catalysis & energy - industrial green chemistry 1 catalysis & energy air purification...

Catalysis & EnergyAir Purification

Catalytic Oxidation Technology

for Air Pollution ControlPresentation for GC&E Seminar, Hyderabad

28 April 2015

Sud Chemie India Fact File

Presentation for GC&E Seminar, Hyderabad

• Private Limited Company

• 50:50 JV with Clariant

• Established in 1969

• Managing Director: Ms Arshia Lalljee

• Products

– Industrial catalysts

– Zeolites

– Environmental catalysts

• Work force: 400

• ISO 9001/14001/OHSAS 18001/ TS

16949 certified

D:/Neumann Washcoat/Robotic coating machine.avi

Domestic Customers…

FERTILIZER/SYNGAS/STEEL AUTOMOTIVE REFINERY/PETROCHEMICAL

Many more…….


Air Pollution & Regulatory standards


Air Pollutants & Its Effects


>2 Billion pounds of pollutants are being released every year to atmosphere

Emission Sources

Emission Sources

TransportationFuel Combustion

in stationary

Industrial process

losses

Solid Waste

disposalMiscellaneous

Motor Vehicles

Off-Highway Fuel

Usage

Aircrafts

Trains

Ships

Residential

Industrial

Power plants

Chemical Process

Food & Agricultural

Metallurgical

Mineral Product

Petroleum refining

Pharma &

Healthcare

Onsite & Municipal

waste incineration

Open Burning

Forest Fires

Structural Fires

Coal refuse

burning

Agricultural

burning

Volcano eruption


Development of Air Pollution Regulations

Major drivers:

1. Protection of human health,

2. Protection of assets,

3. Protection of ozone layer / Climate

Started in 1979: Convention on Long-

Range Trans-Boundary Air Pollution

Most popular: UNFCCC “Framework

Convention on Climate Change” incl.

Kyoto Protocol


Industries SOx NOx PM CO VOC/TOC NH3

T. Dioxins &

Furan

mg / Nm³ng

TEQ/Nm3

Pesticides 200 20-50 100 20 30 0.1-0.2

Pharma-

Incinerator

(Bulk Drugs)

200 50 100 20 0.1

Dyes & Dyes

Intermediate200 50 100 20 30 0.1

Waste

Incinerators200 400 50 50 - 100 20 0.1

Petro-

chemicals50 – 1700 250 – 450 10 – 100 100 – 200 0.1 - 150

Emission Regulation

Actual limit depend on Industry, Plant, Feedstock & Age of Plant

And many more like Heavy Metals, H2S or Organic Particulates etc.


Catalytic Oxidation Technology


Catalytic Oxidation

• Total oxidation of volatile organic compounds and

carbon monoxide…

CxHy + (x + y)/4 O2 → x CO2 + y/2 H2O

CO + ½ O2 → CO2

NH3 + O2 → N2 + H2O

• Catalyst selection based on avoiding undesirable

reactions such as

- Polymerization

- Partial conversion of HC to CO

- NH3 oxidation to Nox


Catalytic Oxidation – Design considerations

• Systems are designed based on

- Inlet concentration

- Conversion requirements

- Temperature limitations

- Space velocity

- Pressure drop

- Durability

- Safety


Catalytic Oxidation steps

• Diffusion of the reactants from the bulk phase to the

catalyst

• Diffusion of the reactants to active sites

• Adsorption of the reactants at the active sites

• Electron transfer process at the active sites

• Desorption of the reaction products at the active sites

• Diffusion of the reaction products to the catalyst

surface

• Diffusion of the reaction products to the bulk phase

Presentation for IICHE, Ankleshwar

Cell Wall

Precious Metal Particle

Washcoat Layer

Schematic of Coated Catalyst Monolith


Applications for Oxidation Processes

Commercial Printing

Flexible Packaging

Wood Products

Wood burning Appliances

Pharmaceuticals

Metal Decorating

Converting / Coating

Painting/Finishing

Automotive Parts

Baking/Food Processes

Chemical Processing


Acrylic Acid (AA)

Polyethylene Terephthalate (PET)

Phthalic Anhydride (PA)

Acrylonitrile (AN)

Phenol/Acetone

Maleic Anhydride (MA)

Methyl Methacrylate (MMA)

Formaldehyde (FA)

Urea Production (H2 removal in

CO2)

