Method and System for Precluding Air Pollution in Industrial Facilities

Abstract

A holistic system for sustained capture, confinement and depuration of acid mist generated in nonferrous metal electrodeposition processes utilizing lead anodes, for precluding zero release of gaseous fluid pollutants in the atmospheric air surrounding electrodeposition processes, providing an assured solution to acid mist control and total abatement in an effective, efficient manner and sustainable in time by immediate recovery and recycling back in the source generating the contaminant effluents as there are produced, according to a “cell by cell” strategy, and directly connecting each cell to a system for depuration, recovery and recycling the contaminants gaseous fluid flow extracted from each cell reducing them to innocuous levels in the discharge to the open atmosphere; complying the condition of “100% Null escape of acid mist” from each individual cell to the working environment, simultaneously with minimum power usage, and substantial global gaseous fluid contaminant reduction, far exceeding present minimum sustainability standards, in terms of human health, energy usage and environmental protection.

What is claimed is: 
     
         1 . A system for precluding air pollution in an electrodeposition tankhouse by capturing and processing byproduct gaseous fluids that emanate as a result of electrodeposition of nonferrous metals within electrolytic cells, said system comprising: an apparatus for confining a gaseous fluid as it is being originated by an electrowinning process within an electrolytic cell, wherein said gaseous fluid comprises at least an acid, fine airborne electrolyte liquid particles, contaminant gasses, and vapors of water and acid, wherein said electrolytic cell comprises a plurality of anodic and cathodic plates; an apparatus for removing said at least one acid, fine airborne electrolyte liquid particles, and vapors of water and acid from said gaseous fluid; and an apparatus for monitoring process variables in real time that allow controlling a plurality of concatenated operations, comprising a plurality of sensors for measuring gaseous fluid flow rates, differential pressures and other variables such as temperatures in said electrolytic cell and in said apparatus for removing said at least one acid, fine airborne electrolyte liquid particles, and vapors of water and acid, from said gaseous fluid, and a plurality of actuators for self-regulation of said variables. 
     
     
         2 . A system according to  claim 1 , wherein said apparatus for capturing said gaseous fluid further comprises a plurality of removable covers each of which covers one of said anodic plates, complemented with fixed covers over both ends of the electrolytic cell. 
     
     
         3 . A system according to  claim 2 , wherein each of said plurality of removable covers further having a monolithic body. 
     
     
         4 . A system according to  claim 3 , wherein each of said plurality of removable covers having said monolithic body further is made of an anticorrosive high impact resistant, electric insulating material. 
     
     
         5 . A system according to  claim 4 , wherein said anticorrosive high impact resistant electric insulating material is a reinforced vinyl-ester composite or equivalent high structural stress, impact resistant, anti-corrosive and electrical insulating polymer composite. 
     
     
         6 . A system according to  claim 2 , wherein each of said plurality of removable covers further comprises a pair of longitudinal sealing elements ( 6 ) each of which is attached to a side of said each of said plurality of covers and extending all the way to contact both side walls of the cell, wherein each of said sealing elements is made of an acid-resistant flexible laminar transparent material and configured to prevent said gaseous fluid from escaping into said tankhouse by tightly coming in contact with an adjacent cathodic plate, and, when said adjacent cathodic plate is removed from said electrolytic cell, by expanding horizontally to come instantly in tight contact with an adjacent longitudinal sealing element of an adjacent removable anodic cover covering an adjacent anodic plate. 
     
     
         7 . A system according to  claim 6 , wherein each of said plurality of covers further comprises, at each of a top end of said anodic plate, a first, a second and a third seal, wherein said first and said second seals, respectively, extend said pair of sealing elements to make a tight contact with an adjacent wall of said electrolytic cell, and wherein said third seal is configured to provide a seal around both extremities of a hanger bar of said anodic plate. 
     
     
         8 . A system according to  claim 1 , wherein said apparatus for removing acid fine airborne electrolyte liquid particles, and vapors of water and acid from said gaseous fluid further comprises a first depurator for receiving said gaseous fluid extracted from said electrolytic cell. 
     
     
         9 . A system according to  claim 8 , wherein said first depurator is further externally attached to an external wall of said electrolytic cell. 
     
     
         10 . A system according to  claim 8 , wherein said depurator further comprises a water or liquid column of controllable height for bubbling said gaseous fluid and obtaining an acid condensate. 
     
     
         11 . A system according to  claim 10 , whereir said depurator further comprises a discharge pipe located at the set height of the liquid column for flowing said acid condensate from said depurator back into said electrowinning electrolyte or electrolytic cell. 
     
     
         12 . A system according to  claim 11 , whereir said first depurator further comprises an automatic device for refilling of a said liquid column to its set height 
     
     
         13 . A system according to  claim 1  comprising:
 a plurality of electrolytic cells; a plurality of first depurators, wherein each one of said plurality of first depurators is connected to one of said plurality of said electrolytic cells with a pipe for receiving said gaseous fluid and obtaining a first acid condensate and a first depurated gaseous fluid; and a second depurator connected through a manifold with each of said plurality of said first depurators, and configured to obtain a second acid condensate and a second depurated gaseous fluid. 
 
