Method of reducing sulfur dioxide content in flue gases

Claim 2

In a method of reducing the amount of sulfur dioxide in combustion gases generated by the combustion of a sulfur-containing fuel in a combustion chamber, including the steps of combusting the sulfur-containing fuel in the combustion chamber to generate combustion gases including sulfur dioxide; introducing a sorbent composition into the combustion chamber at a combustion zone above a fuel and flame area of the combustion chamber, said combustion zone having a sufficient temperature to calcine the sorbent composition; and calcining the sorbent composition in the combustion zone to allow interactions between the calcined sorbent composition and sulfur dioxide in the combustion gases to form a solid inorganic sulfate and decrease the amount of sulfur dioxide in the combustion gases; the improvement comprising introducing into the combustion chamber a sorbent composition comprising: (a) 100 parts by weight of a sorbent, and (b) about 0.25 parts to about 60 parts by weight of an enhancer, said enhancer comprising: (i) about 15% to about 75% by weight of a hydrated inorganic salt; (ii) about 25% to about 85% by weight of a clay; and (iii) 0% to about 10% by weight of a combustible liquid.

Claim 3

The method of claim 1 wherein the combustion zone above the fuel and flame area of the combustion chamber has a temperature of about 1500° F. to about 2400° F., and wherein the sorbent is a calcium-based sorbent.

Claim 4

The method of claim 2 wherein the calcium-based sorbent is selected from the group consisting of limestone, hydrated lime, dolomite, and combinations thereof.

Claim 5

The method of claim 1 wherein the combustion zone above the fuel and flame area of the combustion chamber has a temperature of about 300° F. to about 500° F., and wherein the sorbent is a sodium-based sorbent, a potassium-based sorbent, or a combination thereof.

Claim 6

The method of claim 4 wherein the sodium-based sorbent and potassium-based sorbent are selected from the group consisting of sodium carbonate, sodium bicarbonate, potassium carbonate, potassium bicarbonate, and combinations thereof.

Claim 7

The method of claim 1 wherein the sorbent composition includes about 0.5 parts to about 25 parts by weight of the enhancer to 100 parts by weight of the sorbent.

Claim 8

The method of claim 1 wherein the sorbent composition includes about 1 part to about 5 parts by weight of the enhancer per 100 parts by weight of the sorbent.

Claim 9

The method of claim 1 wherein the enhancer includes about 15% to about 50% by weight of the hydrated inorganic salt.

Claim 10

The method of claim 1 wherein the enhancer includes about 20% to about 35% by weight of the hydrated inorganic salt.

Claim 11

The method of claim 1 wherein the hydrated inorganic salt has the formula M x Y z .aH 2 O, wherein M is an alkali metal ion, or an alkaline earth metal ion, or a combination thereof; Y is a noncorrosive anion; x and z are, independently, numerals in the range of 1 to 3; and a is a numeral in the range of 1 to about 24.

Claim 12

The method of claim 1 wherein the hydrated inorganic salt is selected from the group consisting of trisodium phosphate dodecahydrate, sodium metasilicate pentahydrate, sodium sesquicarbonate (dihydrate), sodium sesquisilicate hydrate, sodium orthosilicate pentahydrate, sodium tripolyphosphate hexahydrate, sodium tetraborate decahydrate, sodium tetraborate pentahydrate, sodium carbonate decahydrate, sodium carbonate heptahydrate, sodium carbonate monohydrate, sodium magnesium sulfate (tetrahydrate), sodium trimetaphosphate hexahydrate, sodium pyrophosphate (decahydrate), sodium sulfate decahydrate, sodium sulfate heptahydrate, potassium pentaborate (tetrahydrate), potassium tetraborate (octahydrate), potassium magnesium sulfate (tetrahydrate), potassium magnesium sulfate (hexahydrate), potassium pyrophosphate (trihydrate), lithium metaborate (octahydrate), lithium pentaborate (octahydrate), calcium carbonate hexahydrate, calcium nitrate tetrahydrate, calcium pyrophosphate pentahydrate, magnesium carbonate pentahydrate, magnesium carbonate trihydrate, magnesium nitrate hexahydrate, magnesium orthophosphate (including twenty-two water molecules of hydration), magnesium sulfate heptahydrate, magnesium sulfate monohydrate, and combinations thereof.

Claim 13

The method of claim 1 wherein the enhancer includes about 30% to about 80% by weight of the clay.

Claim 14

The method of claim 1 wherein the clay is selected from the group consisting of bentonite, kaolinite, attapulgite, montmorillonite, beidellite, nontronite, hectorite, saponite, sepiolite, halloysite, vermiculite, illite, nacrite, leucite, sauconite, and combinations thereof.

Claim 15

The method of claim 1 wherein the enhancer includes about 1% to about 8% by weight of the combustible liquid.

Claim 16

The method of claim 1 wherein the enhancer includes about 2% to about 6% by weight of the combustible liquid.

Claim 17

The method of claim 1 wherein the combustible liquid has a flash point of at least about 100° F.

Claim 18

The method of claim 1 wherein the combustible liquid is selected from the group consisting of kerosene, No. 2 fuel oil, high flash naphtha, heavy aromatic solvent, naphthol spirits, mineral seal oil, mineral spirits, Stoddard solvent, odorless mineral spirits, VM&P naphtha, 2-ethyl hexanol, iso-decyl alcohol, n-decyl alcohol, cyclohexanol, iso-hexyl alcohol, n-hexanol, methyl amyl alcohol, tridecyl alcohol, ethylene glycol, propylene glycol, hexylene glycol, methyl amyl acetate, octyl acetate, diacetone alcohol, isophorone, glycol ethers, pine oil, and combinations thereof.

Claim 19

The method of claim 1 wherein the enhancer includes about 15% to about 50% by weight trisodium phosphate dodecahydrate as the hydrated inorganic salt; about 30% to about 80% by weight bentonite as the clay; and about 1% to about 8% by weight kerosene as the combustible liquid; and wherein the sorbent is limestone, hydrated lime, or a combination thereof.

Claim 20

The method of claim 18 wherein the enhancer is present in an amount of about 1 part to about 5 parts by weight per 100 parts by weight of the sorbent.

Claim 21

The method of claim 1 wherein the sorbent composition is introduced into the combustion chamber in a ratio of sorbent composition to air of at least 20 to 1.