IMPROVED REGENERATION OF CAUSTIC IMPREGNATED ACTIVATED CARBON

Abstract: An improved process for the regeneration of activated carbon impregnated with caustic is described. A two stage wash with caustic solutions of about 50 percent and about 15 percent removes both organic and sulfur contaminants. This regeneration returns the carbon essentially to its original capacity for adsorption of malodorous compounds.

Description: "IMPROVED REGENERATION OF CAUSTIC IMPREGNATED ACTIVATED CARBON" Background of the Invention This invention is directed to a process for the regeneration of activated carbon impregnated with caustic. This invention especially relates to the regeneration of caustic impregnated activated carbon by a three stage process, involving the use of both a high concentration (30 to 50 percent) and then a low concentration (5 to 25 percent) NaOH or KOH solution. Activated carbons impregnated with NaOH have been described in U.S. Patent No. 4,072,479 to Sinha et al and it is my intent to incorporate by reference the contents of the Sinha et al patent. Activated carbons impregnated with KOH have been described in U.S. Patent No. 2,872,412 to McNeill et al and in Swinarski et al, Chem. Stosowana, Ser. A 9(3), 287-94 (1965), (Chemical Abstracts, Vol. 64, 1379c). Caustic impregnated carbons are excellent adsorbents for malodorous sulfur and organic compounds. As used herein, caustic impregnated carbon refers to carbon impregnated with either NaOH or KOH. Caustic, therefore, is defined as NaOH or KOH and may also include any other alkali metal hydroxide. Typical malodorous sulfur containing compounds include principally hydrogen sulfide, mercaptans and sulfides. The malodorous organic compounds include all of those compounds formed by the bacterial breakdown of higher organic compounds, for example, compounds associated with sewer treatment facilities. Adsorption of such malodorous compounds reduces the effective capacity of the carbon for further adsorption. At some point in time (known as the breakthrough), the carbon becomes spent, that is, it loses its capacity to adsorb. At that point, the carbon must be regenerated. Prior to the discovery of the three step regeneration process of the present invention, carbons of the type described by Sinha et al were regenerated by treatment of the spent carbon with a 50 percent NaOH solution for at least 18 hours, followed by one water rinse. By using the process of the present invention, a high concentration caustic wash followed by a low concentration caustic wash, improved regeneration of adsorptive capacity of from 10 to 20 percent over the processes of the prior art is achieved. Summary of the Invention The object of this invention is the improved regeneration of the adsorptive capacity of activated carbons impregnated with caustic. This invention allows for longer useful lifetime of the impregnated carbon, inexpensive reagents and convenient modes of operation. Thus, there is provided a process for the regeneration of spent caustic impregnated activated carbon which comprises the three steps of (a) washing the spent carbon with water at a temperature range of from 720 to 1700F; (b) treating the washed spent carbon with a solution of from 30 to 50 percent (high concentration) of caustic at a temperature range of from 720 to 1800F for a contact time of from 13 to 24 hours to remove organic contaminants; and (c) treating the spent carbon from step (b) with a solution of from 5 to 25 percent (low concentration) of caustic at a temperature range of from 720 to 1800F for a contact time of from 3 to 24 hours to remove sulfur contaminants. Detailed Description Four parameters have been found to be important in the regeneration of caustic impregnated carbon via the process of this invention: (a) moisture content on the carbon; (b) caustic solution temperature; (c) caustic solution concentrations; and (d) contact times. Moisture content on the spent carbon prior to regeneration with the caustic solutions is a critical factor in the efficiency of this process. Irrespective of the moisture content on the active carbon, either before or after adsorption, the carbon must be washed prior to regeneration. Washing the carbon increases the removal of both the organic and sulfur contaminants. By definition, washed carbon contains at least 25 weight percent moistureon the carbon after the washing, while the typical dry carbon contains no more than 18 weight percent moisture. The preferred moisture content on the washed carbon is from 30 to 40 weight percent or at least 25 weight percent. The water wash may be carried out in a temperature range of from 720 to 1700F with about 1200F preferred. After regeneration of the carbon, as described below, moisture content on the carbon may be as high as 40 weight percent. Prior to reuse, this moisture content should be reduced to from 18 to 25 weight percent, preferably to less than 18 weight percent. Sulfur and organic contaminants are