Abstract:
A composition, containing vanadium, potassium and a support is disclosed. A method of preparing such composition is also disclosed. The composition is employed in a process to remove a heavy metal from a gaseous feed stream which can optionally include a separate heavy metal adsorption stage.

Description:
[0001]     The invention relates to a composition useful in the removal of heavy metals from a gaseous feed stream. In one aspect the invention relates to a method of preparing such composition. In yet another aspect the invention relates to a process for removing heavy metals from a gas stream using the inventive composition and, optionally, a second stage adsorption of the heavy metal.  
       BACKGROUND OF THE INVENTION  
       [0002]     Heavy metals are released during the combustion process of many fossil fuels and/or waste materials. These heavy metals include, for example, arsenic, beryllium, lead, cadmium, chromium, nickel, zinc, mercury and barium. Most of these heavy metals are toxic to humans and animals. In particular, lead is thought to compromise the health and mental acuity of young children and fetuses.  
         [0003]     Furthermore, there is every indication that the amount of mercury, and possibly of other heavy metals, now legally allowed to be released by those combusting various fossil fuels and/or waste materials, including coal burning powerplants, chemical plants and petroleum refineries, will be reduced by future legislation. While a variety of adsorbents are available for capture of heavy metals (in particular mercury), these adsorbents tend to have low capacities and are easily deactivated by other components in the gas stream, such as sulfur and nitrogen oxides. We have discovered a material that converts an elemental heavy metal to an oxidation state greater than zero, even in the presence of sulfur and nitrogen oxides.  
       SUMMARY OF THE INVENTION  
       [0004]     It is an object of this invention to provide an improved vanadium and potassium containing material which when used in the removal of heavy metal results in oxidation of the heavy metal to an oxidation state greater than zero, even in the presence of sulfur and nitrogen oxides.  
         [0005]     A further object of this invention is to provide a method for making an improved vanadium and potassium containing material which when used in the removal of heavy metal results in oxidation of the heavy metal to an oxidation state greater than zero, even in the presence of sulfur and nitrogen oxides.  
         [0006]     Another object of this invention is to provide an improved process for the removal of heavy metal from a heavy metal-containing gas which results in oxidation of the heavy metal to an oxidation state greater than zero, even in the presence of sulfur and nitrogen oxides, with an optional second stage for adsorption of oxidized heavy metal.  
         [0007]     In accordance with a first embodiment of the invention, the inventive composition comprises vanadium, potassium and a support selected from the group consisting of: amorphous silica-alumina; a zeolite; a material comprising alumina, expanded perlite, and meta-kaolin; alumina; and combinations thereof.  
         [0008]     In accordance with a second embodiment of the invention, the inventive composition can be prepared by the method of:  
         [0009]     a) adding a vanadium compound and an acid to a mixture of potassium hydroxide and water to form a first mixture;  
         [0010]     b) adding expanded perlite to a mixture of alumina and water to thereby form a second mixture;  
         [0011]     c) adding meta-kaolin to the second mixture to thereby form a third mixture;  
         [0012]     d) adding a dispersant to the third mixture to thereby form a fourth mixture;  
         [0013]     e) combining the first mixture and the fourth mixture to form a fifth mixture;  
         [0014]     f) extruding the fifth mixture to form extrudates; and  
         [0015]     g) calcining the extrudates to thereby form the composition.  
         [0016]     In accordance with a third embodiment of the invention, the inventive composition can be used in the removal of heavy metal from a gaseous feed stream comprising heavy metal by contacting, in a contacting zone, the gaseous feed stream with any of the inventive compositions of embodiments one or two above, with an optional second stage for adsorption of oxidized heavy metal.  
         [0017]     Other objects and advantages of the invention will become apparent from the detailed description and the appended claims. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]     The inventive composition comprises, consists of, or consists essentially of a support, potassium and vanadium.  
         [0019]     The support is selected from the group consisting of: 1) amorphous silica-alumina; 2) a zeolite; 3) a material comprising, consisting of or consisting essentially of alumina, expanded perlite and meta-kaolin; 4) alumina; and 5) combinations thereof. As used in this disclosure, the term “Support” refers to a carrier for another catalytic component. However, by no means is a support necessarily an inert material; it is possible that a support can contribute to catalytic activity and selectivity.  
         [0020]     The vanadium is present in the composition, on an elemental vanadium basis, in an amount in the range of from about 6 to about 30 weight %, preferably from about 8 to about 25 weight %, and most preferably from about 11 to about 22 weight %, based on the total weight of the composition.  
         [0021]     The potassium is present in the composition, on an elemental potassium basis, in an amount in the range of from about 0.5 to about 25 weight %, preferably from about 1.0 to about 6 weight %, and most preferably from about 1.5 to about 6 weight %, based on the total weight of the composition.  
