim 1 where the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed each have a porosity of a total surface area not greater than 800 m²/g.

10. The apparatus as set forth in claim 1 further comprising at least two series of sequential gas flows through the same or different pair of electrodes, and different first catalytic flow-through bed, second catalytic flow-through bed, and third catalytic flow-through bed provided in parallel so stack gases can be cleaned through one of the series of beds while other series of beds can be purged.

11. The apparatus as set forth in claim 1 where a fourth catalytic flow-through bed of calcium zeolite is provided in the gas flow after the pair of electrodes and before the first catalytic flow-through bed with a porosity of a total surface area not greater than 1200 m²/g adapted to collect bauxite compounds before passage through the first catalytic flow-through bed.

12. The apparatus as set forth in claim 11 where the fourth catalytic flow-through bed is adapted to be periodically purged and refreshed with nitrogen.

13. The apparatus as set forth in claim 11 where the fourth catalytic flow-through bed has a porosity of a total surface area not greater than 800 m²/g.

14. The apparatus as set forth in claim 11 where the exhaust stack is adapted to exit gases from the third catalytic flow-through bed with at least 70% reduction in bauxite compounds, carbon oxides, sulfur oxides, and nitrogen oxides compared to the stack gases delivered to the pair of electrodes.

15. The apparatus as set forth in claim 11 where the exhaust stack is adapted to exit gases from the third catalytic flow-through bed with at least 90% reduction in bauxite compounds, carbon oxides, sulfur oxides, and nitrogen oxides compared to the stack gases delivered to the pair of electrodes.

16. A method of drying and cleaning stack gases comprising the steps of:

(a) passing a contained stack gas flow, the stack gas flow selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln, through a pair of electrodes positioned generally inline in the gas flow and applying D.C. voltage between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow in the catalytic flow-through beds;

(b) passing stack gas flow from the electrodes through a first catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles of a majority between 44 μ

m and 64 μ

m in size at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce carbon oxides in the stack gas flow;

(c) passing the stack gas flow from the first catalytic flow-through bed through a second catalytic flow-through bed comprised of a blend between 25 and 75% of sodium zeolite and calcium zeolite of natural sodium and calcium zeolite particles of a majority between 65 μ

m and 125 μ

m in size at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce sulfur oxides in the stack gas flow;

(d) passing the stack gas flow from the second catalytic flow-through bed through a third catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles of a majority between 78 μ

m and 204 μ

m at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce nitrogen oxides in the stack gas flow; and

(e) operating the stack gas flow sequentially past the pair of electrodes and through the first catalytic bed, the second catalytic bed, and the third catalytic bed to provide at least 70% reduction in carbon oxides, sulfur oxides, and nitrogen oxides.

17. The method of drying and cleaning stack gas as claimed in claim 16 where the electrodes in the gas flow upstream of the first catalytic flow-through bed are insulated from containment of the gas flow with voltage applied between the pair of electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow through the catalytic flow-through beds.

18. The method of drying and cleaning stack gas as claimed in claim 16 comprising the additional step of passing the gas flow through a venturi positioned downstream of the third catalytic flow-through bed to stabilize the gas flow through the beds.

19. The method of drying and cleaning stack gas as claimed in claim 16 where the electrodes in step (a) are positioned in the gas flow downstream of a baghouse.

20. The method of drying and cleaning stack gas as claimed in claim 16 where the gas flow sequentially circulated past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed also removes from the gas flow at least 50% of mercury in all forms.

21. The method of drying and cleaning stack gas as claimed in claim 16 where the gas flow sequentially circulated past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed also removes from the gas flow at least 70% of mercury in all forms.

