Deoiling of oil-coated catalyst using high-speed suspending self-rotation in cyclone

Mechanism of highly efficient oil removal from spent hydrodesulfurization catalysts by ultrasound-assisted surfactant cleaning methods

The removal of crude oil from spent hydrodesulfurization catalysts constitutes the preliminary stage in the recovery process of valuable metals. However, the traditional roasting method for the removal exhibits massive limitations. In view of this, the present study used an ultrasound-assisted surfactant cleaning method to remove crude oil from spent hydrodesulfurization catalysts, which demonstrated effectiveness. Furthermore, the study investigated the mechanism governing the process with calculation and experiments, so as to provide a comprehensive understanding of the cleaning method's efficacy. The surfactant selection was predicated on the performance in the IFT test, with SDBS and TX-100 finally being chosen. Subsequent calculations and analysis were then conducted to elucidate their frontier molecular orbitals, electrostatic potential, and polarity. It has been found that both SDBS and TX-100 possess the smallest LUMO-HOMO energy gap (ΔE), registering at 4.91 eV and 4.80 eV, respectively, and presenting the highest interfacial reactivity. The hydrophilic structure in the surfactant regulates the wettability of the oil-water interface, and the long-chain alkanes have excellent non-polar properties that promote the dissolution of crude oil. The ultrasonic-assisted process further improves the interface properties and enhances the oil removal effect. Surprisingly, the crude oil residue was reduced to 0.25% under optimal conditions. The final phase entailed the techno-economic evaluation of the entire process, revealing that, in comparison to the roasting method, this process saves $0.38 per kilogram of spent HDS catalyst, with the advantages of operational simplicity and emission-free. Generally, this study shed new light on the realization of efficient oil removal, with the salience of green, sustainable, and economical.

A facile method of treating spent catalysts via using solvent for recovering undamaged catalyst support

The process of washing and removing crude oil from spent catalysts is a serious issue in both catalyst regeneration and precious metals recovery. In this work, five different solvents with various polar and aromatic properties were chosen to evaluate their impact on the catalyst support structure and crude oil recovery from oil-contaminated spent catalysts. After the deoiling process, the spent catalyst was analyzed by scanning electron microscopy, X-ray diffraction (XRD), Fourier transform-infrared spectroscopy, elemental analyzer, contact angle measurement, gas chromatography-mass spectrometry, inductively coupled plasma-atomic emission spectroscopy, and Brunauer Emmet Teller (BET) method. Our findings demonstrate that p-xylene and kerosene are more effective in removing oil than other solvents. This is due to crude oil's similar polarity and molecular nature with kerosene and p-xylene. Considering the economical reason, kerosene is a better choice for deoiling spent catalyst compared to p-xylene as it is more affordable than p-xylene. XRD data show that the structure of the catalyst support was unaltered by the solvent treatment process, while BET data reveals that the surface area and pore volume are significantly enhanced after the deoiling process. These results imply that deoiling is a very crucial step for the recycling, regeneration, and reuse of spent catalysts. Our work is significant in developing sustainable approaches for managing spent catalysts, and minimizing waste and environmental pollution.

Self-circulation of oily spent hydrodesulphurization (HDS) catalyst by catalytic pyrolysis for high quality oil recovery

In this study, roasted spent HDS ash (sHDSc-A) was used for the first time to catalytically pyrolyze oily spent HDS catalysts (sHDSc) to improve the yield and quality of pyrolysis oil. The results showed that sHDSc-A promoted the decomposition of coke in oily sHDSc, resulting in the recovery of more oil and gas. Meanwhile, sHDSc-A significantly improved the quality of the pyrolysis oil. They inhibited the aromatization of alkanes to increase the saturation of the pyrolysis oil from 59.39% to 74.25% and the H/C radio from 1.62 to 1.72; promoted the decomposition of long-chain alkanes to increase the content of C11-C22 from 41.97% to 61.99%; enhanced the conversion of carboxylic acids to ketones led to the reduction of heteroatomic compounds such as N (56.10%-45.39%), S (66.95%-56.59%), and O (45.26%-26.70%) in the pyrolysis oil. The promotion of sHDSc-A in the pyrolysis process is attributed to the catalytic effect of the metal oxides in sHDSc-A. Among them, Al₂O₃ and Fe₂O₃ can promote decarboxylation of carboxylic acids and reduce O mobility, while MoO₃ and Fe₂O₃ play a significant role in reducing coke and increasing pyrolysis oil. NiO can also promote methane vapor reforming, and thus increase the production of H₂ in non-condensable gas. This study achieves self-circulation of oily sHDSc with a "waste-treatment-waste" strategy that presents the advantage of value-added energy recovery and waste reuse.

