Patent ID: 12246991

DETAILED DESCRIPTION

This invention is a chemical processing system with two concentric tubes. The wall of the inner concentric tube bounds an interior cylindrical space, defined for the purposes of this entire disclosure as the inner tube space. The annular space within the outer concentric tube, but external to the inner tube space, which is bounded by the wall of the inner tube and the wall of the outer tube, is defined for the purposes of this disclosure as the outer tube space.

One of the two concentric tube spaces contains an atmosphere of carbon dioxide and hosts the decomposition reaction of one or more metal carbonates, such as: MgCO3, CaCO3, Na2CO3, K2CO3, and others, into metal oxides and CO2. The other of the two concentric tube spaces contains an atmosphere of steam and hosts the hydration reaction of the metal oxides produced in the first tube, to create hydroxides, such as: Mg(OH)2, Ca(OH)2, NaOH, KOH, and others.

The use of two concentric tubes provides excellent thermal coupling between the two reactions. The wall of the inner concentric tube separates the inner tube space, in which one reaction occurs, from the outer tube space in which the other reaction occurs and conducts heat from the hydration reaction in one of the two tube spaces to the decomposition reaction in the other tube space. The wall of the inner concentric tube also conducts heat to cool the outgoing metal hydroxide and warm the incoming metal carbonate. Apart from the thermal coupling, the two reactions are isolated from each other. They operate at different pressures, with different atmospheres, and with different reactants.

The tube which has its corresponding tube space hosting the decomposition reaction may for convenience be termed the “first concentric tube”, and depending on the embodiment can be either the inner or the outer tube. Accordingly, the other tube, whose corresponding tube space hosts the hydration reaction is termed the “second concentric tube”, and would be either the outer or inner tube, respectively. In all cases, heat flows from the tube space within which the hydration process occurs, through the inner tube wall, to the other tube space within which the decomposition process occurs.

FIG.1illustrates an embodiment in which decomposition occurs in the outer tube (1) and hydration occurs in the inner tube (3). A metal carbonate (5), such as CaCO3is input at the right side of outer tube (1), and flows to the left through the outer tube space, the annulus between the inner and outer tube walls. As it flows, heat (8) generated by the hydration reaction in the inner tube (3) flows through the inner tube wall along its entire length to heat the CaCO3in the outer tube. Additional heat needed to drive the decomposition reaction is added by a heater (2) on the left side. In the particular embodiment shown inFIG.1, the heater (2) is located inside the outer tube and outside the inner tube, but, in other embodiments, the heater can be located inside the inner tube, or outside the inner and outer tubes.

The carbon dioxide (4a) produced by the decomposition of the carbonate in outer tube (1) flows to the right and is collected at the right side of the outer tube by a gas blower, gas pump, vacuum pump, or gas compressor (4b). The metal oxide (10) produced by that same decomposition reaction exits the outer tube at the left, flows into the end cap (9), is injected into the inner tube on the left, and flows through the lumen of that inner tube to the right. Water (6) is input at the right side of the inner tube, vaporizes within the inner tube, and flows to the left, hydrating the metal oxide it encounters to form a metal hydroxide (7) which finally exits on the right side of the inner tube. The water input is metered to produce the amount of steam required for the hydration reaction. The flows of the metal carbonate in the outer tube and the metal hydroxide in the inner tube are in opposite directions. The left side of each tube is at or above the temperature required for decomposition, while the right side is at room temperature. As the metal hydroxide flows to the right, moving away from the region of the heater, it cools and transfers its heat through the inner tube wall to warm the incoming metal carbonate.

In the embodiment illustrated inFIG.1, and with CaCO3as the metal carbonate, the decomposition occurs according to reaction (2), noted above, and reproduced here for convenience:
Heat+CaCO3→CaO+CO2(+178 KJ/mole)  (2)

This decomposition reaction is reversible. Its equilibrium temperature is a function of the CO2partial pressure, as given approximately by the table below. At a temperature above its equilibrium temperature, CaCO3decomposes to CaO+CO2. At a temperature below its equilibrium temperature, CaO+CO2will recombine to from CaCO3. Thus, the partial pressure of carbon dioxide in the outer tube sets the temperature at which the CaCO3will decompose,

CO2 PartialEquilibriumPressure (atm)Temperature ° C.18980.34198300.07757480.01866800.00306050.00065500.0001500

By adjusting the partial pressure of carbon dioxide in the outer tube, the temperature at which CaCO3(or other metal carbonates in other embodiments) decompose can be controlled. For example, for CaCO3, if the CO2partial pressure is set at 0.078 atmospheres, then, at temperatures above 748° C., CaCO3will decompose. At temperatures below 748° C., CaO will recombine with CO2and form CaCO3.

