System and method of converting environmentally pollutant waste gases to methanol

Abstract: A continuous flow method and system is provided for converting environmentally pollutant by-product waste gases emitted during the manufacture of a product in a first manufacturing plant to a useful product in a second manufacturing plant such that release of the gases into the atmosphere may be prevented.

Description: This invention relates generally to a system and method of converting environmentally pollutant gases such as hydrogen sulfide and carbon monoxide emitted during a manufacturing process such as the manufacture of silicon carbide in order to achieve a beneficial use of the gases as well as to prevent their evolution into the atmosphere. Background Of The Invention Industrial silicon carbide is generally produced by a discontinuous or batch process in a furnace typically of the electrical resistance type. Silicon carbide production is important because silicon carbide is considered a strategic stockpiled material by the government. The process generally involves mixing raw materials of silica, sand and petroleum coke and placing these materials in an electric resistance furnace. The reaction is then carried out by direct electrical heating. As a result of the process, various by-product waste gases consisting primarily of carbon monoxide, carbon dioxide and hydrogen are produced in large amounts. Other by-product waste gases, such as hydrogen sulfide and hydrocarbons such as methane also form from the impurities in the coke. United States patent 3,976,829 discloses a gas collection system developed in the late 1970's for use with an electrical resistance furnace of the type disclosed in United States patents 3,950,602, 3,989,883 and 4,158,744. The gas collection system allows collection of the by-product waste gases during the manufacture of silicon carbide for subsequent incineration. During incineration the gases are converted into carbon dioxide and sulfur dioxide and then emitted into the atmosphere. However, carbon dioxide and sulfur dioxide are pollutant gases, and emission thereof into the atmosphere is regulated for health and environmental reasons. In this connection, evolution of sulfur dioxide into the atmosphere is presently scrutinized in connection with the "acid-rain" effect. Many processes are available for removing the sulfurous contaminants from the gases. But these processes generally are costly in capital investment and wasteful in energy conservation. Furthermore, evolution of carbon dioxide into the atmosphere is presently scrutinized in connection with the "green-house" effect. Therefore, an economical system and method of converting environmentally pollutant by-product waste gases, such as hydrogen sulfide and carbon monoxide emitted during the manufacture of silicon carbide, whereby evolution of the gases into the atmosphere may be prevented would be desirable. Furthermore, the storage of the by-product gases for later use in a manufacturing process requires uneconomical storage handling steps. Therefore, it is desirable, to avoid storage while advantageously converting the by-product waste gases into useful products wherein they are not disadvantageously emitted to the atmosphere. The production of silicon carbide in batch furnaces is known. It is also known to convert carbon monoxide, carbon dioxide and hydrogen into methanol. The problem is, however, that the by-product gases emitted during the production of silicon carbide are not emitted continuously rather than batchwise while the production of methanol is a continuous method requiring continuous supply of carbon monoxide, carbon dioxide, hydrogen etc. It is the underlying objective of the invention to prevent emission into the atmosphere of pollutant by-product waste gases produced during the manufacture of silicon carbide in a first manufacturing plant. This problem cannot be simply solved by providing a methanol manufacturing plant for processing the by-product gases. It is necessary to adjust the continuous production of methanol to the batchwise emission of the by-product gases. The solution to this objective is provided by the invention by a method comprising: (a) operating a plurality of batch furnaces of a silicon carbide manufacturing plant thereby producing silicon carbide and emitting by-product gases during the operation of the furnaces; (b) staggering the operation of the batch furnaces to achieve a continuous emission of the by-product gases; (c) continuously flowing the by-product gases as emitted from the batch furnaces directly to a methanol manufacturing plant; (d) cleansing the by-product gases of particulate matter, including removing the element sulfur from the by-product gases, as they are flowed to the methanol manufacturing plant, sufficiently for use of the by-product gases in producing methanol; and (e) immediately producing methanol from the by-product gases at the methanol manufacturing plant whereby the producing of silicon carbide is joined