22. A method of drying and cleaning stack gases comprising the steps of:

(a) passing a contained stack gas flow selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln by a pair of electrodes positioned generally inline in the gas flow and applying a D.C. voltage between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow through the catalytic flow-through beds;

(b) passing stack gas flow from the pair of electrodes through a first catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles of a majority between 44 μ

m and 64 μ

m in size at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce carbon oxides in the stack gases;

(c) passing the stack gas flow from the first catalytic flow-through bed through a second catalytic flow-through bed comprised of a blend between 25 and 75% of sodium zeolite and calcium zeolite of natural sodium and calcium zeolite particles of a majority between 65 μ

m and 125 μ

m in size at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce sulfur oxides in the stack gases;

(d) passing the stack gas flow from the second catalytic flow-through bed through a third catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles of a majority between 78 μ

m and 204 μ

m at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce nitrogen oxides in the stack gases and providing a stack gas flow exiting the third catalytic bed with at least 70% reduction in sulfur oxides, nitrogen oxides and carbon oxide; and

(e) purging residuals from the first catalytic bed, the second catalytic bed, and the third catalytic bed by intermittently passing nitrogen through the beds to remove residuals collected from the stack gas flow by the beds.

23. The method of drying and cleaning stack gas as claimed in claim 22 where the pair of electrodes in the gas flow upstream of the first catalytic flow-through bed insulated from containment of the gas flow applies such D.C. voltage less than 34 volts to ionize water vapor in the gas flow and reduce moisture content of the gas flow in the catalytic flow-through beds.

24. The method of drying and cleaning stack gas as claimed in claim 22 comprising the additional step of passing the gas flow through a venturi positioned downstream of the third catalytic flow-through bed to stabilize the gas flow through the beds.

25. The method of drying and cleaning stack gas as claimed in claim 22 where the electrodes in step (a) are positioned in the gas flow downstream of a baghouse.

26. The method of drying and cleaning stack gas as claimed in claim 22 where the stack gas flow sequentially circulated past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed also removes from the gas flow at least 50% of mercury in all forms.

27. The method of drying and cleaning stack gas as claimed in claim 22 where the gas flow sequentially circulated past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed also removes from the gas flow at least 70% of mercury in all forms.

28. The method of drying and cleaning stack gas as claimed in claim 22 comprising in addition a fourth catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles between 44 μ

m and 64 μ

M in size positioned in the stack gas flow after the pair of electrodes and before the first catalytic bed with an electrical charge on said fourth catalytic flow-through bed to separately collect bauxite compounds from the stack gas flow before passing through the first catalytic bed.

29. The method of drying and cleaning stack gas as claimed in claim 28 the stack gas exiting a stack from the third catalytic bed has at least 90% reduction in bauxite compounds, carbon oxides, sulfur oxides, and nitrogen oxides compared to the stack gas flow delivered through the stack.

30. The method of drying and cleaning stack gas as claimed in claim 22 where at least two series of stack gas flows are provided in parallel to provide for the gas flow to past the same or a different pair of electrodes inline and through first catalytic bed, second catalytic bed, and third catalytic beds so that at least one in one of the series of beds can be purged while the stack gas flow can be dried and cleaned through a pair of electrodes and beds.

31. A method of drying and cleaning stack gases comprising the steps of:

(a) passing a stack gas flow of less than 7% oxygen selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln by a pair of electrodes positioned generally inline in the gas flow and applying a D.C. voltage between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow,

(b) passing the gas flow from the pair of electrodes through a first catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce carbon oxides from the stack gases and increase oxygen levels in the stack gas;

(c) passing the gas flow from the first catalytic flow-through bed through a second catalytic flow-through bed comprised of a blend between 25 and 75% of sodium zeolite and calcium zeolite of natural sodium and calcium zeolite particles at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce sulfur oxides from the stack gases and increase oxygen levels in the stack gas; and

(d) passing the gas flow from the second catalytic flow-through bed through a third catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce nitrogen oxides in the stack gases and increase oxygen levels in the stack gas and providing gas exiting the third catalytic bed with at least 70% reduction in sulfur oxides, nitrogen oxides and carbon oxide and greater than 15% oxygen.

32. The method of drying and cleaning stack gas as claimed in claim 31 where the pair of electrodes in the gas flow upstream of the first catalytic flow-through bed insulated from containment of the gas flow applies the D.C. voltage to ionize water vapor in the gas flow less than 34 volts and reduce moisture content of the gas flow in the catalytic flow-through beds.

33. The method of drying and cleaning stack gas as claimed in claim 31 comprising the additional step of passing the gas flow through a venturi positioned downstream of the third catalytic flow-through bed to stabilize the gas flow through the beds.

34. The method of drying and cleaning stack gas as claimed in claim 31 where the pair of electrodes in step (a) are positioned in the gas flow downstream of a baghouse.

