Zeolite Composite Materials from Fly Ash: An Assessment of Physicochemical and Adsorption Properties

Waste fly ash, with both low (with the addition of vermiculite) and high contents of unburned coal, were subjected to hydrothermal syntheses aiming to obtain zeolite composite materials-zeolite + vermiculite (NaX-Ver) and zeolite + unburned carbon (NaX-C). The composites were compared with parent zeolite obtained from waste fly ash with a low content of unburned carbon (NaX-FA). In this study, the physicochemical characteristics of the obtained materials were evaluated. The potential application of the investigated zeolites for the adsorption of ammonium ions from aqueous solutions was determined. Composite NaX-Ver and parent zeolite NaX-FA were characterized by comparable adsorption capacities toward ammonium ions of 38.46 and 40.00 mg (NH₄⁺) g^-1, respectively. The nearly 2-fold lower adsorption capacity of composite NaX-C (21.05 mg (NH₄⁺) g^-1) was probably a result of the lower availability of ion exchange sites within the material. Adsorbents were also regenerated using 1 M NaCl solution at a pH of 10 and subjected to 3 cycles of adsorption-desorption experiments, which proved only a small reduction in adsorption properties. This study follows the current trend of waste utilization (fly ash) and the removal of pollutants from aqueous solutions with respect to their reuse, which remains in line with the goals of the circular economy.

Modeling of a Two-Bed Reactor for Low-Temperature Removal of Nitrogen Oxides in Nitric Acid Production

In this study, the modeling of the low-temperature catalytic abatement of NOX and N2O from tail gases in a weak nitric acid plant utilizing a single-pressure 0.716 MPa system was performed. A one-reactor concept assumes that in the first bed, NOX is reduced by ammonia on a commercial vanadia–alumina catalyst, and in the second bed, N2O is decomposed on a proprietary nickel–cobalt catalyst. The kinetics of N2O decomposition on a Cs/Ni0.1Co2.9O4 catalyst was experimentally studied in an isothermal flow reactor. The reaction rate constants were determined by varying the residence time and temperature; these data formed the basis for modeling kinetics and heat and mass transport in an adiabatic reactor in which the low-temperature mitigation of nitrogen oxides occurred. Taking into account the given spatial limitations inside the reactor and the allowable temperatures, the layer heights were evaluated to ensure a residual NOX and N2O content of less than 50 ppm. Catalyst loading using layers in a commercial reactor was estimated for the tail-gas flow rates of 46,040–58,670 m3/h. Simulations showed that the optimum inlet temperature was 260 °C; in this case, the NOX and N2O conversion targets were achieved in the range of 46,040–58,670 m3/h while adhering to catalyst bed height and outlet temperature limitations.

Two-Stage Catalytic Abatement of N2O Emission in Nitric Acid Plants

Different variants for abatement of N2O emission from nitric acid plants with the use of catalysts developed at Łukasiewicz-INS were analyzed. Activity tests on a pilot scale confirmed the high activity of the studied catalysts. A two-stage catalytic abatement of N2O emission in nitric acid plants was proposed: by high-temperature decomposition in the nitrous gases stream (HT-deN2O) and low-temperature decomposition in the tail gas stream (LT-deN2O). The selection of the optimal variant for abatement of N2O emission depends on the individual characteristics of the nitric acid plant: ammonia oxidation parameters, construction of ammonia oxidation reactor and temperature of the tail gas upstream of the expansion turbine. It was shown that the combination of both deN2O technologies, taking into account their technological constraints (dimensions of the catalyst bed), allows for a greater abatement of N2O emission, than the use of only one technology. This solution may be economically advantageous regarding the high prices of CO2 emission allowances.