with the producing of methanol as a unified process. The invention also provides a system for carrying out this method. The invention is further described by reference to the various Figures in the drawings. Brief Description Of The Drawings Fig. 1 discloses a schematic view of a system according to the present invention. Fig. 2 discloses a schematic view of the control system thereof. Fig. 3 discloses a side view of a manhole used in the system. Fig. 4 discloses a schematic view of manholes of the system which are associated with each furnace in a furnace group. Fig. 5 discloses a schematic view of a sump pump system associated with the manholes illustrated in Fig. 4. Fig. 6 discloses a simplified elevation schematic view of the system of Fig. 1 illustrating the slope of the pipelines between first and second plants. Detailed Description Of The Preferred Embodiments The term "continuous flow", as used herein, refers to the Substantially uninterrupted flow of by-product gases, as emitted during the manufacture of a product at a first manufacturing plant, from the first manufacturing plant to a second manufacturing plant. This is in contrast to a process which includes storing the by-product gases such as in containers. The term "as emitted", as used herein, with reference to the by-product gases, refers to the by-product gases as produced from the manufacture of the product at the first manufacturing plant including collection or bringing together of the gases for immediate flow toward the second manufacturing plant. With reference to Figures 1 and 2, there is illustrated a continuous flow method of converting environmentally pollutant by-product gases, such as carbon monoxide and hydrogen sulfide, emitted in a silicon carbide manufacturing plant, generally indicated at 1, during the manufacture of silicon carbide. The silicon carbide is manufactured at silicon carbide manufacturing plant 1 from a mixture of silica sand and carbonaceous materials. The basic reaction for the manufacture of silicon carbide is: Si0₂ + 3C -----> SiC + 2C0. The silicon carbide is prepared according to a batch or discontinuous process in a furnace generally shown in Figures 1 and 2. With reference to Figure 1, the silicon carbide manufacturing plant 1 includes a plurality of furnace groups, one such group generally shown at 2, which provide outputs respectively through lines 60. Typically, each furnace group 2 includes four furnaces 4, 6, 8 and 10. Each furnace group includes one transformer building 12 per group of four furnaces. The transformer building 12 conventionally includes a transformer (not shown), capacitor (not shown), pump (not shown) and control system, generally indicated 14 in Figure 2, for operating the furnaces in each furnace group. The furnaces 4, 6, 8 and 10 are typical of the furnaces in the other furnace groups and are batch or discontinuous flow furnaces. During operation, the furnaces are staggered to provide continuous production of silicon carbide. For example, the silicon carbide manufacturing plant 1 shown in Figure 1 includes six furnace groups wherein one furnace within each group is running at any given time of plant operation. When a furnace running within each group shuts down another furnace in that group starts or will have begun running. Such operation of the furnaces may be regulated using principles commonly known to those of ordinary skill in the art to which this invention pertains. Except for the furnaces 4, 6, 8 and 10 preferably being batch furnaces, the particular construction of the furnaces forms no part of the present invention. The furnaces may be of any suitable construction such as, for example, of the electrical resistance type disclosed in United States patents 3,989,883, 3,950,602 and 4,158,744. The present invention is only concerned with the disposition or use made of the gases no matter how they are produced though preferably in batch furnaces the operation of which are staggered to achieve uniform continuous flow. Various environmentally pollutant by-product gases, particularly carbon monoxide, carbon dioxide, and hydrogen, are produced as a result of the reaction. In addition, other by-product gases produced include other gaseous compounds such as hydrocarbons, in particular, methane and hydrogen sulfide which are formed from the impurities of the coke used. The by-product gases as emitted during the manufacture of silicon carbide are collected by a collector apparatus, generally indicated 16, associated with the furnaces. The collector apparatus 16 is characterized by arranging beneath a ballast 5 with the resistance core embedded therein, a bed filled with porous material (not shown), and/or the base and the slopes of the bed may be suitably sealed with a gas-impervious layer, i.e., flat cover 17 above the ballast. Within the bed and beneath the cover, gas outlet ducts 18, 20 are installed through which the by-product gas collected are removed from the furnaces. The bed is arranged beneath the ballast 5 and preferably