removed by two different caustic concentrations. NaOH concentrations between 5 to 25 percent were found to be effective for the removal of sulfur contaminants, with 15 to 20 percent NaOH the preferred concentration. Organic contaminants were removed with a NaOH concentration between 30 to 50 percent, with 50 percent the preferred concentration. KOH concentrations between 5 to 25 percent were found to be effective for the removal of sulfur contaminants, with 15 to 25 percent KOH the preferred concentration. Organic contaminants were removed with KOH concentrations between 30 to 50 percent, with 50 percent the preferred concentration. The temperature of the caustic solutions has a direct effect on contaminant removal efficiency. As the temperature of the caustic solutions increase, the percentage of both sulfur and organic contaminants removed increase. The useful temperature range for both the high and the low concentration caustic solutions is from 72" to 1800F with a preferred caustic temperature of 1400F. The contact times for the two solutions of NaOH vary from 3 to 24 hours for the low (5 to 25 percent) concentration and from 13 to 24 hours for the high (30 to 50 percent) concentration solution. The preferred contact time for the high concentration solution is about 18 hours. After this time, organic contaminants are removed with decreasing efficiency. The preferred contact time for the removal of sulfur contaminants with the low concentration solution is from 5 to 10 hours. The contact times for the two solutions of KOH vary from 3 to 24 hours for the low concentration and from 13 to 24 hours for the high concentration solutions. The preferred contact times for the low and high concentration KOH solutions are 18 and 5 hours respectively. Contact time is dependent upon the temperature of the caustic solution, the concentration of the caustic solution and the level of contamination by sulfur and organic compounds on the spent carbon. The suggested and preferred values serve as a guide to those skilled in the art and as parameters for the regeneration of caustic impregnated carbon. While the description of this process calls for the regeneration of caustic impregnated carbons with either NaOH or KOH solutions, the variety of regeneration combinations will be readily apparent to those skilled in the art of carbon adsorption. For example, NaOH impregnated carbon may be regenerated with either NaOH or XOH solutions, and KOH impregnated carbons may be regenerated with either KOH or NaOH solutions. Although the present invention is exemplified in conjunction with a small scale static regeneration scheme, it will be readily understood by those skilled in the art of carbon adsorption that the spirit of this invention will readily translate to a carbon recycle scheme or any large "field scale" application without any major deviation from the parameters set forth herein. These examples merely illustrate the process and are not intended to limit the application of this invention in any way. The process of the present invention can best be understood by reference to the following examples which demonstrate the effect of the four parameters discussed above upon the regeneration of caustic impregnated activated carbon. In general, the regeneration was carried out in a static mode. Two hundred fifty grams of spent carbon was placed in a 1000 ml erlenmeyer flask with 700 ml caustic solution poured on top (varied concentrations). Samples were held at 720F and room conditions for the contact times indicated. Samples at other temperatures were controlled in hot or-cold water baths. After the contact time interval passed, the caustic was removed and the carbon twice rinsed with water. Carbon samples were then dried and analysed for the percentage of removed contaminants. Example 1 Sulfur removal from spent carbon - sulfur removal was compared using five different NaOK concentrations, all at ambient temperature over four contact times. Results for dry carbon are shown below in Table I. Table I Percent Sulfur Removal for Caustic Concentration Dry Carbon Washed NaOH Concentration 0.5 .15 .20 .25 .50 0.5 0.15 .20 0.25 Contact Time 3 Hours 62.7 68.6 67.1 66.9 40.4 * * 73.1 * 5 Hours 68.3 75.8 72.6 70.2 48.2 61.8 75.5 79.4 75.9 7 1/2 Hours 71.2 77.1 75.2 74.6 57.0 * * 81.3 * 24 Hours 71.6 78.0 77.0 75.5 59.4 67.4 79.2 82.5 76.8 (All percentages are in percent sulfur removed) *Data not collected at this contact time interval. Example II Organic removal from spent carbon - Two samples of spent carbon were treated at varying concentrations of NaOH for varying contact times to determine the most effective NaOH concentration for removal of organic contaminants. The results of these tests are shown in Tables IIa (low organic level) and IIb (high organic level). Washed carbon data is shown in Table IIc. Table IIa PERCENT ORGANIC REMOVAL FOR CAUSTIC CONCENTRATION ON LOW (2.84 PERCENT) ORGANIC NaOH Concentration .15 .25 .50 Contact Time 6 