     
     
         14 . A system according to  claim 13 , whereir said second depurator further having at least one chamber. 
     
     
         15 . A system according to  claim 14 , wherein said second depurator further having four vertically stacked connected chambers, wherein a bottom chamber is configured to receive said first treated gaseous fluid through said manifold connected to a bottom of said first chamber. 
     
     
         16 . A system according to  claim 15 , wherein said four vertically stacked connected chambers having each at least one baffle plate, wherein said baffle plate further having a flat surface and inclined so as to increase linear travel distance and friction contact during the passage of said gaseous fluid. 
     
     
         17 . A system according to  claim 16 , whereir at least one of said four chambers further comprises a turbulent bubbler device. 
     
     
         18 . A system according to  claim 16 , whereir at least one of said plurality of chambers further comprises a set of cooling tubes optimally mounted to intercept an ascending gaseous fluid flow. 
     
     
         19 . A system according to  claim 18 , further comprising an adequately sized chiller configured to condense acid vapors still remaining in said second depurated gaseous fluid so as to achieve any desired innocuous level in said acid vapors. 
     
     
         20 . A system according to  claim 16 , whereir at least one of said four chambers is filled with a hygroscopic, absorbent or desiccating substances to capture remaining acid humidity or to remove any other corrosive contaminants that may be present in the gaseous fluid to safeguard the integrity of said electrolytic cell components or equipment such as cathodic plates, etc. 
     
     
         21 . A system according to  claim 1  further comprising a plurality of said electrolytic cell, wherein said apparatus for controlling said plurality of operations further comprising: a plurality of a first programmable automation controller configured to control a single one of said plurality of said electrolytic cells, wherein each of said plurality of said first programmable automation controller is configured to monitoring process variables in real time in each individual electrolytic cell of said plurality of electrolytic cells; and a second programmable automation controller configured for sustained concatenation and complex self-regulation of said plurality of said first programmable automation controller. 
     
     
         22 . A system according to  claim 21 , whereir each of said first programmable automation controller is configured to minimize a use of suction power of an extraction turbine, while assuring reliable, sustained operation. 
     
     
         23 . A system according to  claim 21 , whereir said apparatus for controlling said plurality of operations further comprises a pressure differential sensor acting as an auditor of health process safety, provides continuous monitoring ot said pressure underneath said covered electrolytic cell and an alarm system, wherein  2  millibars depression relative to working atmosphere in tankhouse is set to activate said alarm system any time depression in said electrolytic cell reaches  1  millibars; triggering an overriding signal to the cell or cells causing the alarm to immediately increase its or their extraction flows rates setting to set off the alarms. 
     
     
         24 . A system according to  claim 21 , wherein said apparatus for controlling said plurality of operations is further configured to assure continuous operations of a remaining electrolytic cells when one or more electrolytic cells are disconnected or re connected from said plurality of said electrolytic cells. 
     
     
         25 . A system according to  claim 24 , whereir said apparatus for controlling said plurality of operations is further configured to instantaneously re-establish operations maintaining their settings within a said plurality of electrolytic cells when said one or more electrolytic cells are reintroduced. 
     
     
         26 . A system according to  claim 24 , whereir said apparatus for controlling said plurality of operations is further configured to instantaneously re-establish operations at their original settings within a said plurality ot electrolytic cells when an unpredictable power plant outages occur to their last settings pricr to the outage. 
     
     
         27 . A system according to  claim 1 , wherein said apparatus for controlling said plurality of operations further comprises an electrolyte temperature sensing device comprising an infeed temperature sensor mounted at an electrolyte infeed point and an overflow temperature sensor located at an electrolyte overflow point, wherein a measured difference in temperature between said infeed temperature sensor and said overflow temperature is representative of an electrolyte temperature loss in circulating through said electrolytic cell in real time and triggers an alarm to reestablish the correct maximum/minimum temperature setting. 
     
     
         28 . A system according to  claim 1 , wherein said apparatus for controlling said plurality of operations further comprises one or more sensors for measuring electric currents in said electrolytic cells, wherein said apparatus for controlling said plurality of operations is configured to receive an electronic signal from said one or more sensors for measuring electric currents and monitor the instantaneous current density flowing through each cathode in said electrolytic cell. 
     
     
         29 . A system according to  claim 28 , whereir said apparatus for controlling said plurality of operations is further configured to monitor each cathode and issue an alarm if said current density gets outside the window of maximum/minimum acceptable set range of operational values. 
     
     
         30 . A method of precluding air pollution in electrodeposition facilities by acid mist that is generated during the process of electrodeposition of non-ferrous metals, the method comprising the steps of:
 confining a gaseous fluid being as it is beinc generated by an electrodeposition process within an electrolytic cell, wherein said gaseous fluid comprises an acid mist, wherein said electrolytic cell comprises a plurality of anodic and cathodic plates, and wherein said confining further comprises capturing said gaseous fluid within a plurality of hollow coalescer mini chambers ( 30 a); over regular mini chamber ( 30 b); removing said acid mist and acid vapor from said gaseous fluid; and controlling a plurality of operations by sensing a plurality of variables of a plurality of operation parameters,   wherein said plurality of operations include monitoring temperature, pressure and acidity levels within said electrolytic cell, comparing said plurality of values to a plurality of preset values, and emitting a plurality of electronic signals to act on a plurality of actuators for modifying said plurality of values to change toward said plurality of preset values.   
     