below the furnace bottom and advantageously extends through the length of the furnace between the electrodes 7. The cross-sectional configuration for this bed is not limnited to any particular configuration. The seal 17 can be made, for example, of a concrete layer of a synthetic material that is situated at a suitable distance from the hot burden. For filling the bed, a heat resistant solid material having a porous or granular structure such as pumice, grit, granulated pumice, concrete gravel, sand, or quartz grit and preferably a sandstone (silica rock) may be provided for filling the bed. The flat cover or sheet 17 disposed above ballast 5 also extends advantageously over the length of the furnace. When using an adequately high ballast if care is taken that the surface is no longer sufficiently hot to damage the cover 17, or to destroy it, the cover 17 may suitably be a material not absolutely heat resistant such as gas-impervious sheets, impregnatated fabrics, or canvas covers. The material preferably comprises polyethylene sheets having a thickness of from about 0.1 to about 0.5 millimeters and preferably about 0.3 millimeters. The flat cover 17 may advantageously be used with furnace installations of the electrical resistance type having bottom electrode arrangements 7 which are operated as open mound furnaces without walls. In such installations, the whole charge cone can be covered up to the ground level without the danger of the covering material coming into contact with hot parts of the furnace. Gas outlet ducts 18, 20 are suitable pipes placed within the porous bed of material in the furnace and beneath the cover and are provided with side openings (not shown) in the part of the pipes which project into the porous bed and/or under the cover to receive the by-product gases as emitted during the manufacturing process. Gas outlet ducts 18, 20 may be constructed of iron or synthetic material that can be perforated or provided with slots within the furnace. The number and cross section of the pipes arranged within the porous bed and/or beneath the cover depends on the size of the furnace and on the electric charge provided which regulates the amount of by-product gases expected. With reference to Fig. 2, overgas outlet duct 18, and undergas outlet duct 20 extend from above and below the furnace, respectively. Overgas outlet duct 18 connects to modulating valve 22. Modulating valve 22 is controlled by a suitable process controller 24 which receives a pressure signal through line 47 from a suitable pressure transmitter 28 of the pressure under cover 17 to open and close modulating valve 22 so as to regulate the gas pressure under cover 17 such that the cover constitutes an air supported structure. Each furnace group has its own process controller 24 that controls the modulating valve associated with that furnace. Undergas outlet duct 20 connects to hand valve 58 which is pre-set manually to the desired vacuum pressure. For a more complete interface between the silicon carbide plant and the methanol plant additional controls may be implemented. For purposes of illustration and, not limitation, the process controller 24 from each furnace group may provide feedback to a suitable main process controller 26 for each furnace group on the status of the operating conditions of the one furnace per group that is operating. The process controller 24 compares the pressure signal to the valve position, as determined from a signal potentiometer (not shown) within modulating valve 22, and suitably opens or closes the valve 22 to control the gas pressure under the cover. This process occurs at each furnace group simultaneously for the one furnace per each group that is operating at any one time. A four way selector switch 30 to select currently operating furnaces and a timer switch 32 to prevent over reaction of modulating valve 22 are also provided. The main process controller 26 would provide a secondary level of process control for maintaining the pressure under cover 17. Process controllers 24 would provide signals to the main process controller 26 through lines 49 when predetermined maximum operating pressures are exceeded beneath the cover 17 and the modulating valve 22 is accordingly fully opened. When this condition occurs, the main process controller 26 would automatically start a blower fan motor, generally indicated 34, for added control capacity of the flow of the by-product gas. The by-product gases are collected in collector apparatus 17 during the manufacture of silicon carbide in the furnaces. Thereafter, the pollutant by-product gases are continuously flowed through piping 40 from the silicon carbide manufacturing plant 1 to a methanol manufacturing plant, generally indicated 36, for immediate processing in the manufacture of methanol to thereby advantageously eliminate costly intervening storage steps of the gas while preventing evolution of the pollutant by-product waste gas into the atmosphere. The methanol manufacturing plant 36 is therefore