In an embodiment with CaCO3as the metal carbonate, water and CaO react in the inner tube to form Ca(OH)2, according to reaction (3), noted above, and reproduced here for convenience:
CaO+H2O (liquid)→Ca(OH)2+heat (−65 KJ/mole)  (3)

The decomposition reaction consumes heat, and the hydration reaction produces heat.

Some of the hydration heat converts liquid water to steam, and some of the heat (8) flows through the inner tube wall to provide part of the heat required by the decomposition reaction.

This hydration reaction (3), like decomposition reaction (2), is reversible. Its equilibrium temperature versus steam partial pressure is given approximately by the following table:

Steam PartialEquilibriumPressure (atm)Temperature ° C.118898658302974813680560525501500

By setting the partial pressure of the steam, the temperature at which lime, or another metal oxide, in another corresponding embodiment, is hydrated can be controlled. In one embodiment of the type illustrated inFIG.1, using CaCO3, the steam partial pressure can be set to 120 atm, resulting in an equilibrium temperature for hydrating CaO of approximately 898° C. If the CO2partial pressure is set to below 1 atm, for example to 0.34 atm, the decomposition reaction will proceed at a temperature above 830° C. This higher temperature of the hydration reaction in the inner tube and the lower temperature of the decomposition reaction in the outer tube will create a temperature gradient. Heat will flow down the temperature gradient from the hydration reaction that produces heat in the inner tube, through the thermally conducting inner tube wall, (experiencing a small temperature drop), into the outer tube, and provide part of the heat to drive the carbonate decomposition reaction.

In another embodiment of the type illustrated inFIG.1, also using CaCO3, the steam partial pressure may be set to 65 atm, giving a hydration equilibrium temperature of 830° C., and the CO2partial pressure may be set to 0.078 atm, giving an equilibrium decomposition temperature of 748° C. As before, the temperature of the hydration reaction is above the temperature of the decomposition reaction, and heat flows through the inner wall down the thermal gradient from the hydration reaction to the decomposition reaction. In one embodiment, the drop in temperature through the thermally conducting inner wall is 30° C. The hydration reaction would operate at 804° C., 26° C. below its equilibrium temperature, and the decomposition reaction would operate 774° C., 26° C. above its equilibrium temperature. Both processes would be far enough from their equilibrium temperatures to proceed. In an extreme case, where the temperature drop through the inner tube wall is nearly zero, for both reactions to proceed at a reasonable rate, the partial pressures must be set so that the temperature of the hydration reaction is at least 5° C. below its equilibrium temperature, and the temperature of the of the decomposition reaction is at least 5° C. above its equilibrium temperature.

In other embodiments, by adjusting the carbon dioxide partial pressure to be at or less than 1 atm, over a range from 0.0001 atm to 1 atm, the equilibrium temperature of the decomposition reaction will be in the range from 500° C. to 950° C. This temperature range requires that the steam partial pressure is correspondingly adjusted over a range from 1 atm to 200 atm. The choice of operating pressures is a trade-off. Lower decomposition temperatures require lower partial pressures, and more energy consumed by vacuum pumps to achieve those lower pressures. In some embodiments, the carbon dioxide partial pressure is close to or equal to 1 atm to minimize the energy consumed by vacuum pumps. In other embodiments, the steam pressure is minimized, and the carbon dioxide pressure is set well below 1 atm.

In yet other embodiments, with metal carbonates other than calcium carbonate, the tables of equilibrium temperatures versus pressures of carbon dioxide and steam will be different. The corresponding chemical systems will operate over different pressure and temperature ranges than listed for calcium carbonate in the embodiments discussed above. However, the basic principle is the same. The steam and carbon dioxide pressures are set so that the hydration reaction occurs at a temperature higher than the decomposition reaction, causing heat to flow from the hydration reaction, down a thermal gradient, through the inner tube wall, and provide some of the heat required for the decomposition reaction.