         [0022]     In accordance with the second embodiment of the present invention, the inventive composition can be prepared by the method of, and a method is provided including:  
         [0023]     a) adding a vanadium compound and an acid to a mixture of potassium hydroxide and water to form a first mixture;  
         [0024]     b) adding expanded perlite to a mixture of alumina and water to thereby form a second mixture;  
         [0025]     c) adding meta-kaolin to the second mixture to thereby form a third mixture;  
         [0026]     d) adding a dispersant to the third mixture to thereby form a fourth mixture;  
         [0027]     e) combining the first mixture and the fourth mixture to form a fifth mixture;  
         [0028]     f) extruding the fifth mixture to form extrudates; and  
         [0029]     g) calcining the extrudates to thereby form the composition.  
         [0030]     The vanadium compound can be any vanadium containing compound capable of incorporation onto and/or into a support. Preferably, the vanadium compound is selected from the group consisting of 1) ammonium metavanadate, 2) an alkali metavanadate of the formula MVO 3 , wherein M can be an alkali metal selected from Group IA, and combinations thereof; 3) vanadium pentoxide; and 4) combinations of any two or more thereof. The most preferable vanadium compound is vanadium pentoxide.  
         [0031]     The potassium compound can be any potassium containing compound capable of incorporation onto and/or into a support. Preferably, the potassium compound is potassium hydroxide. The acid is preferably sulfuric acid.  
         [0032]     The calcining of step g) preferably comprises heating the extrudates to a temperature in the range of from about 100° C. to about 200° C. for a first time period in the range of from about 0.5 hour to about 2 hours; and subsequently heating the extrudates to a temperature in the range of from about 500° C. to about 750° C. for a second time period in the range of from about 0.5 hour to about 2 hours. Preferably, the resulting support is crushed and sieved to obtain 10 to 40 mesh granules; more preferably 10-20 mesh granules.  
         [0033]     In accordance with the third embodiment of the present invention, the inventive composition can be used in the removal of heavy metal from a gaseous feed stream comprising heavy metal by a process comprising, consisting of, or consisting essentially of contacting, in a contacting zone, under heavy metal removal conditions, the gaseous feed stream with any of the inventive compositions, and combinations thereof, of embodiments one through two above. A gaseous product stream is withdrawn from the contacting zone. The gaseous feed stream is typically a combustion gas; and is more typically a stack gas derived from the combustion of coal. The gaseous feed stream can also further comprise compounds selected from the group consisting of sulfur oxides, CO 2 , water, nitrogen oxides, HCl, and combinations of any two or more thereof.  
         [0034]     The contacting of the gaseous feed stream with the inventive composition is preferably carried out at a temperature in the range of from about 100 to about 325° C., more preferably from about 110 to about 275° C., and most preferably from about 120 to about 225° C.  
         [0035]     The heavy metal typically comprises a metal selected from the group consisting of arsenic, beryllium, lead, cadmium, chromium, nickel, zinc, mercury, barium, and combinations of any two or more thereof. The heavy metal most typically comprises mercury.  
         [0036]     When the heavy metal is mercury, the mercury is typically present in the gaseous feed stream in an amount in the range of from about 0.1 to about 10,000 μg/m 3 , more typically in the range of from about 1 to about 800 μg/m 3  and most typically from about 3 to about 700 μg/m 3 .  
         [0037]     The composition preferably converts at least a portion of the heavy metal in the gaseous feed stream to an elevated oxidation state. In the case of mercury, the composition preferably converts at least a portion of the mercury contained in the gaseous feed stream from a zero oxidation state to a +1 or a +2 oxidation state and also preferably removes mercury. “At least a portion”, as used in this paragraph, can mean at least 20 weight %, preferably at least 30 weight %, and more preferably at least 50 weight % mercury based on the total amount of mercury contained in the gaseous feed stream.  
         [0038]     The gaseous product stream preferably contains less than about 20 weight %, more preferably less than about 10 weight %, and most preferably less than about 5 weight % of the mercury contained in the gaseous feed stream.  
         [0039]     The gaseous product stream is optionally contacted with a separate adsorbent in an adsorption zone. The adsorbent can be any adsorbent capable of adsorbing a heavy metal. More preferably, the adsorbent comprises, consists of or consists essentially of a material selected from the group consisting of a zeolite, amorphous carbon, and combinations thereof. The amorphous carbon can be an activated carbon or an activated charcoal. A treated gaseous product stream is withdrawn from the adsorption zone and contains less than about 20 weight %, preferably less than about 10 weight %, and more preferably less than about 5 weight % of the heavy metal contained in the gaseous feed stream.  