preferably located in proximity to the silicon carbide manufacturing plant 1, i.e., sufficiently close, for example, a distance, illustrated at 77 in Fig. 6, therebetween which is less than about 1,6 km (1 mile) apart so as to not be unduly expensive to build and operate. The methanol manufacturing plant 36 may be a conventional high pressure or low pressure manufacturing plant, and more preferably is a high pressure plant. The by-product gases are processed in methanol manufacturing plant 36 into methanol and sulfur. The first step in the processing of the by-product gases at the methanol manufacturing plant for production of methanol and sulfur is compressing the by-product gases which consist mainly of hydrogen, and carbon monoxide. The next step is the desulfurization of the by-product gases using a sulfur removal system (not shown). The sulfur removal system may consist of any currently available system capable of removing sulfur from gases. One type is the wet process which involves scrubbing the gases by contact with organic or aqueous solutions of alkaline chemicals to extract the acid sulfur compounds by either physical or chemical reactions between components of the gases and liquids. The reactive chemicals utilized in these processes include ammonia, organic amines, oxides, and carbonates and sulfites of alkali and alkaline earth metals. Another type of process which may be utilized involves contacting the gases with dry solid sorbents. A process of this type utilizes the physical properties of sorbents such as activated alumina, activated carbon and silicon gel and operate at low temperatures. Alternatively, this type of process may utilize minerals and chemicals such as dolomite, magnesite, calcite, siderite, magnetite, hematite, bauxite, lime, soda ash and/or magnesia, as solid sorbents containing components that react chemically with sulfur compounds in the gas and operate at relatively high temperatures. Further suitable processes for the desulfurization of the gases involve cooling the hot gas and desulfurizing the cooled gas by contact with agueous solutions of alkaline chemicals. These processes utilize heat exchange equipment of alloy construction. Desulfurization of the gases by contact with minerals or chemicals at high temperatures is another proposed process which may be utilized and involves the use of limestone or dolomite as a sorbent for the sulfur whereby chemical reactions between calcium and the minerals and sulfur in the gas occur which provide calcium sulfide and calcium sulfate in the reactive solids thereby removing the sulfur from the sulfur bearing gases. The sulfur removed from the by-product gases is thereafter collected and sold. Thus, evolution of the sulfur into the atmosphere is prevented, as is increasingly demanded by the public for health and environmental reasons. After the sulfur removal step, the remaining by-product gases, which consists mainly of hydrogen and carbon monoxide, are mixed with natural gas, which is mostly methane, to provide a constant flow rate and a correct carbon balance for processing the gas into methanol. The amount of natural gas mixed with the by-product gas is dependent upon the volume of by-product gas supplied to the methanol manufacturing plant from the silicon carbide manufacturing plant. Thus, as the amount of by-product gas is increased, the amount of natural gas may be decreased. In processing the gases into methanol, perhaps 75% of the feedstock will initially be natural gas with the remaining 25% being the by-product gases produced from the manufacturer of silicon carbide. As the silicon carbide manufacturing plant increases its capacity and thereby produces larger amounts of by-product gases, the amount of natural gas may be decreased as a percentage of the feedstock used in the production of methanol. The next step in the production of methanol is reformation of the feedstock gases which now consist mainly of hydrogen, carbon monoxide, methane and water. Reformation shifts the oxygen to the carbon to form more carbon monoxide. The basic reaction for the reformation of the feedstock gases is: CH₄ + H₂O --> CO + 3H₂ The reformation process is controlled to provide a balance of one part carbon monoxide to two parts of hydrogen. This process in the methanol manufacturing industry is known as steam reforming. The synthetic gas (CO + 2H2) formed as a result of the reformation step is then compressed Thereafter, reaction of the synthetic gas (CO + 2H2) to form methanol (CH₃OH) is carried out. The reaction of converting the synthetic gas to form methanol may be accomplished by means of equipment known as a "Synthetic-loop", designed and manufactured by Lurgi Kohle & Mineraloltechnik GmbH. The last step in the methanol production process is purifying any unwanted compounds or material which are formed or present after the synthetic gas is converted to methanol. The purification process is accomplished using a standard distillation system. After purification, the methanol is