Iron oxide process operation

In the second step, H2 and CO2 are produced by water-gas shift (WGS) reaction (12.20) and this process occurs in two stages consisting of high temperature shift (HTS) and low pressure shift (LTS) reactors. TTie HTS is loaded with high temperature catalyst, generally chromium-promoted iron oxide which operates at 350-400°C, whereas the LTS is loaded with low-temperature catalyst of copper-promoted zinc oxide, which operates at 200°C (Ledjeff-Hey et al, 2000). 

Oxidation of methanol to formaldehyde with vanadium pentoxide catalyst was first patented in 1921 (90), followed in 1933 by a patent for an iron oxide—molybdenum oxide catalyst (91), which is stiU the choice in the 1990s. Catalysts are improved by modification with small amounts of other metal oxides (92), support on inert carriers (93), and methods of preparation (94,95) and activation (96). In 1952, the first commercial plant using an iron—molybdenum oxide catalyst was put into operation (97). It is estimated that 70% of the new formaldehyde installed capacity is the metal oxide process (98). 

The Iron Bla.stFurna.ee, The reduction of iron oxides by carbon in the iron (qv) blast furnace is the most important of all extractive processes, and the cornerstone of all industrial economies. Better understanding of the reactions taking place within the furnace has made possible a more efficient operation through better preparation of the burden, higher blast temperature, and sometimes increased pressure. Furnace capacity has doubled since the 1800s, whereas coke consumption has been reduced by about half The ratio of coke to iron produced on a per weight basis is ca 0.5 to 1. 

Iron oxide yellows can also be produced by the direct hydrolysis of various ferric solutions with alkahes such as NaOH, Ca(OH)2, and NH. To make this process economical, ferric solutions are prepared by the oxidation of ferrous salts, eg, ferrous chloride and sulfate, that are available as waste from metallurgical operations. The produced precipitate is washed, separated by sedimentation, and dried at about 120°C. Pigments prepared by this method have lower coverage, and because of their high surface area have a high oil absorption. 

The old Bechamp batch process for reduction of nitroben2ene (iron-hydrochloric acid) is obsolete however, Mobay Chemical Corporation is operating a plant using this process for production of pigment grade iron oxide as weU as aniline. 

Foulants enter a cooling system with makeup water, airborne contamination, process leaks, and corrosion. Most potential foulants enter with makeup water as particulate matter, such as clay, sdt, and iron oxides. Insoluble aluminum and iron hydroxides enter a system from makeup water pretreatment operations. Some well waters contain high levels of soluble ferrous iron that is later oxidized to ferric iron by dissolved oxygen in the recirculating cooling water. Because it is insoluble, the ferric iron precipitates. The steel corrosion process is also a source of ferrous iron and, consequendy, contributes to fouling. 

Liquefaction. Liquefaction of coal to oil was first accompHshed in 1914. Hydrogen was placed with a paste of coal, heavy oil, and a small amount of iron oxide catalyst at 450° and 20 MPa (200 atm) in stirred autoclaves. This process was developed by the I. G. Earbenindustrie AG to give commercial quaUty gasoline as the principal product. Twelve hydrogenation plants were operated during World War II to make Hquid fuels (see CoAL... 

In catalytic incineration, there are limitations concerning the effluent streams to be treated. Waste gases with organic compound contents higher than 20% of LET (lower explosion limit) are not suitable, as the heat content released in the oxidation process increases the catalyst bed temperature above 650 °C. This is normally the maximum permissible temperature to which a catalyst bed can be continuously exposed. The problem is solved by dilution-, this method increases the furnace volume and hence the investment and operation costs. Concentrations between 2% and 20% of LET are optimal, The catalytic incinerator is not recommended without prefiltration for waste gases containing particulate matter or liquids which cannot be vaporized. The waste gas must not contain catalyst poisons, such as phosphorus, arsenic, antimony, lead, zinc, mercury, tin, sulfur, or iron oxide.(see Table 1.3.111... 

The iron sponge process uses the ehemical reaction of ferric oxide with Hi.S to sweeten gas streams. This process is applied to gases with low H S concentrations (300 ppm) operating at low to moderate pressures (. vO-SOO psig). Carbon dioxide is not removed by this process. 

Deep-bed condensate polishers are commonly used for nuclear reactor power plants. Due to the extreme operating conditions, the resin is sometimes taken out of service as frequently as every 3 weeks for ultrasonic cleaning. This process removes the iron oxides and other particulates filtered out by the resin media. 

Flydrochloric acid regeneration. This process is used to treat the spent pickle liquor containing free hydrochloric acid, ferrous chloride, and water that is obtained from steel finishing operations. The liquor is concentrated by heating to remove some of the water, followed by thermal decomposition in a roaster at temperatures (925 to 1050°C) sufficient for complete evaporation of water and decomposition of ferrous chloride into iron oxide (ferric oxide, Fe203) and hydrogen chloride (HC1) gas.19 The iron oxide is separated for offsite recovery or... 

Carpenter-Evans A catalytic process for removing organic sulfur compounds from synthesis gas by hydrogenation to hydrogen sulfide, which is absorbed by iron oxide. The hydrogenation catalyst is nickel sub-sulfide, Ni3S2. Invented by E. V Evans and C. C. Carpenter in England around 1913 and operated in three commercial plants. 

Fischer-Tropsch A process for converting synthesis gas (a mixture of carbon monoxide and hydrogen) to liquid fuels. Modified versions were known as the Synol and Synthol processes. The process is operated under pressure at 200 to 350°C, over a catalyst. Several different catalyst systems have been used at different periods, notably iron-zinc oxide, nickel-thoria on kieselgtihr, cobalt-thoria on kieselgiihr, and cemented iron oxide. The main products are C5-Cn aliphatic hydrocarbons the aromatics content can be varied by varying the process conditions. The basic reaction was discovered in 1923 by F. Fischer and... 

Holmes-Maxted A process for removing organic sulfur compounds from coal gas. The gas, mixed with hydrogen, is passed over a metal thiomolybdate catalyst at 300 to 380°C, which converts the sulfur compounds to hydrogen sulfide which is then absorbed by iron oxide. Developed by E. B. Maxted at W. C. Holmes Company, UK, based on an invention made in 1937. More than 50 units were in operation by 1985. 

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