35. The method of drying and cleaning stack gas as claimed in claim 31 where the stack gas flow sequentially circulated past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed also removes from the gas flow at least 50% of mercury in all forms.

36. The method of drying and cleaning stack gas as claimed in claim 31 where the gas flow sequentially circulated past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed also removes from the gas flow at least 70% of mercury in all forms.

37. The method of drying and cleaning stack gas as claimed in claim 31 comprising in addition a fourth catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles between 44 μ

m and 64 μ

m in size positioned in the stack gas flow after the pair of electrodes and before the first catalytic bed with an electrical charge on said fourth catalytic flow-through bed to separately collect bauxite compounds from the stack gas flow before passing through the first catalytic bed.

38. The method of drying and cleaning stack gas as claimed in claim 37 the stack gas exiting a stack from the third catalytic bed has at least 70% reduction in bauxite compounds, carbon oxides, sulfur oxides, nitrogen oxides, and mercury oxide compared to the stack gas flow delivered through the stack.

39. The method of drying and cleaning stack gas as claimed in claim 37 the stack gas exiting a stack from the third catalytic bed has at least 90% reduction in bauxite compounds, carbon oxides, sulfur oxides, nitrogen oxides, and mercury oxide compared to the stack gas flow delivered through the stack.

40. The method of drying and cleaning stack gas as claimed in claim 31 where at least two series of stack gas flows are provided in parallel to pass a pair of electrodes inline and through a series of the first catalytic bed, the second catalytic bed, and the third catalytic bed so that one stack gas flow can be dried and cleaned by the method described while another stack gas flow is purges for reuse.

41. A method of drying and cleaning stack gases comprising the steps of:

(a) passing a stack gas flow selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln by a pair of electrodes positioned generally inline in the gas flow and applying a D.C. voltage between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow;

(b) passing the gas flow from the pair of electrodes through a first catalytic flow-through bed comprised of calcium zeolite with a porosity of a total surface area not greater than 1200 m²/g to reduce carbon oxides from the stack gases and increase oxygen levels in the stack gas;

(c) passing the gas flow from the first catalytic flow-through bed through a second catalytic flow-through bed comprised of a blend between 25 and 75% of sodium zeolite and calcium zeolite with a porosity of a total surface area not greater than 1200 m²/g to reduce sulfur oxides from the gas flow and increase oxygen levels in the gas flow; and

(d) passing the gas flow from the second catalytic flow-through bed through a third catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles with a porosity of a total surface area not greater than 1200 m²/g and providing gas exiting the third catalytic bed with at least 70% reduction in sulfur oxides, nitrogen oxides and carbon oxide and greater than 15% oxygen.

42. The method of drying and cleaning stack gas as claimed in claim 41 where the pair of electrodes in the gas flow upstream of the first catalytic flow-through bed is insulated from containment of the gas flow with the D.C. voltage applied to the electrode to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow in the catalytic flow-through beds.

43. The method of drying and cleaning stack gas as claimed in claim 41 comprising the additional step of passing the gas flow through a venturi positioned downstream of the third catalytic flow-through bed to stabilize the gas flow through the beds.

44. The method of drying and cleaning stack gas as claimed in claim 41 where the electrodes in step (a) are positioned in the gas flow downstream of a baghouse.

45. The method of drying and cleaning stack gas as claimed in claim 41 where the stack gas flow sequentially circulated past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed also removes from the gas flow at least 50% of mercury in all forms.

46. The method of drying and cleaning stack gas as claimed in claim 41 where the gas flow sequentially circulated past the pair of electrodes and through the first catalytic flow-through bed, the second catalytic flow-through bed, and the third catalytic flow-through bed also removes from the gas flow at least 70% of mercury in all forms.

47. The method of drying and cleaning stack gas as claimed in claim 41 comprising in addition a fourth catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles with a porosity of a total surface area not greater than 1200 m²/g positioned in the stack gas flow after the pair of electrodes and before the first catalytic bed with an electrical charge to separately collect bauxite compounds from the stack gas flow before passing through the first catalytic bed.