stored for sale to third parties. Means, generally indicated at 38, for continuously flowing the by-product gases as emitted from silicon carbide manufacturing plant 1 directly to methanol manufacturing plant 36 for immediate processing in the manufacturing of methanol and sulfur comprises a gas routing and condensation drainage system. The gas routing and condensation drainage system 38 includes piping lines 40 for continuously flowing the by-product gases to methanol manufacturing plant 36 and manholes, generally indicated at 42, associated with piping lines 40 for receiving sludge and water condensation that drops-out from the by-product gas as it is flowed from silicon carbide manufacturing plant 1 to methanol manufacturing plant 36. Piping lines 40 of the present system are preferably sized Sufficiently for receiving the gases at maximum flow output conditions from silicon carbide manufacturing plant 1 so that friction of the flowing gas in pipe lines 40 is minimized. The size of piping lines 40, is suitably related to the composition of the constituents in the by-product gas. Therefore, it is understood that the size of the piping lines 40 in accordance with the present invention would vary from plant to plant, being dependent on the composition of the by-product gas as well as expected maximum flow rates. It is desirable to remove as much sludge, i.e., furnace residue and particulate matter, as possible in order to provide a sufficiently clean gas for use as feed stock in the production of methanol. As the by-product gas flows through pipe lines 40 from silicon carbide manufacturing plant 1 to methanol manufacturing plant 36, a cooling effect on the gas occurs. This cooling effect, facilitated by the slope of the pipe 40 and sizing thereof as hereinbefore discussed, causes sludge and water condensate to drop out of the by-product gas to thereby cleanse it. But practical considerations, namely geographical, may limit the amount of slope achievable. It is desirable that the piping lines Stay clean of sludge and water condensate because if sludge builds-up in the line, in addition to clogging, the inside pipe diameter will decrease which will increase the velocity of the gas through the pipe such that less cooling effect will be apparent giving a dirtier gas. The slope, illustrated at 74 in Fig. 6, of the piping lines 40 is preferably at least about 1% downwardly in the direction of gas flow from the first plant 1 to the second plant 36, as indicated by arrows 75 in Figures 1, 2, and 6, and for a distance, preferably over the entire distance, length and geographic conditions permitting, between the plants 1 and 36, sufficient to prevent clogging of the system as well as provide a relatively cleansed gas free of furnace residue and particulate matter sufficient for use in plant 36, for example, over a distance of about a mile. The portion of gas flow piping within plant 1 may, of course, also be similarly sloped, as illustrated at 75 in Fig. 1. In order to prevent clogging problems from sludge drop-out, any time there is a change in elevation a suitable manhole, generally indicated at 42, is preferably provided to collect the sludge and water condensate that drop-out from the by-product gas due to the cooling effect because of velocity and direction changes as the gas moves through piping lines 40. The more manholes utilized in the present system, within practical considerations, the better cleansed the final by-product gas will be and the less likelihood of sludge build-up and eventual clogging in the piping line system itself. With reference to Figures 1 and 2, a manhole 42 is provided in the piping between the plants 1 and 36 preferably, at each change in elevation of the piping. It is therefore understood that the positioning and numbering of the manholes will vary. For example, the positioning of piping lines 40 and manholes 42 may differ on opposite sides of a plant due to geographical considerations. With reference to Figure 3, there is shown a typical manhole 42. The manhole 42 is comprised of a pre-cost manhole Section 44 which is positioned beneath the ground 46. In order to most effectively achieve drop-out of particulate as the gas rises. The by-product gas generally enters the manhole 42 at a lower end thereof through piping line 40 as shown by arrow 50 and generally exits the manhole at a position above where it entered such as at the top thereof through piping line 40, as shown by arrow 48. Each manhole further contains a water seal 47 to maintain the System under vacuum and prevent air from entering the system and possibly causing an explosion. As a result of the change in elevation and the cooling effect on the by-product gases, sludge and water condensate 52 drop out of the by-product gas and are collected at the bottom of manhole 42. Drainage pipe 54 is provided to remove the sludge and condensate water from the manhole 42. Furthermore, and with reference to Figure 4, each furnace per furnace group in the silicon carbide manufacturing