Flue Gas Purification Process Using A Sorbent Polymer Composite Material

Abstract

This invention provides a process of removing sulfur oxides, mercury vapor, and fine particulate matters from industrial flue gases that contain such pollutants. The pollutants are removed by modules, which contain microporous adsorbent (i.e., sorbent) material that is held within a polymer matrix. The preferred polymers are fluoropolymers. The composite material that contains the microporous absorbent material held within a polymer matrix removes sulfur oxides by converting them into high concentration sulfuric acids. It also removes mercury vapor by chemically adsorbing the mercury into the matrix. It also removes fine particulate matters by surface filtration. The sulfuric acid that is produced inside the composite material is automatically expelled onto the external surfaces of the composite material and is drained into an acid reservoir together with the fine particulate matters which are washed from the external surfaces of the composite material by the constant dripping of the sulfuric acid along the external surfaces of the composite material.

1 . A sorbent-polymer-composite material comprising: 
 (a) a sorbent material in the form of porous particles; and    (b) a polymer material comprising at least one fluoropolymer or a copolymer or terpolymer containing at least one fluoromonomer;    wherein the sorbent material is held within a matrix of the polymer material such that the particles of sorbent material are in contact with the polymer material such that the particles of sorbent material are in contact with the polymer material and said sorbent material is either untreated or treated with at least one chemical substance that is retained in or on the sorbent material.    
     
     
         2 . A module comprising at least two sorbent-polymer-composite sheets held on a solid frame, wherein: 
 (a) the sorbent-polymer-composite sheets consist essentially of: (i) sorbent material consisting essentially of porous particles that are either untreated or treated with at least one chemical substance that is retained in or on the porous particles; and (ii) a polymer material comprising at least one fluoropolymer or a copolymer or a terpolymer containing at least one fluoromonomer; and the sorbent material is held within a matrix of the polymer material such that the particles of sorbent material are in contact with the polymer material;    (b) the solid frame consists of a material that is compatible with sulfuric and nitric acid solutions; and    (c) the sorbent-polymer-composite sheets are held on the solid frame in parallel to one another with a gap between each of the sheets;    further wherein said module is stackable or designed to fit into a larger framework which can hold at least two of said modules.    
     
     
         3 . A sorbent house comprising at least two of the modules of  claim 2 .  
     
     
         4 . The module of  claim 2 , wherein said module contains at least three of said sorbent-polymer-composite sheets.