48. The method of drying and cleaning stack gas as claimed in claim 47 the stack gas exiting a stack from the third catalytic bed has at least 70% reduction in bauxite compounds, carbon oxides, sulfur oxides, nitrogen oxides, and mercury oxide compared to the stack gas flow delivered to the stack.

49. The method of drying and cleaning stack gas as claimed in claim 47 the stack gas exiting a stack from the third catalytic bed has at least 90% reduction in bauxite compounds, carbon oxides, sulfur oxides, nitrogen oxides, and mercury oxide compared to the stack gas flow delivered to the stack.

50. The method of drying and cleaning stack gas as claimed in claim 41 where at least two series of stack gas flows are provided in parallel to pass a pair of electrodes inline and through the first catalytic bed, the second catalytic bed, and the third catalytic bed so that one stack gas flow can be dried and cleaned by the method described while another stack gas flow is purged.

51. The method of drying and cleaning stack gas as claimed in claim 41 the stack gas exiting a stack from the third catalytic bed has at least 70% reduction in bauxite compounds, carbon oxides, sulfur oxides, nitrogen oxides, and mercury oxide compared to the stack gas flow delivered through the stack.

52. The method of drying and cleaning stack gas as claimed in claim 41 the stack gas exiting a stack from the third catalytic bed has at least 90% reduction in bauxite compounds, carbon oxides, sulfur oxides, nitrogen oxides, and mercury oxide compared to the stack gas flow delivered through the stack.

53. A fertilizer product produced by the steps of:

(a) passing a stack gas flow selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln by a pair of electrodes positioned generally inline in the gas flow and applying a D.C. voltage between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow,

(b) passing the gas flow from the pair of electrodes through a first catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles of a majority between 44 μ

m and 64 μ

m in size at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce carbon oxides in the stack gases;

(c) passing the gas flow from the first catalytic flow-through bed through a second catalytic flow-through bed comprised of a blend between 25 and 75% of sodium zeolite and calcium zeolite of natural sodium and calcium zeolite particles of a majority between 65 μ

m and 125 μ

m in size at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce sulfur oxides in the stack gas flow;

(d) passing the gas flow from the second catalytic flow-through bed through a third catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles of a majority between 78 μ

m and 204 μ

m at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce nitrogen oxides in the stack gas flow and providing gas exiting the third catalytic bed with at least 70% reduction in sulfur oxides, nitrogen oxides and carbon oxide; and

(e) purging residuals from the first catalytic bed, the second catalytic bed, and the third catalytic bed by intermittently passing nitrogen through the beds to remove residuals collected from the stack gases by the beds.

54. A fertilizer product produced by the steps of:

(a) passing a stack gas flow of less than 7% oxygen selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln by at least two electrodes positioned generally inline in the gas flow and applying a D.C. voltage between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow,

(b) passing the gas flow from the electrodes through a first catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce carbon oxides from the stack gases and increase oxygen levels in the stack gas;

(c) passing the gas flow from the first catalytic flow-through bed through a second catalytic flow-through bed comprised of a blend between 25 and 75% of sodium zeolite and calcium zeolite of natural sodium and calcium zeolite particles of at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce sulfur oxides from the stack gases and increase oxygen levels in the stack gas; and

(d) passing the gas flow from the second catalytic flow-through bed through a third catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce nitrogen oxides in the stack gases and increase oxygen levels in the stack gas flow; and

providing gas flow exiting the third catalytic bed with at least 70% reduction in sulfur oxides, nitrogen oxides and carbon oxide and greater than 15% oxygen.

55. A fertilizer product produced by the steps of:

(a) passing a stack gas flow from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln by a pair of electrodes positioned generally inline in the gas flow and applying a D.C. voltage between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow;

(b) passing the gas flow from the pair of electrodes though through a first catalytic flow-through bed comprised of natural calcium zeolite with a porosity of a total surface area of not greater than 1200 m²/g adapted to reduce carbon oxides in a stack gas;

(c) passing the gas flow from the first catalytic flow-through bed through a second catalytic flow-through bed comprised of a blend of natural sodium zeolite and natural calcium zeolite with a porosity of a total surface area of not greater than 1200 m²/g adapted to reduce sulfur oxides in a stack gas with the blend of sodium zeolite and calcium zeolite between 25 and 75%;

(d) passing the gas flow from second catalytic flow-through bed through third catalytic flow-through bed comprised of natural calcium zeolite with a porosity of a total surface area not greater than 1200 m²/g adapted to reduce nitrogen oxides in a stack gas and providing gas exiting the third catalytic bed with at least 70% reduction in carbon oxides, sulfur oxides, and nitrogen oxides; and

(e) purging residuals collected on the first catalytic bed, the second catalytic bed, and the third catalytic bed and collecting said residuals purged from the first catalytic bed, the second catalytic bed, and the third catalytic bed to provide a fertilizer product.

