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US 8,821,818 B1Granted
Cleaning stack gas
AssigneeThree D Stack, LLC
InventorJames Gary Davidson
Life of this patent
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Abstract
A method and apparatus for cleaning carbon oxides, sulfur oxides and nitrogen oxides, from stack gas, from combustion of coal, combustion of natural gas or propane, or from a cement kiln by reaction using calcium zeolite and sodium zeolite catalysts. The method also includes cleaning the catalytic beds with nitrogen to remove the collected reactants and recover a fertilizer product and the catalysts for reusable.
Claims81
A method of cleaning stack gases comprising the steps of:
- (a) providing in a stack adapted to pass stack gases through a first catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 44 μm and 64 μm in size adapted to reduce carbon oxides from the stack gases,
- (b) providing in the stack adapted to pass stack gases positioned adjacent the first catalytic flow-through bed, a second catalytic flow-through bed of a blend between 25 and 75% of sodium zeolite and calcium zeolite comprising zeolite particles of a majority between 65 μm and 125 μm in size adapted to reduce nitrogen oxides from the stack gases,
- (c) providing in the stack adapted to pass stack gas positioned adjacent the second catalytic flow-through bed, a third catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 78 μm and 204 μm adapted to reduce sulfur oxides in the stack gases, and
- (d) passing stack gases selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or propane or from a cement kiln sequential through the first catalytic bed, the second catalytic bed, and the third catalytic bed each collecting solids in the catalytic beds and providing gas exiting the third catalytic bed with at least 90% reduction in sulfur oxides, nitrogen oxides, and carbon oxide.
1 more element
A method of cleaning stack gases comprising the steps of:
- (a) providing in a stack adapted to pass stack gases through a first catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 44 μm and 64 μm in size adapted to reduce carbon oxides from the stack gases,
- (b) providing in the stack adapted to pass stack gases positioned adjacent the first catalytic flow-through bed, a second catalytic flow-through bed of a blend between 25 and 75% of sodium zeolite and calcium zeolite comprising zeolite particles of a majority between 65 μm and 125 μm in size adapted to reduce nitrogen oxides from the stack gases,
- (c) providing in the stack adapted to pass stack gas positioned adjacent the second catalytic flow-through bed, a third catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 78 μm and 204 μm adapted to reduce sulfur oxides in the stack gases,
- (d) passing stack gases selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or propane or from a cement kiln sequential through the first catalytic bed, the second catalytic bed, and the third catalytic bed each collecting solids and liquids in the catalytic beds and providing gas exiting the third catalytic bed with at least 90% reduction in sulfur oxides, nitrogen oxides, and carbon oxide compared to the stack gases before entering the first catalytic bed,
- (e) purging solids and liquids from the first catalytic bed, the second catalytic bed, and the third catalytic bed by intermittently passing nitrogen through the beds to remove solids and liquids collected from the stack gases by the beds.
2 more elements
A method of cleaning sulfur oxides from stack gases comprising the steps of:
- (a) providing in a stack adapted to pass stack gas a catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 78 μm and 204 μm adapted to reduce sulfur oxides in the stack gases,
- (b) passing stack gases selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or from a cement kiln sequential through the catalytic flow-through bed collecting solids in the catalytic bed and providing gas exiting the catalytic bed with at least 90% reduction in sulfur oxides, and
- (c) purging solids and liquids from the catalytic flow-through bed by intermittently passing nitrogen through the beds to remove solids and liquids collected from the stack gases by the bed.
Apparatus of cleaning carbon oxides, sulfur oxides, and nitrogen oxides from stack gases comprising:
- (a) assembling an stack adapted to pass stack gases selected from the group consisting of gases from combustion of coal or from combustion of natural gas or propane or from a cement kiln,
- (b) assembling in the stack adapted to pass stack gases a first catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 44 μm and 64 μm in size adapted to reduce carbon oxide from the stack gases,
- (b) assembling in the stack adapted to pass stack gases positioned adjacent the first catalytic flow-through bed, a second catalytic flow-through bed of a blend between 25 and 75% of sodium zeolite and calcium zeolite comprising zeolite particles of a majority between 65 μm and 125 μm in size adapted to reduce nitrogen oxides from the stack gases,
- (c) assembling in the stack adapted to pass stack gas positioned adjacent the second catalytic flow-through bed, a third catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 78 μm and 204 μm adapted to reduce sulfur oxides in the stack gases, and
- (d) such that the first catalytic bed, the second catalytic bed, and the third catalytic bed are adapted to collect solids and liquids in the catalytic beds so that stack gases exiting the third catalytic bed have at least at least 90% reduction in sulfur oxides, nitrogen oxides, and carbon oxide compared to the stack gases delivered to the a first catalytic flow-through bed.