plant includes a manhole 56 to which the by-product gas is first flowed upon emission from the furnace. By-product gases flow through overgas outlet duct 18 and undergas outlet duct 20 directly from the silicon carbide furnace to manhole 56. The overgas is regulated out of manhole 56 through modulating valve 22 and the undergas is regulated out of manhole 56 through manually regulated valve 58. The by-product gases are then combined into a single pipe line 60 for flow to the main piping lines 40 where all the by-product gases produced from each of the furnace groups are combined for flow to the methanol manufacturing plant. With reference to Figure 1, a suitable water treatment lagoon system which transports the water condensate that drops from the by-product gas for treating and recycling of the water is also provided. The transport system is indicated by segmented lines 64 which transport the water filter bed to 65 for subsequent transportation to the water treatment lagoon (not shown). The water treatment lagoon system is conventional in nature and any known system may be utilized in accordance with the present invention. For example, with reference to Figure 5, each manhole 56 in the system may comprise a suitable sump pump 62, such as a longshaft pumps for 180° water use, Supplied by Tramco. The sump pump 62 pumps out the water from the manholes to the filter bed 65 for subsequent transport and treatment at the lagoon system (not shown). Alternatively, the furnace group may include lines associated with the manholes which flows the water therefrom by gravity to a downward sloping tile through which transports the water to the logoon system for treatment. The sludge remaining in manholes 42 and 56 is periodically removed from the manholes and appropriately disposed of. Thus, water condensate in manholes 42 may be drained periodically through pipe 54 or pumped by the sump pump for removal. It is understood that the manhole system utilized in the present invention to collect the sludge and condensate water drop-out, is for purposes of illustration only, and not limitation. It is within the scope of the present invention to employ any conventional filter system which would remove the sludge and condensate water and reduce clogging of the system. With reference to Figures 1 and 2, a plurality of high temperature, radial, heavy duty blower fans, generally indicated 34, are provided to regulate the flow rate of the by-product gases from silicon carbide manufacturing plant 1 to the methanol manufacturing plant 36. Six blower fans 35, 37, 39 in parallel and 41, 43, 45 in parallel are balanced and manually regulated as determined by the amount of by-produce gas produced. As previously mentioned, if a main process controller 26 (Fig. 2) is provided, the fans could be automatically regulated on and off by the main process controller 26 in accordance with desired gas flow. The maximum gas flow is dependent on fan capacity. Also, a suitable computer program, which may be developed using principles commonly known to those of ordinary skill in the art to which this invention pertains, may be used to coordinate and balance the fans to maximize flow rate of the by-product gases. The flow rate of the by-product gases is determinative of the diameter of the piping which may be selected based on the capacity of the blower fans used taking into account the friction factor of the flowing gases. Each blower fan is operated by a conventional motor 19 and comprises a manually operated valve for isolating the fan. It is understood that one large blower fan, having a speed adjustment control for regulating the fan in accordance with changes in by-product gas flow, may be substituted herein for the plurality of small blower fans. The by-product gas is continuously flowed through the piping lines by regulating the capacity of the blower fans to accomodate the gas output from the furnaces at any given time. If the volume of the by-product gas being flowed is such that it is higher than the volume necessary at any one time during the methanol production, excess by-product gas is directed to pilot burner 69 at incinerator 64 by process controller 63 opening and closing modulating valve 65. Routing of the by-product gas to the methanol plant 36 is through modulating valve 67 which is also controlled by process controller 63. If shutdown occurs at the methanol manufacturing plant, for example due to maintenance, all gas is flowed to a main burner 71 at incinerator 64 through modulating valve 73. The incinerator may typically have a capacity to incinerate a gas flow volume of 15,000 S.C.F.M. The by-product gas flow which is diverted to either of the burners 69 or 71 of incinerator 64 is flowed through a water seal pot 66 to prevent flames during the incineration process from coming back into the system and potentially causing an explosion. Water seal pot 66 functions similarly as the water seal in the manholes. Additionally, each furnace group may comprise a backup incinerator 68.