     
         31 . A method according to  claim 30 , wherein said step of removing said acid vapor from said gaseous fluid further comprising:
 applying suction so that a continuous and stable negative pressure results within said plurality of hollow coalescer mini chambers ( 30 a) over regular mini chamber ( 30 b);for extracting said gaseous fluid to a first depurator and precluding said gaseous fluid from escaping from said electrolytic cell into an ambient air surrounding said electrolytic cell; and bubbling said gaseous fluid through a water or liquid column of given height within said depurator diluting said acid vapor in said liquid column for obtaining a first acid condensate, and for substantially reducing a presence of said acid vapor in a first resulting gaseous fluid.   
     
     
         32 . A method according to  claim 31  further comprising bubbling said gaseous fluid with water or a liquid column containing a basic solution of a given height for capturing said acid vapor or other contaminants entrained in the depurated gaseous flow. 
     
     
         33 . A method according to  claim 31 , wherein said step of removing said acid vapor from said gaseous fluid further comprising: sensing contents of said acid vapor in said first gaseous fluid for determining a concentration in said first resulting gaseous fluid; releasing said resulting gaseous fluid into an ambient air if said concentration is below a predetermined release level. 
     
     
         34 . A method according to  claim 31 , wherein said step of removing said acid vapor from said gaseous fluid further comprises feeding back said first acid condensate into said electrolytic cell. 
     
     
         35 . A method according to  claim 31 , wherein said step of removing said acid vapor from said gaseous fluid further comprising: carrying said first resulting gaseous fluid from at least one of said first depurator to a second depurator, wherein said second depurator having a plurality of chambers, wherein at least one of said chambers is for condensation of vapors in the gaseous fluid flow, and wherein said first resulting gaseous fluid is ascendingly carried through said at least one condensation chamber; and intercepting said first resulting gaseous fluid within said at least one condensation chamber by a plurality of optimally mounted cooling tubes for cooling said first resulting gaseous fluid and producing a second acid condensate and a second resulting gaseous fluid. 
     
     
         36 . A method according to  claim 35 , wherein said step of removing said acid from said gaseous fluid further comprises feeding back said second acid condensate into at least one of said electrolytic cell or electrolyte discharge, and releasing said second resulting gaseous fluid into an ambient air. 
     
     
         37 . A method according to  claim 30 , wherein said step of controlling said plurality of operations further comprising controlling a flow rate of said gaseous fluid, a flow rate of said first resulting gaseous fluid and a flow rate for said second gaseous fluid. 
     
     
         38 . A method according to  claim 30 , wherein said step of controlling said plurality of operations further comprising for continuously monitoring said pressure inside the gaseous fluid confinement volume in said electrolytic cell by sensing a pressure differential and issuing an alarm, wherein  2  millibars depression relative to working atmosphere in tankhouse is maintained and said alarm is activated any time depression in said electrolytic cell reaches  1  millibars. 
     
     
         39 . A method according to  claim 30 , wherein said step of controlling said plurality of operations in a system having a plurality of said electrolytic cells, further comprising maintaining individually said operations settings in a remaining set of electrolytic cells when one or more electrolytic cells are dismissed from said plurality of said electrolytic cells. 
     
     
         40 . A method according to  claim 39 , wherein said step of controlling said plurality of operations in a system having a plurality of said electrolytic cells, further comprising instantaneously re-establishing said operations at their individually settings within a said plurality of electrolytic cells when said one or more electrolytic cells are reintroduced. 
     
     
         41 . A method according to  claim 30 , wherein said step of controlling said plurality of operations in a system having a plurality of said electrolytic cells, further comprising in unpredictable power outages events, instantaneously re-establishing operations at their last individual settings prior to the outage within said plurality of electrolytic cells when the power is reestablished. 
     
     
         42 . An apparatus for precluding air pollution in an electrodeposition tankhouse by capturing and processing byproduct gaseous fluids that emanate as a result of electrodeposition of nonferrous metals within electrolytic cells, said system comprising:
 a plurality of flexible laminae wherein a plurality of pair of said plurality of said flexible laminae, each of which form a double longitudinal seal ( 6 ); and   a plurality of hollow coalescer mini chambers ( 30 a), each of which formed by one pair of said plurality of pairs of said flexible laminae, wherein each of said plurality of hollow coalescer mini chambers having a roof and a bottom and wherein said roof is cooler than said bottom, and wherein vertical movement of both continuous double longitudinal seals ( 6 ) upon extraction/re insertion of cathode plates ( 4 ) detaches coalesced electrolyte drops from the surfaces of the double longitudinal seals ( 6 ).