Classifications

• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
  • C01F11/00—Compounds of calcium, strontium, or barium
  • C01F11/46—Sulfates
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01D—COMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
  • C01D1/00—Oxides or hydroxides of sodium, potassium or alkali metals in general
  • C01D1/02—Oxides
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01D—COMPOUNDS OF ALKALI METALS, i.e. LITHIUM, SODIUM, POTASSIUM, RUBIDIUM, CAESIUM, OR FRANCIUM
  • C01D7/00—Carbonates of sodium, potassium or alkali metals in general
  • C01D7/02—Preparation by double decomposition
• • C—CHEMISTRY; METALLURGY
  • C01—INORGANIC CHEMISTRY
  • C01F—COMPOUNDS OF THE METALS BERYLLIUM, MAGNESIUM, ALUMINIUM, CALCIUM, STRONTIUM, BARIUM, RADIUM, THORIUM, OR OF THE RARE-EARTH METALS
  • C01F11/00—Compounds of calcium, strontium, or barium
  • C01F11/18—Carbonates

Definitions

• the subject design relates generally to a process that produces an aqueous solution through a remarkably simple but highly effective chemical reaction.
• the aqueous solution is composed of a blended solution with water and an added solubilizer for the reaction.
• the results produce an ionic solid and an alkaline liquid solution which is a useful commercial product.
• the second step involves the use of a reaction chamber within which a solubilizer, such as glycerol is added to calcium hydroxide.
• a solubilizer such as glycerol
• This addition enhances its solubility to reduce flue gases from a fossil fuel power plant and generate calcium carbonate for use in the wet scrubber.
• Various patents and publications including Pub. No. 2010/0251937 Al, WO 2017/029509, and US 2010/0251937 all teach processes consisting of contacting carbon dioxide laden gas with lime in a reactor such that the lime captures carbon dioxide by the formation of calcium carbonate.
• the calcium oxide or lime is regenerated by calcination leading to the formation of fresh lime sorbent and the release of a concentrated stream of carbon dioxide.
• the “regenerated” lime is then recycled for the future capture of carbon dioxide.
• blended solutions that could be mixed to chemically produce important commercial blended solutions.
• sodium bicarbonate, sodium hydroxide, sodium carbonate, sodium phosphate, calcium hydroxide and calcium carbonate are not readily available and/or expensive to buy or produce.
• sodium carbonate is either found naturally or is manufactured from sodium chloride (common salt).
• sodium carbonate There are two main sources of sodium carbonate. They are from salt and calcium carbonate (Solvay process) or made from sodium carbonate and hydrogen carbonate ores (trona and nahcolite mined).
• Sodium carbonate has many uses, for example but not limited to, paper and manufacturing glass.
• the production of sodium carbonate also requires high heat energy and a high array of equipment to complete the process.
• Ammonia is one of the most expensive materials used in the process and any impurities in the ammonia can cause corrosion in various high temperature areas of the process.
• the process also requires mined limestone and coke. All of this adds major costs to the process.
• Sodium hydroxide is another solution that has been used in the capture of CO 2, as set forth in the article published in the WORLD RESOURCE REVIEW vol. 16 NO. 2 noted above. In the noted paper, their process starts with sodium hydroxide ((NaOH). Their attempt to recover sodium hydroxide has a rather involved process, by itself, which adds heavily to their overall costs.
• Sodium hydroxide can be defined as a strong base of an alkali metal. It has varied applications including being used in manufacturing of soap, detergents, paper and many other different chemicals. It is also used in petroleum refining, in laboratories, or in the purification of aluminum ore, bauxite and many more. This has led to manufacturing of sodium hydroxide on an industrial scale.
• chlor-alkali produces sodium hydroxide and chlorine as coproducts. As is well known, this is accomplished by passing an electric current through a salt solution (common sodium chloride). This process has not been used in the United States for many years because it cannot compete with the production of electrolytic sodium hydroxide. Production of electrolytic sodium hydroxide is the preferred version due to the lesser cost over other processes. There are many issues with the production and transportation of sodium hydroxide. The costs of manufacture and transportation are very high due to its corrosiveness and its high viscosity. As is well known with any chemical, its viscosity is inversely related to its temperature.
• a process is provided that chemically mixes water and a blended solution with a solubilizer to produce an ionic solid and an alkaline liquid solution.
• the subject concept is operational to overcome the high costs of competitive processes and to improve their overall functionality.
• Fig. 1 is a partial flow chart and a partial diagrammatic representation of an embodiment of the subject concept
• Fig. 1 A is a partial flow chart and a partial diagrammatic representation of a more detailed concept from the embodiment of Fig. 1;
• Fig. IB is a partial flow chart and a partial diagrammatic representation of another more detailed concept from the embodiment of Fig. 1;
• Fig. 1C is a partial flow chart and a partial diagrammatic representation of yet another more detailed concept from the embodiment of Fig. 1;
• Fig. ID is a partial flow chart and a partial diagrammatic representation of still another more detailed concept from the embodiment of Fig. 1.
• a solution mixing tank 12 receives one blended solution 14 for mixing with a solubilizer 16 and water 18 via line 19 from the pure water tank 20.
• a fluid pump 21 is disposed in the line 19 and controllably delivers water from the water tank 20 to the mixing tank 12.