FIG.2illustrates an embodiment in which the decomposition occurs in the inner tube (3) and hydration occurs in the outer tube (1), a reversal of the arrangement shown inFIG.1. Heat (8) still flows from the hydration reaction through the inner tube wall to the decomposition reaction, and from the outgoing metal hydroxide to the incoming metal carbonate. In the particular embodiment shown, the heater (2) is placed inside the inner tube, but, in other embodiments, it can be located outside the inner tube and inside the annulus between the walls of the inner and outer tubes, or outside of the outer tube. A metal carbonate (5), such as CaCO3, is introduced into the inner tube and flows to the left. CO2(4a) produced during the decomposition of the carbonate flows from the hot region on the far left, and out of the inner tube at the far right, where it is collected by a gas blower, gas pump, vacuum pump, or compressor (4b). On the left, after decomposition, CaO (10) or, in embodiments where another metal carbonate is involved, its corresponding metal oxide, flows out of the inner tube, flows into the end cap (9), and is injected into the outer tube. In the outer tube (1), the CaO or other metal oxide combines with steam to form a corresponding hydroxide+heat. The hydroxide (7) flows from left to right and exits on the far right from the outer tube. Water (6), needed to create the steam, is injected into the outer tube at the far right.

In one embodiment, the metal carbonate and the metal hydroxide are both granular, with a texture like sand. They can be moved through the tubes by any of a number of methods. In one embodiment, they are moved by Archimedes Screws. In one embodiment, the Archimedes Screws are oriented in opposite directions and both concentric tubes are rotated together in the same direction. The oppositely-directed Archimedes Screws will move the carbonate to the left and the hydroxide to the right. In another embodiment, without Archimedes Screws, the tubes are rotated to constantly mix the reactants, and to facilitate the transfer of heat from the tube walls to and from the reactants.

From the discussion above, for embodiments that use calcium carbonate, one tube has an atmosphere of steam at a partial pressure in the range of 1 to 200 atm, and the other tube has an atmosphere of carbon dioxide at a partial pressure in the range 0.0001 to 1 atm. Valves (not shown) withstand the pressure differences, and move material into and out of each tube. Possible valve types include spool valves and others. The end cap (9) has a carbon dioxide atmosphere at a pressure at or below 1 atm. At the left side of the tube in which the hydration reaction occurs a valve is required to separate the carbon dioxide atmosphere of the decomposition reaction from the steam atmosphere of the hydration reaction, and to inject the metal oxide to be hydrated. At the right side, each of the tubes requires a valve and/or a rotary seal to separate its internal atmosphere from external air at 1 atm, and to input metal carbonates and output metal hydroxides.

The materials from which the tubes are constructed must meet significant demands for high mechanical strength and good thermal conductivity at elevated temperatures. For operation in the 750° C. to 950° C. region, the combined temperatures and pressures are too high for many materials. Also, the inner tube wall, must be thin enough to adequately conduct heat and minimize the temperature drop across the wall, which should be less than 50° C. With either Schedule 40 or Schedule 80 dimensions, the tensile or compressive stress in the inner wall is 6.7 to 27 times the pressure inside the tube. The choice of materials for constructing the two concentric tubes and the end caps, includes: metal alloys, including: stainless steel alloys, nickel alloys, tungsten alloys, chrome alloys, molybdenum alloys, titanium alloys, zirconium alloys, and others; and various ceramics, including: SiC, SiN, alumina, and others.

The materials from which the tubes are constructed must also be highly corrosion resistant in an environment of high temperature steam and highly alkaline reactants. And, they must be resistant to abrasion from the flow of particles of metal carbonates, metal oxides, and metal hydroxides. Therefore, the tube walls must be constructed from a highly corrosion resistant and abrasion resistant material, or from another material that is coated with a highly corrosion resistant and abrasion resistant material. The choice of corrosion and abrasion resistant materials for constructing the two concentric tubes and the end caps includes: nickel alloys, chrome alloys, alumina ceramics, and others. The choice of corrosion and abrasion resistant coating materials for coating the tubes, when the tubes are constructed with other materials, such as SiC, molybdenum, or molybdenum alloys, includes: nickel, chrome, nickel-chrome alloys, refractory metals, alumina, Mo—Si—B, and others.

The atmosphere in the first concentric tube, which hosts the deposition process, is almost pure carbon dioxide that can subsequently be collected and sequestered. However, one can add, or allow a small amount of water vapor to be present, in the range of 0.1% to 10% by volume. Water vapor will catalyze the decomposition, and increase the rate at which the metal carbonates decompose. Too high a concentration of water vapor will burden the compressors or blowers that are exhausting the carbon dioxide and creating a carbon dioxide partial pressure at or below 1 atm. In one embodiment, water vapor is added to the carbon dioxide atmosphere. In another embodiment, some drying of the incoming carbonate may be desirable.

In some embodiments, the carbon dioxide produced is collected, compressed, and sequestered, and the compression heat is used to heat and/or dry the incoming carbonate, and/or used to heat the water used for hydrating the metal oxide and, thereby, further lower the total energy required for recycling the metal carbonate.