2 more elements
Apparatus of cleaning carbon oxides, sulfur oxides, and nitrogen oxides from stack gases comprising:
- (a) assembling an stack adapted to pass stack gases selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or propane or from a cement kiln,
- (b) assembling in the stack adapted to pass stack gases through a first catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 44 μm and 64 μm in size adapted to reduce carbon oxides, aluminum oxide, and methane gas from the stack gases,
- (b) assembling in the stack adapted to pass stack gases positioned adjacent the first catalytic flow-through bed, a second catalytic flow-through bed of a blend between 25 and 75% of sodium zeolite and calcium zeolite comprising zeolite particles of a majority between 65 μm and 125 μm in size adapted to reduce nitrogen oxides from the stack gases,
- (c) assembling in the stack adapted to pass stack gas positioned adjacent the second catalytic flow-through bed, a third catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 78 μm and 204 μm adapted to reduce sulfur oxides in the stack gases, and
- (d) such that the first catalytic bed, the second catalytic bed, and the third catalytic bed adapted to collect solids in the catalytic beds so that stack gases exiting the third catalytic have at least at least 90% reduction in sulfur oxides, nitrogen oxides, and carbon oxide, and
- (e) an input to intermittently purge first catalytic bed, the second catalytic bed, and the third catalytic bed with nitrogen to remove liquids and solids collected in the first catalytic bed, the second catalytic bed, and the third catalytic bed.
3 more elements
Apparatus of cleaning sulfur oxides from stack gases comprising:
- (a) assembling an stack adapted to pass stack gases selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or propane or from a cement kiln,
- (b) assembling in the stack adapted to pass stack gas through positioned adjacent the second catalytic flow-through bed, a catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 78 μm and 204 μm adapted to reduce sulfur oxides in the stack gases, and
- (d) such that the catalytic flow-through bed is adapted to collect solids from such stack gases exiting the catalytic flow-through bed have at least at least 90% reduction in sulfur oxides compared to the stack gases delivered to the catalytic flow-through bed through the stack.
Apparatus of cleaning sulfur oxides from stack gases comprising:
- (a) assembling an stack adapted to pass stack gases selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or propane or from a cement kiln,
- (b) assembling in the stack adapted to pass stack gas positioned adjacent the second catalytic flow-through bed, a catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 78 μm and 204 μm adapted to reduce sulfur oxides in the stack gases, and
- (d) such that the catalytic flow-through bed is adapted to collect solids and liquids from such stack gases exiting the catalytic flow-through bed have at least at least 90% reduction in sulfur oxides compared to the stack gases delivered to the catalytic flow-through bed through the stack;
- (e) a input provides nitrogen to intermittently purge the catalytic flow-through bed with nitrogen to remove sulfur compounds collected on the catalytic flow-though bed.
1 more element
A fertilizer product produced by the steps of:
- (a) providing in a stack adapted to pass stack gases through a first catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 44 μm and 64 μm in size adapted to reduce carbon oxides from the stack gases,
- (b) providing in the stack adapted to pass stack gases positioned adjacent the first catalytic flow-through bed, a second catalytic flow-through bed of a blend between 25 and 75% of sodium zeolite and calcium zeolite comprising zeolite particles of a majority between 65 μm and 125 μm in size adapted to reduce nitrogen oxides from the stack gases,
- (c) providing in the stack adapted to pass stack gas positioned adjacent the second catalytic flow-through bed, a third catalytic flow-through bed of calcium zeolite comprising zeolite particles of a majority between 78 μm and 204 μm adapted to reduce sulfur oxides in the stack gases,
- (d) passing stack gases selected from the group consisting of volatiles from combustion of coal or from combustion of natural gas or propane or from a cement kiln sequential through the first catalytic bed, the second catalytic bed, and the third catalytic bed each collecting solids in the catalytic beds and providing gas exiting the third catalytic bed with at least 90% reduction in sulfur oxides, nitrogen oxides, and carbon oxide compared to the stack gases delivered to the catalytic flow-through bed through the stack,
- (e) purging solids and liquids from the first catalytic bed, the second catalytic bed, and the third catalytic bed by intermittently passing nitrogen through the beds to remove solids and liquids collected from the stack gases by the beds.
2 more elements
Dependencies are inferred from the claim text.