Hours 86.62 90.49 100 24 Hours 100 100 100 Table IIb PERCENT ORGANIC REMOVAL FOR CAUSTIC CONCENTRATION ON HIGH (9.38 PERCENT) ORGANIC NaOH Concentration .15 .25 .50 Contact Time 3 Hours 0 0 0 5 Hours 1.95 8.23 59.30 24 Hours 25.1 33.8 80.10 Table IIc PERCENT REMOVAL FOR CAUSTIC CONCENTRATION NaOH .50 Caustic to Carbon .50 Caustic to Carbon Concentration .50 Dry Low Ratio* Washed (2-1) High Ratio* Washed (5-1) Contact Time 3 Hours 0 0 0 5 Hours 59.30 49.68 62.65 24 Hours 80.10 61.32 82.84 (All percentages are in percent organics removed) *Dilution factor of caustic by the water retained on the washed carbon. (a) low ratio; e.g. - 500 grams carbon to 1000 grams caustic; (b) high ratio; e.g. - 500 grams carbon to 2500 grams caustic. Example III Two samples of spent impregnated carbon (NaOH) were treated with (a) the three stage process of the present invention using NaOH solutions and (bj the regeneration process of the prior art. (a) Spent carbon (NaOHj, moisture free, containing 7.84 weight percent sulfur and 9.98 weight percent organic contaminants was washed with one bed volume of water at 720F. The water was drained and the adsorber immediately filled with one bed volume of 50 percent NaOH solution. The caustic solution temperature was held at 720F, for a contact time of about 18 hours. The caustic solution was removed except for 1/4 bed volume. The adsorber was filled with 3/4 bed volume of water producing a 15 percent NaOH solution and the sulfur removal contact time was 5 hours at a temperature of 720F. The caustic was removed and the adsorbent was washed with two bed volumes of water. The carbon was air dried and ready for reuse. The sulfur removal was 97.5 percent and the organic removal was 100 percent. (b) Spent carbon (NaOHj, moisture free, containing 7.84 weight percent sulfur and 9.98 weight percent organic contaminants was treated with one bed volume of 50 percent NaOH solution. The caustic solution temperature was held at 720F for a contact time of 18 hours. The caustic solution was removed and the adsorbent was washed with one bed volume of water. The carbon was air dried and ready for reuse. The sulfur removal was 58.6 percent and the organic removal was 98.9 percent. Example IV Two samples of spent impregnated carbon (NaOH) were treated with (a) the three stage process of the present invention using KOH solutions and (bj the regeneration process of the prior art. (a) Spent carbon (NaOH), moisture free, containing 16.0 weight percent sulfur and 8.76 weight percent organic contaminants was washed with one bed volume of water at 1700F. The water was drained and the adsorber immediately filled with one bed volume of 50 percent KOH solution. The caustic solution was held at 720F for a contact time of 18 hours. The KOK solution was removed. The adsorber was filled with a 15 percent KOH solution and the sulfur removal contact time was 5 hours at a temperature of 720F. The caustic was removed and the adsorbent was washed with two bed volumes of water. The carbon was air dried and ready for reuse. The sulfur removal was 81.4 percent and the organic removal was 43.2 percent. (b) Spent carbon (NaOH), moisture free, containing 16.0 weight percent sulfur and 8.76 weight percent organic contaminants was washed with one bed volume of water at 1700F. The water was drained and the adsorber immediately filled with one bed volume of 15 percent KOK solution. The caustic solution was held at 720F for a contact time of 18 hours. The caustic was removed, the carbon was air dried and ready for reuse. The sulfur removal was 47.8 percent and the organic removal was .05 percent.

Claims: WHAT IS CLAIMED IS: 1. A process for the regeneration of spent caustic impregnated activated carbon which comprises the steps of: (a) Washing the spent carbon with water at a temperature range of from 720 to 1700F; (b) Treating the washed spent carbon with a solution of from 30 to 50 percent caustic at a temperature range of from 720 to 1800F for a contact time of from 13 to 24 hours to remove organic contaminants; and (c) Treating the spent carbon from step (b) with a solution of from 5 to 25 percent caustic at a temperature range of from 720 to 1800F for a contact time of from 3 to 24 hours to remove sulfur contaminants 2. The process of Claim 1 wherein the concentration of caustic sufficient to remove organic contaminants is 50 percent and the contact time is about 18 hours at a temperature of 1400F. 3. The process of Claim 1 wherein the concentration of caustic sufficient to remove sulfur contaminants is from 15 to 20 percent and the contact time is from 5 to 10 hours at a temperature of 1400F. 4. The process of Claim 1 wherein the caustic is NaOH. 5. The process of Claim 1 wherein the caustic is KOH. 6. The process of Claim 1 wherein the water temperature for washing the spent carbon is 120 F.

Inventors: FARMERIE, JOHN J.
Applicants: CALGON CORPORATION
Application year: 1982
Main classification: C01B31
IPC codes: C01B31, B01J20