       EXAMPLES  
       [0040]     The following examples are intended to be illustrative of the present invention and to teach one of ordinary skill in the art to make and use the invention. These examples are not intended to limit the invention in any way.  
       Preparation of Sorbents  
       [0000]     Sorbent A  
         [0041]     The following is a specific procedure for making a specific Sorbent A sample. Other Sorbent A samples were prepared using the same basic process, but varying the amount of potassium, and the calcination temperatures. In one case the extrudates were crushed and sieved to 25-40 mesh.  
         [0042]     A 30 gram quantity of Vista Dispal alumina was mixed with 60 grams of de-ionized water. To this slurry, 60 grams of expanded crushed perlite and 20 grams of ASP-600 metakaolin clay from Engelhard were added.  
         [0043]     Separately, a 12.4 gram quantity of potassium hydroxide was dissolved in 60 grams of de-ionized water. A 77.2 gram quantity of vanadium pentoxide was dissolved in the KOH solution. Sulfuric acid (10.84 grams of 98% H 2 SO 4 ) was added to turn the potassium hydroxide to potassium sulfate, form a second mixture, and generate freshly precipitated vanadium pentoxide.  
         [0044]     The first and second mixtures were then combined into a paste which was then extruded ( 1/16 inch extrudates) and calcined for one hour at 150° C. This Sorbent A contained about 21.7 wt % V on an elemental basis and about 4.3 wt. % K on an elemental basis.  
         [0000]     Sorbent B  
         [0045]     To a solution of ammonium metavanadate (NH 4 VO 3 ) in 2 molar oxalic acid, a few drops of hydrogen peroxide (50 wt %) were added. (The red color of the solution suggested that vanadium was in +5 oxidation state). The vanadium solution was then impregnated onto a fluidized catalytic cracking unit catalyst (FCCU catalyst) consisting of 20 to 120 micron microspheres by incipient wetness using one-third of the solution in three separate steps. Between impregnation steps, the vanadium-impregnated support was heated to 120° C. in a drying oven for one hour. Sorbent B was calcined for one hour at 150° C. Sorbent B contained 11.2 wt % V on an elemental basis.  
       Evaluation of Sorbents to Remove Mercury  
       [0046]     The following procedure was used to test the ability of the sorbent to remove mercury from a gas stream. Mercury was added by passing a dry air stream at room temperature through a gas bottle containing elemental mercury. The mercury-containing stream was then passed through a sample tube containing a quantity of the sorbent to be tested at a gas hourly space velocity of 10,000 (approximately 40 to 50 ml/min). The tube was located in a furnace held at a temperature of around 150° C. The inlet and outlet elemental mercury concentrations were measured using a Jerome Mercury Analyzer. The efficiency of mercury removal was determined from the amount of mercury entering and leaving the solid sorbent, and is defined as the difference between the inlet and outlet mercury concentrations divided by the inlet concentration.  
         [0000]     Sorbents A and B  
         [0047]     Table 1 below summarizes the results obtained when passing mercury in dry air and wet air over Sorbents A and B. The removal efficiency was determined as a function of mercury uptake; i.e., the cumulative amount of mercury already adsorbed on the sample in units of micrograms of mercury per gram of sorbent (μg/g).  