Purified Terephthalic Acid (PTA)

CO2 Purification

PO/SM – Propylene oxide/Styrene monomer

Cyclohexanone

Chemical Off-Gas Application

VOCs (Volatile Organic Compounds):

Alcohols, ethers, aromatics,

Ketones, acetates, acids,

Alkanes, Etc.Carbon

Monoxide

OXIDATION

Several hundred installations for this processes worldwide


VOCs

Hydrocarbon

Alkanes Methane, Propane, Butane, Hexane, Heptane, Cyclopentane,

Cyclohexane

Alkenes Ethylene, Propene, Cyclohexene

Aromatics Benzene, Toluene, Xylene, Methyl-subtituted aromatic,

Phenanthrene

Halogenated H/C Methyl Bromide, MDC, Chlorobenzene, Tricholoethylene,

Oxygenated VOC

Alcohols Methanol, Ethanol, Propanol, Butanol

Ketones Acetone, MEK,

Aldehydes Formaldehyde, Acetaldehyde,

Esters Ethyl Acetate, Butyl Acetate, MethylMethacrylate

Other VOCs

Diethyl amine, Thiophene, Gasoline Vapor, Pyridine & Pyridine

derivates, Mercaptans, Dimethyl Disulphide

Dioxins & Furans

NON-VOCs

Ammonia, CO, NOx, N2O,

Typical List of pollutants for catalytic oxidation


Various Products


• Lower operating temperature ~ Lower Energy ~ REDUCED COSTS

• High destruction efficiency (>99%)

• Low secondary pollutants,

• Less severe MOC, hence lower equipment costs

• High selectivity

• Ease of Operation.

• Less Space Requirement.

Advantages of Catalytic Oxidation

Temperatures (⁰C) for 99% Destruction Efficiency

VOC Catalytic Thermal

Alcohols ~250 ~690

Aldehyde ~300 ~775

Ester ~325 ~750

Aromatics ~250 ~845

Alkanes ~425 ~750


Need Paradigm Shift – Process Emission

Stream 1 – Air + VOC + NH3

Stream 2 – Air + Halogenated H/C + CO + CO2 + NOx

Stream 3 – Air + metal halide + PM

Stream 4 - Air + Complex hydrocarbons

Stream

Segregation &

Divert to

Catalytic Unit

Conventional Treatment Philosophy

Thermal Oxidizer/

Incinerator

Stream 1

Stream 2

Stream 3

Stream 4

Scrubber

(Optional)To Atm

Fuel


Different Areas of Application

Municipal /Waste

incinerator

Condenser Fugitive Emission

Scrubber Outlet

Vacuum Pump outlet

Catalytic

Incinerator

Dioxins

To Atm

Storage tank vents

Drying chamber vents


Catalytic Vs Thermal Oxidation

Off Gas Flow – 20000 scfm

VOC – 18.14 kg/hr,

LHV – 40,705 KJ/kg

Temp – 40 ⁰C

Pressure – Ambient

Operating Parameters/Technology

Regenerative Thermal

Oxidizer

Regenerative Catalytic

Oxidizer

Working Temp, ⁰C 760 371

System Pressure Drop, inch wc 12 8

Thermal Energy Recovery95% 92%

Fuel consumption, mmbtu/hr 0.81 0.39

Fan power, HP 58 39

RCORTO


Typical Catalytic Incineration System

Confidential

Catalytic Combustion

Reactor (CCR)Thermic Fluid Heater/

Direct Fired HeaterOff Gas In

By-Pass to Atm

To Atmosphere

Pre-

Heater

Sud Chemie Catalyst

Sud Chemie Standard Catalysts and applications


Catalyst Application Remarks

EnviCat ® 15200 CH VOC Oxygenated

hydrocarbons

EnviCat ® 2003 CH VOC, CO

EnviCat ® 2060 CH VOC, NH3

EnviCat ® 5006 VOC

EnviCat ® 5028 VOC Alkanes

EnviCat ® 15700 NOx SCR

EnviCat ® 2311 De Oxo CO2 purification

EnviCat ® 3363 Ozone

And many more custom catalysts

– Wide range of Environmental Catalysts for Off-Gas treatment.

– State-Of-Art Facility in India and World Wide

– Customized solutions and after sales services

– Complete turnkey solutions with its engineering partner

– Technical support, feasibility study

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