# US 10,870,762 B2 · Methods and systems for particulate matter removal from a process exhaust gas stream

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- Number: US 10,870,762 B2
- Document ID: US10870762B2
- Status: Granted
- Kind: B2
- Application number: 15/752,331
- Filed: 2016-08-10
- Published: 2019-03-21
- Granted: 2020-12-22
- Earliest claimed: 2015-08-14
- Assignees: Orion Engineered Carbons GmbH
- Applicants: Orion Engineered Carbons GmbH
- Inventors: Russell Webb; Rodney Taylor; Daniel Horn; Ralf Bergsträsser; Donnie Loubiere; Kay Schmidt
- Web page: https://patentgrep.com/patent/US10870762B2

## CPC

- C09C 1/50: Furnace black {; Preparation thereof (separation or recovery C09C1/487)}
- B01D 53/502: {characterised by a specific solution or suspension}
- B01D 53/8625: {Nitrogen oxides}
- B01D 53/869: {Multiple step processes}
- B01J 8/00: Chemical or physical processes in general, conducted in the presence of fluids and solid particles; Apparatus for such processes
- B01J 8/02: with stationary particles, e.g. in fixed beds
- C09C 1/48: Carbon black
- C09C: TREATMENT OF INORGANIC MATERIALS, OTHER THAN FIBROUS FILLERS, TO ENHANCE THEIR PIGMENTING OR FILLING PROPERTIES (treatment of materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone C04B14/00, C04B18/00, C04B20/00); PREPARATION OF CARBON BLACK {; PREPARATION OF INORGANIC MATERIALS WHICH ARE NO SINGLE CHEMICAL COMPOUNDS AND WHICH ARE MAINLY USED AS PIGMENTS OR FILLERS}
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS

## Abstract

Disclosed herein are systems and methods for reducing the particulate matter content of an exhaust gas from a carbon black process.

## Claims

### Claim 1

A method of reducing particulate matter from an exhaust gas from a process for the production of carbon black, comprising:
producing carbon black and the exhaust gas in the process for the production of carbon black;
collecting the carbon black, wherein collecting the carbon black comprises filtering to separate the carbon black from the exhaust gas, thereby producing a separated exhaust gas;
combusting the separated exhaust gas to thereby produce a combusted exhaust gas comprising particulate matter; and
catalytically oxidizing at least a portion of the particulate matter of the combusted exhaust gas by passing the combusted exhaust gas through a vessel comprising an oxidation catalyst, thereby removing at least a portion of the particulate matter from the combusted exhaust gas to thereby produce an oxidized exhaust gas.

### Claim 2 (depends on 1)

The method of claim 1, wherein the combusted exhaust gas is not passed through an electrostatic precipitator.

### Claim 3 (depends on 1)

The method of claim 1, wherein the oxidized exhaust gas comprises from 10 to 50 wt. % water, less than 10 mg/Nm3 particulate matter, and from 50 ppmv to 10 wt. % sulfur dioxide.

### Claim 4 (depends on 1)

The method of claim 1, wherein the exhaust gas is produced from thermal decomposition of a hydrocarbon or incomplete combustion of a hydrocarbon.

### Claim 5 (depends on 4)

The method of claim 4, wherein the hydrocarbon comprises a heavy distillate oil, a heavy residual oil, a vacuum distillate oil, a heavy vacuum oil, a fluidized catalytic cracker distillate oil, a fluidized catalytic cracker residual oil, a distillate oil from coal gasification, a residual oil from coal gasification, a tar oil from coal gasification, a distillate oil from coal distillation, a residual oil from coal distillation, a tar oil from coal distillation, a distillate oil from steam cracking, a residual oil from steam cracking, a tar oil from steam cracking, a distillate oil from polymer reaction distillation processes, a residual oil from polymer reaction distillation processes, a tar oil from polymer reaction distillation processes, a distillate oil from a biological source, a fuel oil from a biological source, a residual oil from a biological source, a distillate oil from a renewable source, a fuel oil from a renewable source, a residual oil from a renewable source, or combinations thereof.

### Claim 6 (depends on 1)

The method of claim 1, wherein the oxidized exhaust gas further comprises a sulfur oxide and the method further comprises treating the oxidized exhaust gas in a wet sulfuric acid process without heating the oxidized exhaust gas to thereby remove at least a portion of the sulfur oxide.

### Claim 7 (depends on 6)

The method of claim 6, wherein the sulfur oxide is removed from the oxidized exhaust gas with increased thermal efficiency as compared to a method in which substantially equivalent particulate matter reduction is achieved using an electrostatic precipitator.

### Claim 8 (depends on 1)

The method of claim 1, wherein the exhaust gas comprises from 1 to 5,000 mg/Nm3 of particulate matter.

### Claim 9 (depends on 1)

The method of claim 1, wherein the exhaust gas comprises 30 mg/Nm3 or less of particulate matter.

### Claim 10 (depends on 1)

The method of claim 1, wherein the combusted exhaust gas comprises from 1 to 5,000 mg/Nm3 of particulate matter.

### Claim 11 (depends on 1)

The method of claim 1, wherein the combusted exhaust gas comprises from 50 to 6,000 ppmv sulfur dioxide.

### Claim 12 (depends on 1)

The method of claim 1, wherein the oxidation catalyst is a catalyst capable of catalytically converting SO2 to SO3 out of a wet gas stream.

### Claim 13 (depends on 1)

The method of claim 1, wherein the oxidation catalyst oxidizes 90 wt. % or more of the particulate matter, based on the total mass of particulate matter present in the combusted exhaust gas before passing the combusted exhaust gas through the vessel comprising the oxidation catalyst.

### Claim 14 (depends on 1)

The method of claim 1, wherein the oxidized exhaust gas comprises 30 mg/Nm3 or less of particulate matter.

### Claim 15 (depends on 1)

The method of claim 1, wherein the oxidation catalyst comprises vanadium, cobalt, molybdenum, manganese, sodium, potassium, cesium, platinum, palladium, iron, or combinations thereof.

### Claim 16 (depends on 1)

The method of claim 1, wherein the oxidation catalyst is supported on a thermally stable substrate.

### Claim 17 (depends on 16)

The method of claim 16, wherein the thermally stable substrate comprises alumina, silica, chromia, zirconia, tungsten, diatomaceous earth, cordierite, or combinations thereof.