• the chemical reaction in the mixing tank 12 creates an ionic solid 22 that is delivered by line 24 to an ionic solid tank 26 for commercial use and/or reuse in the process.
• the chemical reaction also creates an alkaline liquid solution 28 that is delivered by line 30 to an alkaline liquid storage tank 32.
• the alkaline liquid solution in the liquid storage tank 32 could be used further as needed or sold commercially.
• the water 18 in the water tank 20 provides greater efficiency if the pH factor of the water 18 is at least a pH factor of 7.
• several different blended solutions and solubilizers could be used in the embodiment of Fig. 1 without departing from the essence of the subject invention.
• FIG. 1A an embodiment is illustrated providing a source of water 18, calcium hydroxide 36 (blended solution), and sodium phosphate 38 (solubilizer).
• the result of the chemical reaction between the calcium hydroxide 36 and the sodium phosphate 38 are calcium phosphate 40 (an ionic solid) and sodium hydroxide 42 (an alkaline liquid solution).
• the calcium phosphate 40 is now available for commercial use.
• the sodium hydroxide 42 is available for additional processing or, if desirable, it could be sold for commercial uses.
• FIG. IB another embodiment is illustrated providing a source of water 18, a calcium carbonate 46 (blended solution), and a sodium phosphate 38 (solubilizer).
• the results of the chemical reaction between the calcium carbonate 46 and the sodium phosphate 38 creates calcium phosphate 40’ (an ionic solid) and sodium carbonate 48 (alkaline liquid solution).
• the calcium phosphate 40’ is now available for commercial use or redirected for use in additional processing.
• the sodium carbonate solution 48 is now available for use in the current or additional processes or available for commercial uses.
• FIG. IC yet another embodiment is illustrated providing a source of water 18, one of calcium hydroxide 36'. a kiln dust, and a furnace slag (blended solution), and one of sodium bicarbonate and sodium carbonate solution 48' (solubilizer).
• the results of the chemical reaction between the respective ones of the calcium hydroxide solution 36'. the kiln dust, and the furnace slag with the one of sodium bicarbonate and sodium carbonate solution 48' creates calcium carbonate 46' (an ionic solid) and a sodium hydroxide solution 42' (alkaline liquid solution).
• the calcium carbonate 46' is now available for use in the current or additional processes or sold for commercial use.
• the sodium hydroxide solution 42' is now available for additional processing (use in one of the current processes) or available for commercial uses.
• Kiln dust are predominately a solid by-product generated during cement and lime kiln production operations while furnace slag is predominantly waste by-products generated during iron and steel manufacturing.
• lime kiln dust (LKD) and cement kiln dust (CKD) various amounts of calcium oxide (CaO) and ' free lime ' are present.
• CaO calcium oxide
• CKD cement kiln dust
• MgO magnesium oxide
• These oxides also react with the sodium carbonate (Na2COs) to produce additional sodium oxide (NaiO), which when mixed in water becomes sodium hydroxide (NaOH).
• Fig. ID still another embodiment is illustrated providing a source of water 18, calcium carbonate 46’ (blended solution), and sodium sulfate 50 (solubilizer).
• the results of the chemical reaction between the calcium carbonate 46’ and the sodium sulfate 50 creates calcium sulfate 54 (an ionic solid) and a sodium carbonate solution 48’ (alkaline liquid solution).
• the calcium sulfate 54 and the sodium carbonate solution 48’ may each be used in one of the current processes or sold for other commercial uses.
• the subject process with the various examples provides simple, safe, cost-effective designs for producing the alkaline liquid solutions and ionic solid for use in the current or additional processes and/or sold for other commercial uses.
• the subject designs far exceed the other suppliers of these products in production cost effectiveness, more secure ways of storing the products, and in many applications, not needing to store the product but keep redirecting it for other application on site.
• kiln dust or furnace slag With use of kiln dust or furnace slag in the subject process, large volumes of kiln dust or furnace slag will not be stored in huge piles in landfills or used as an aggregate in road projects throughout the country.
• the Federal Highway Administration reported that approximately 14.2 million tons of cement kiln dust (CKD) are produced annually and approximately 2 to 4 million tons of lime kiln dust (LKD) are generated each year in the United States. Furthermore, the FHA also highlighted 15 million tons of furnace slag are also produced per year in the U.S. Most of this kiln dust and furnace slag are disposed of in landfills or stockpiles, with 100 million tons currently stockpiled throughout the country. Even though some of this kiln dust can be sold, and the furnace slag can be used in other manufacturing processes, the cement/lime and iron/steel manufacturing industries still incur high costs for handling the kiln dust and furnace slag. In some applications, the kiln dust and/or furnace slag could be used in another process as it is being generated.
• CKD cement kiln dust
• LLD lime kiln dust

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• Chemical & Material Sciences (AREA)
• Organic Chemistry (AREA)
• Inorganic Chemistry (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Geology (AREA)
• Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)

Applications Claiming Priority (2)

Publications (1)

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• 2023
  • 2023-07-24 EP EP23850845.1A patent/EP4565534A2/de active Pending
  • 2023-07-24 WO PCT/US2023/070860 patent/WO2024030773A2/en not_active Ceased

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