Claims: Continuous flow method of converting environmentally pollutant by-product gases emitted during the manufacture of a product to methanol comprising: (a) operating a plurality of batch furnaces (4, 6, 8, 10) of a silicon carbide manufacturing plant (1) thereby producing silicon carbide and emitting by-product gases during the operation of the furnaces; (b) staggering the operation of the batch furnaces (4, 6, 8, 10) to achieve a continuous emission of the by-product gases; (c) continuously flowing the by-product gases as emitted from the batch furnaces (4, 6, 8, 10) directly to a methanol manufacturing plant (36); (d) cleansing the by-product gases of particulate matter, including removing the element sulfur from the by-product gases, as they are flowed to the methanol manufacturing plant (36), sufficiently for use of the by-product gases in producing methanol; and (e) immediately producing methanol from the by-product gases at the methanol manufacturing plant (36) whereby the producing of silicon carbide is joined with the producing of methanol as a unified process. Method according to claim 1, characterized in that the by-product gases include carbon monoxide and hydrogen sulfide. Method according to claim 1, characterized by flowing the by-product gases as emitted from the silicon carbide plant to the methanol plant (36) through piping (40) which extends between the silicon carbide plant (1) and the methanol plant (36) and which has a slope of at least about 1% over a distance sufficient to cleanse the by-product gases of particulate matter sufficiently for use of the by-product gases in the methanol manufacturing plant (36). Method according to claim 3, characterized by providing at least one manhole (42, 56) at a pipe bend in said piping (40) for collecting said particulate matter to thereby facilitate cleansing of the system. Method according to claim 1, characterized by: removing the element sulfur from the by-product gases by using the remaining gases being comprised mainly of hydrogen and carbon monoxide; combining the remaining gases with methane; reforming the gases to provide a balance of one part carbon monoxide to two parts hydrogen; compressing the gases up to the methanol reactor pressure; reacting the gases to form methanol; and purifying the methanol. System for carrying out the method according to anyone of claims 1 to 5, characterized by a first manufacturing plant (1) including a plurality of batch furnace means (4, 6, 8, 10) for heating a mixture of coke and silicon dioxide to produce silicon carbide and which emits environmentally pollutant by-product gases including carbon monoxide and hydrogen sulfide during the production of the silicon carbide and including means (24, 26, 30) for staggering the operation of said batch furnace means to provide a continuous flow of the by-product gases from said first manufacturing plant (1); a second manufacturing plant (36) for processing the by-product gases for production of a product; and means (40) for continuously flowing the by-product gases as emitted from said first manufacturing plant (1) directly to said second manufacturing plant (36) for immediate processing for production of the product whereby evolution of the pollutant by-product gases into the atmosphere may be prevented. System according to claim 6, characterized in that said means (40) for continuously flowing the by-product gases comprises a piping system having a slope of at least about 1 % over a distance sufficient to cleanse the by-product gas of particulate matter sufficiently for use of the by-product gas in the methanol manufacturing plant (36). System according to claim 7, characterized by at least one manhole (42, 56) at a pipe bend in said piping system (40) for collecting said particulate matter to thereby facilitate cleansing of said piping system (40).

Inventors: EBERLE LUDWIG DR, LADAGE ARMAND, MARTYNIUK WALTER, MCNALLY TOM, MYERS ROBERT, PFINGSTL HANS, EBERLE, LUDWIG, DR.,, LADAGE, ARMAND, MARTYNIUK, WALTER, MCNALLY, TOM, MYERS, ROBERT, PFINGSTL, HANS
Applicants: EXOLON ESK CO, KEMPTEN ELEKTROSCHMELZ GMBH, ELECTROSCHMELZWERK KEMPTEN GMBH, EXOLON-ESK COMPANY
Application year: 1991
Main classification: C07C29
IPC codes: C07C29, C01B31, B01J19