Methods and apparatuses for dilute phase impregnation of a milled sorbent with a chemical compound in an aqueous solution

Abstract

The present disclosure relates to apparatus designed to impregnate a sorbent. In some embodiments apparatus of the disclosure may comprise a mixing vessel having either a conical mixing chamber or an cylindrical mixing chamber designed to increase the contact surface area and/or contact/residence time of a sorbent and impregnant to produce compositions comprising an impregnated sorbent. Apparatus of the disclosure may also comprise one or more atomizers operable to produce atomized droplets of impregnant. The disclosure also provides methods for impregnation of a milled sorbent or an un-milled sorbent. Methods of the disclosure provide several technical advantages and may be cost effective. Impregnant sorbent compositions produced by methods and/or apparatus of the disclosure may have higher concentrations of an impregnant, a more uniform distribution of an impregnant and may have a greater sorbent efficiency.

1 . A method for impregnation of a sorbent, comprising: receiving a milled sorbent in a sorbent delivery chamber; forming a dilute phase milled sorbent; receiving an impregnant in a container; and contacting the dilute phase milled sorbent with the impregnant under conditions to cause impregnation of the impregnant into the sorbent. 
     
     
         2 . The method of  claim 1 , wherein the impregnant is atomized to form atomized impregnant droplets prior to contacting. 
     
     
         3 . The method of  claim 1 , wherein the impregnant comprises a selected one of a halogen, a halogen salt, a halogen acid, a cation, silver, and sulfur. 
     
     
         4 . (canceled) 
     
     
         5 . (canceled) 
     
     
         6 . The method of  claim 3 , wherein the halogen is further comprised in an aqueous solution. 
     
     
         7 . The method of  claim 1 , wherein the milled sorbent comprises an activated carbon, a non-carbon sorbent or combinations thereof. 
     
     
         8 . The method of  claim 7 , wherein the non-carbon sorbent is selected from the group consisting of a zeolite, an aluminosilicate, a polymeric resin, a non-metallic resin, a clay, or an ion exchange resin. 
     
     
         9 . The method of  claim 7 , wherein the activated carbon is selected from the group consisting of a powdered activated carbon, a granular activated carbon, a lignite, a brown coal, an activated carbon having a diameter to 40 microns or less, an activated carbon having a diameter of 10 microns to 30 microns, and combinations thereof. 
     
     
         10 . The method of  claim 1 , wherein the range of particle size of the milled sorbent is similar to the range of particle size of impregnant. 
     
     
         11 . The method of  claim 1 , wherein contacting the dilute phase milled sorbent and the impregnant is performed in a mixing vessel having a conical chamber. 
     
     
         12 . The method of  claim 1 , wherein contacting the dilute phase milled sorbent and the impregnant is performed in a mixing vessel having a cylindrical chamber. 
     
     
         13 . A method for impregnation of a sorbent, comprising: receiving a sorbent having a respective sorbent particle size; atomizing an aqueous impregnant solution to form an aqueous atomized impregnant droplets having a respective aqueous atomized impregnant droplet size; contacting the sorbent with the aqueous atomized impregnant droplets; mixing the sorbent with the aqueous atomized impregnant droplets, thereby forming an impregnated sorbent. 
     
     
         14 . The method of  claim 13 , wherein a size range of the sorbent particle size is similar to a size range of the aqueous atomized impregnant droplet size. 
     
     
         15 . The method of  claim 13 , wherein contacting the sorbent and the aqueous atomized impregnant droplets comprises turbulence formation. 
     
     
         16 . The method of  claim 13 , wherein mixing the sorbent and the aqueous atomized impregnant droplets comprises turbulent mixing. 
     
     
         17 . The method of  claim 13 , wherein contacting and mixing the sorbent with the aqueous atomized impregnant droplets is performed in a mixing vessel having a conical chamber. 
     
     
         18 . The method of  claim 13 , wherein contacting and mixing the sorbent with the aqueous atomized impregnant is performed in a mixing vessel having a cylindrical chamber. 
     
     
         19 . The method of  claim 13 , wherein the sorbent is a milled sorbent. 
     
     
         20 . The method of  claim 13 , wherein the sorbent is a powdered sorbent. 
     
     
         21 . The method of  claim 13 , wherein the impregnant comprises a halogen selected from the group consisting of bromine, chlorine, iodine and fluorine. 
     
     
         22 . The method of  claim 21 , wherein the halogen comprises a selected one of a halogen salt and a halogen acid. 
     
     
         23 - 38 . (canceled)