56. A method of drying and cleaning stack gases comprising the steps of:

(a) passing a contained stack gas flow selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln by a pair of electrodes positioned generally inline in the gas flow and applying D.C. voltage between the electrodes to ionize water vapor in the gas flow without creating substantial amounts of hydrogen gas and reduce moisture content of the gas flow in the first catalytic flow-through bed;

(b) passing stack gas flow from the electrodes through a catalytic flow-through bed comprised of a mixture of calcium zeolite of natural zeolite particles of a majority between 44 μ

m and 64 μ

m in size, a blend between 25 and 75% of sodium zeolite and calcium zeolite of natural sodium and calcium zeolite particles of a majority between 65 μ

m and 125 μ

m in size, and calcium zeolite of natural zeolite particles of a majority between 78 μ

m and 204 μ

m at a temperature above the dew point between 125°

F. and 500°

F. and a pressure between 3 psi and 200 psi adapted to reduce carbon oxides in the stack gas flow, the mixture with a porosity of a total surface area not greater than 1200 m²/g; and

(c) operating the stack gas flow sequentially past the pair of electrodes and through the catalytic bed to provide at least 70% reduction in sulfur oxides, nitrogen oxides and carbon oxide.

57. The method of drying and cleaning stack gas as claimed in claim 56 where the pair of electrodes in the gas flow upstream of the catalytic flow-through bed insulated from containment of the gas flow applies a D.C. voltage of less than 34 volts to ionize water vapor in the gas flow and reduce moisture content of the gas flow in the catalytic flow-through bed.

58. The method of drying and cleaning stack gas as claimed in claim 56 comprising the additional step of passing the gas flow through a venturi positioned downstream of the catalytic flow-through bed to stabilize the gas flow through the beds.

59. The method of drying and cleaning stack gas as claimed in claim 56 where the electrodes in step (a) are positioned in the gas flow downstream of a baghouse.

60. The method of drying and cleaning stack gas as claimed in claim 56 where the stack gas flow sequentially circulated past the pair of electrodes and through the catalytic flow-through bed also removes from the gas flow at least 50% of mercury in all forms.

61. The method of drying and cleaning stack gas as claimed in claim 56 where the gas flow sequentially circulated past the pair of electrodes and through the catalytic flow-through beds also removes from the gas flow at least 70% of mercury in all Runs.

62. The method of drying and cleaning stack gas as claimed in claim 56 comprising in addition a second catalytic flow-through bed comprised of calcium zeolite of natural zeolite particles with a porosity of a total surface area not greater than 1200 m²/g positioned in the stack gas flow after the pair of electrodes and before the first catalytic bed, with an electrical charge applied to the second catalytic flow-through bed, to separately collect bauxite compounds from the stack gas flow before passing through the first catalytic bed.

63. The method of drying and cleaning stack gas as claimed in claim 62 the stack gas exiting a stack from the first catalytic bed has at least 70% reduction in bauxite compounds, carbon oxides, sulfur oxides, nitrogen oxides, and mercury oxide compared to the stack gas flow delivered to the stack.

64. The method of drying and cleaning stack gas as claimed in claim 62 the stack gas exiting a stack from the first catalytic bed has at least 90% reduction in bauxite compounds, carbon oxides, sulfur oxides, nitrogen oxides, and mercury oxide compared to the stack gas flow delivered to the stack.

65. The method of drying and cleaning stack gas as claimed in claim 56 where at least two series of stack gas flows are provided in parallel to pass the same or a different pair of electrodes generally inline and through first catalytic flow-through bed, second catalytic flow-through bed, and third catalytic flow-through beds so that the stack gas flow can be dried and cleaned by the method described while one or more other catalytic flow-through beds are purged.