Highly cost effective technology for capture of industrial emissions without reagent for clean energy and clean environment applications

An equipment that can be connected as a bolt-on to a flue gas emission line from a power or industrial plant in general, for cost-effective and energy-efficient capture of emission components from an industrial flue gas, the flue gas containing but not limited to Carbon Dioxide (CO2), mercury vapor, oxides of sulfur, oxides of nitrogen, acid vapors, each component being captured separately, without using any chemical/reagent, without using any storage systems for refrigerants and using only fixed amount of water that is repeatedly usable and for production of large amount of liquefied CO2 and a frozen dry ice, which are sources of very pure CO2, the equipment comprising:

• a. a plurality of chambers containing a plurality of ceramic filters to remove a fly ash including oxides of mercury from the said flue gas;
• b. a plurality of fabric filters and a plurality of electro static precipitators to remove a soot, smoke, and floating particles such VOCs (volatile organic compounds) from the said flue gas;
• c. an ammonia super heater with an ammonia turbine for generation of an auxiliary power using a heat of the flue gas via a turbine expansion of an ammonia, a surface of the ammonia super heater chamber is coated with a film of material with high heat absorptivity and low emissivity, said film of materials being nickel oxide;
• d. an ammonia-condenser, for the ammonia to cool further and condense the ammonia after the turbine expansion and a pump to push the cooled ammonia to capture some of the heat with a first heat exchanger from the said flue gas;
• e. a plurality of a first type of heat exchanger comprising, the first heat exchanger, a second heat exchanger, a third heat exchanger, a fourth heat exchanger, a fifth heat exchanger, a sixth heat exchanger and a seventh heat exchanger, wherein all of said heat exchangers contain water, the first heat exchanger, the third heat exchanger, the fifth heat exchanger, and the seventh heat exchanger each having a collecting chamber for cooling and capturing components including Hg vapor, H2O, SO3, NO2 which have a boiling point above 0° C. from the said flue gas, the heat exchangers containing water within a heat exchanger chamber which is cooled by passing a cold nitrogen gas through a plurality of tubes wrapped around a flue gas tube, the tubes all being embedded in the water inside the heat exchanger chamber, wherein the flue gas tube is made of materials that can stand a temperature up to 300° C. and with high heat conductivity (>100 W/m·K) and non-corrosive to a toxic components, said toxic components comprising SO3, SO2, N2O, NO and acid vapors contained within the flue gas;
• f. a plurality of a second type of heat exchanger for cooling and capturing components of a flue gas with boiling point below 0° C., the cooling being accomplished by passing a very cold nitrogen gas having a temperature between −194 C to −195 C, in a direction opposite to a direction of flow of flue gas, through a coil of a tube that surrounds the coil of a tube carrying the flue gas, the coil of the tube and the tube carrying the flue gas being embedded within each of the plurality of second type of heat exchangers;
• g. the plurality of second type of heat exchangers each containing conducting pebbles or metal chips arranged on a plurality of racks surrounding the flue gas flow tube and a heat exchanger chamber containing helium gas for superior heat conduction (compared to air or vacuum) for the capture of components with boiling point below 0° C. in the flue gas flow tubes;
• h. the flue gas-flow tubes and cold nitrogen gas flow tubes of the plurality of second type of heat exchangers being made of materials that can tolerate temperatures up to 300° C. and low temperatures down to −195 C in respect of no structural changes in these temperature range and that have high thermal conductivity (>100 W/m·K), an external surface of the flue gas flow tube painted black for superior heat radiation inside the heat exchanger for further enhancement in cooling of flue gas and an internal surface being coated with toxicity resistant materials, wherein a portion of the flue gas lines and cold nitrogen gas lines extend outside the heat exchangers and are insulated;
• i. Fifteen compressors to compress the said flue gas to specific pressures and at specific temperatures required during the capture processes;
• j. wherein at least one of the chambers is for condensation of a CO2 of the flue gas and for rapid collections of liquefied CO2 while a non-condensed component of the flue gas can pass to other heat exchangers for further processing;
• k. a flash chamber for throttling of liquefied CO2 and an arrangement for production of dry ice, wherein a cooling and freezing of a dry ice vapor and the dry ice is accomplished by passing the very cold nitrogen gas exiting from the flash chamber to enter the a twelfth heat exchanger, so that the very cold nitrogen gas from the twelfth can cool a condenser to condense a nitrous oxide, with an arrangement for collection of dry ice from the flash chamber, the flash chamber being air-tight to prevent the cold nitrogen gas escaping to outside air;
• l. a first turbine expander, a second turbine expander, and a third turbine expander for performing the turbine expansion of flue gas;
• m. a metallic chamber embedded in an insulating chamber for rapid condensation & collection of a liquefied N2O of the flue gas, after the first turbine expander causes expansion of the compressed flue gas, said metallic chamber including an arrangement for cooling the chamber to a temperature 6 to 10 degrees below the boiling point of N2O at 1 bar by the very cold nitrogen gas flowing through the insulating chamber, the very cold nitrogen gas being obtained after condensation of a carbon monoxide following a third turbine expansion of the flue gas by the third turbine expander;
• n. a second metallic chamber embedded in a second insulating chamber for rapid condensation & collection of liquefied NO of the flue gas, after the second turbine expander causes expansion of the compressed flue gas, with an arrangement for cooling the chamber to a temperature 10 to 14 degree below the boiling point of NO at 1 bar by the very cold nitrogen gas flowing the very through the second insulating chamber,
• o. a third metallic chamber embedded in a third insulating chamber for rapid condensation & collection of liquefied CO (carbon monoxide) of the flue gas, after a third turbine expansion of the third turbine expander causes expansion of the compressed flue gas, with an arrangement for rapid collection of the condensed CO, wherein the very cold nitrogen gas is pumped a reverse direction (opposite to the direction of flow of the flue gas) to cool the the twelfth heat exchanger;
• p. a plurality of split lines to pass the said cold nitrogen gas through different first, second, third, fourth, fifth, sixth, seventh and twelfth heat exchangers a portion of the split lines that extend outside the heat exchangers are covered with thermally insulating materials;
• q. a plurality of temperature sensors & a temperature controller and a plurality of pressure sensors and a plurality of pressure controllers and a gas flow meter for said very cold nitrogen gas flow and the flue gas;
• r. insulation materials to thermally insulate the all of the heat exchangers, all of the condensing chambers and a plurality of connecting flow lines, through which flue gas and the very cold nitrogen gas pass and the coatings of tubes, and the ammonia superheat surface being applied prior to the use of the apparatus.