Sludge low-temperature drying with mainly non-phase change in mere seconds based on particle high-speed self-rotation in cyclone

Improper sludge treatment will cause serious environmental problems, and sludge drying is the key to effective treatment. Almost all the existing sludge drying technologies use heating to overcome the great latent heat of moisture vaporization, which leads to high drying energy consumption. In this study, based on the particle high-speed self-rotation in the cyclone and micro-interface oscillations, the cyclone self-rotation drying (CSRD) technology was developed. It can realize drying of the dewatered landfill sludge (DLS) and the urban sewage dewatered sludge (UDSS) with mainly non-phase change. The obtained results reveal that at low carrier gas temperatures (< 100 °C) and very short residence time (< 15 s), the moisture content of the DLS decreased from 53% to 6.85%, and that of the UDSS decreased from 67% to 18.92%. Through calculation, the proportions of moisture non-phase change removal during the CSRD process touched 68.94% and 63.39%, respectively. Based on the experimental studies, we proposed an enlarged industrial application program (50 t/d) for the UDSS drying by employing the CSRD technology. The operating cost was 159.69 CNY/t H₂O, showing prominent advantages. This study can provide guidelines for the practical application of CSRD technology and fill the scientific gap in the field of moisture non-phase change separation for sludge drying.

Effects of Reservoir Parameters on Separation Behaviors of the Spiral Separator for Purifying Natural Gas Hydrate

The spiral separator is an important tool for desanding in natural gas hydrate production, and the change of hydrate reservoir parameters has a great impact on spiral separator behavior. Mastering the influence law is helpful to improve the separation performance. Until now, there was still no detailed analysis of the effect mechanism between reservoir parameters and spiral separator behavior. In this paper, a downhole spiral separator was designed. Then, the effects of reservoir parameters (particle size, hydrate, volume fraction, and sand volume fraction) on separation performance (discrete phase distribution, separation efficiency, and differential pressure) with different flow rates were investigated by numerical simulation method Fluent 18.0. The results show that effects degree of reservoir parameters is in order from large to small: sand phase volume fraction, particle size, hydrate volume fraction. As the particle size increases, the separation performance is improved. When the sand volume fraction increases, the natural gas hydrate (NGH) recovery efficiency and differential pressure both increase, but the sand removal efficiency decreases. When the hydrate fraction increases, the separation performance change law is opposite to that when the sand volume fraction increases. In addition, with increasing the flow rate, the efficiency and differential pressure increase. Therefore, reservoir saturation and porosity can balance NGH recovery efficiency and sand removal efficiency. Furthermore, the spiral separator has good performance under the change of reservoir parameters. The performance of the NGH spiral separator can be also maintained by increasing the flow rate.

Soot elimination and heat recovery of industrial flue gas by heterogeneous condensation

Industrial flue gas systems include fine soot and high-temperature vapor. The continuous emission of the flue gas not only causes fine particulate pollution but also wastes considerable heat energy. Separating soot and purifying flue gas are of great significance for industrial conditions and environmental protection. In this paper, the process of cyclone soot elimination and waste heat recovery by heterogeneous condensation were coupled for the first time. The effects of the flue gas material system and separation operation parameters on the cyclone soot elimination efficiency and heat transfer efficiency were systematically investigated through unit experiments and industrial side-lines. Additionally, the mechanism of enhanced cyclone soot elimination by heterogeneous condensation was also theoretically explored. The experimental results show that the corresponding maximum cyclone heat transfer efficiency and soot elimination efficiency of the Ф40 mm cyclone separator are 42.1% and 89.2%, respectively, while the Ф80 mm cyclone separator can attain an elimination efficiency of 91% and a maximum increase of 67.3% for the heat transfer efficiency, as indicated by the industrial side-line. During the process of cyclone soot elimination and heat recovery by heterogeneous condensation, the heterogeneous condensation caused by heat transfer increases the quality difference between the flue gas molecules and soot droplets, thus improving the cyclone separation efficiency of soot.