                                                                                   TABLE 1                           Mercury Removal Efficiency                                    Removal   Air/Flow           Wt %   Wt %       Reactor   HG Uptake   Efficiency   Rate       Sorbent   V   K   Size   Temp.   (μg/g)   (%)   (ml/min)                    A   21.7   4.3   1/16″   300° F.   6.2   100   Dry/100       Calcined           extrudates   300° F.   167.3   100   Dry/100       at 150° C.               300° F.   1048.6   100   Dry/100                       275° F.   1573   100   Dry/100                       250° F.   1684.4   100   Dry/100                       250° F.   1795.8   98   Wet/100                       250° F.   1818.9   99   Wet/100                       275° F.   1956.4   97   Wet/100                       275° F.   2321.3   95   Wet/100                       275° F.   2742.1   98   Wet/100                       275° F.   3399.7   98   Wet/100                       275° F.   3843.9   93   Wet/100       A   21.7   2.9   1/16″   300° F.   0   98   Dry/50       Calcined           extrudates   300° F.   5.8   97   Dry/50       at 150° C.               300° F.   42.1   94   Dry/50                       300° F.   229.6   98   Dry/50                       300° F.   811.9   100   Dry/50                       300° F.   1198.0   99   Dry/50                       300° F.   1552.5   98   Dry/50       A   21.7   2.2   1/16″   300° F.   0.2   98   Dry/50       Calcined           extrudates   300° F.   346.5   100   Dry/50       at 150° C.               300° F.   2052.1   100   Dry/50                       300° F.   3787.3   97   Dry/50                       300° F.   4337.1   85   Dry/50                       300° F.   5174.6   76   Dry/50                       300° F.   5578.8   71   Dry/50                       300° F.   6429.9   49   Dry/50                       300° F.   6630.8   38   Dry/50       A   21.7   4.3   1/16″   300° F.   1.58   95.2   Dry/100       Calcined           extrudates   300° F.   321.6   61.8   Dry/100       at 450° C.               300° F.   881.6   81.2   Dry/100                       300° F.   1942.6   89.3   Dry/100                       300° F.   2510.2   66.3   Dry/100                       300° F.   3806.1   65.7   Dry/100                       300° F.   4015.7   60.5   Dry/100                       300° F.   4030.26   31.7   Dry/200                       300° F.   4081.4   43.6   Dry/200       A   21.7   4.3   1/16″   300° F.   21.3   99.3   Dry/200       Calcined           extrudates   300° F.   1096.1   99.3   Dry/200       at 300° C.               300° F.   1271.0   99.6   Wet/200                       300° F.   2739.9   90.2   Wet/200                       300° F.   3309.5   69.0   Wet/200                       300° F.   3354.2   52.8   Wet/200                       300° F.   3416.2   0   Wet/200                       300° F.   3443.8   86.9   Dry/200                       300° F.   3840.6   70.1   Dry/200                       300° F.   4109.3   3.7   Dry/200                       300° F.   4431.3   94.3   Dry/200                       300° F.   4777.3   0   Dry/200       A   21.7   4.3   1/16″   300° F.   37.8   99.8   Dry/100       Calcined           extrudates   300° F.   720.2   100   Dry/100       at 300° C.               300° F.   1691.9   99.9   Dry/100                       300° F.   2066.0   99.9   Dry/150                       300° F.   2171.0   100   Dry/200                       300° F.   2258.7   97.2   Dry/400                       300° F.   2275.7   90.5   Dry/400                       300° F.   2284.2   86.3   Dry/600                       300° F.   2321.4   85.4   Wet/600                       300° F.   2383.6   88.7   Wet/600                       300° F.   2467.5   0   Wet/600       A   21.7   4.3   Crushed and   300° F.   6.1   100   Dry/50       Calcined           sieved to   300° F.   214.2   100   Dry/50       at 150° C.           25-40 mesh   300° F.   1900.7   100   Dry/50                       300° F.   2458.3   100   Dry/50                       300° F.   3014.5   100   Dry/50                       300° F.   3181.6   99   Dry/50       A   21.7   4.3   1/16″   300° F.   27   99   Dry/100       Calcined           extrudates   300° F.   2711.8   100   Dry/100       at 150° C.               300° F.   2784.0   99   Dry/150                       300° F.   3042.1   98.9   Dry/200                       300° F.   3195.9   90   Dry/400                       300° F.   3214.7   80.8   Dry/600                       300° F.   3245.0   74   Dry/600                       300° F.   3348.0   68.8   Dry/600       A   21.7   4.3   1/16″   300° F.   6   98.1   Dry/200       Calcined           extrudates   300° F.   570.2   100   Dry/200       at 300° C.               300° F.   1051.5   98.9   Dry/200                       300° F.   1440.3   91.2   Dry/200                       300° F.   1544.5   88.5   Dry/200                       300° F.   1646.7   79.1   Dry/200                       300° F.   1743.7   61.9   Dry/200                       300° F.   2170.9   62.3   Dry/200       B   11.2   —   20-120   300° F.   3399.6   100   Dry/30       Calcined           micron   300° F.   3596   99   Dry/30       at 150° C.           microspheres   300° F.   3655   98   Wet/30                       300° F.   3659.3   94   Wet/30                       300° F.   3665.8   88   Wet/30                       320° F.   3671.6   86   Wet/30                       320° F.   3676.4   90   Wet/30                       320° F.   3718.1   89   Wet/30                       340° F.   3730   95   Wet/30                       340° F.   3774.7   98   Wet/30                       340° F.   3847.5   97   Wet/30                       340° F.   4016   98   Wet/30                       340° F.   4172.9   98   Wet/30                  
 
         [0048]     The results in Table 1 indicate that the efficiency of mercury removal has some dependence upon mercury uptake. In addition, the presence of potassium in Sorbent A appears to have a positive affect on performance as compared to Sorbent B.  
         [0049]     Reasonable variations, modifications and adaptations can be made within the scope of the disclosure and appended claims without departing from the scope of the present invention.