PFAS PROCESSING
20230052342 · 2023-02-16
Assignee
Inventors
Cpc classification
H05B2206/045
ELECTRICITY
B09B3/50
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
The processing of PFAS to convert them into safer substances comprises introducing gaseous or vapour phase PFAS into a treatment zone where microwave radiation of predetermined frequency and power level creates a plasma which at least partially dissociates the PFAS. There is also a system for remediating particulate solids, particularly soil, contaminated with PFAS, the method including directing microwave radiation to a body of particulate solids in the closed vessel so as to promote vaporization of PFAS which are then treated by exposure to the microwave produced plasma. Continuous and batch processing apparatus are disclosed. A preheating stage can dry the particulate solids to a pre-determined moisture content, and then a higher energy microwave heating promotes vaporization of PFAS. A partial vacuum created where particulate solids heated by the microwave radiation are yielding up PFAS promotes the vaporization of PFAS. Alternating cycles of high pressure during microwave irradiation and low pressure or partial vacuum can avoid plasma generation in the heating stage while optimizing vaporization of PFAS from the particulate solids.
Claims
1. A method of remediating particulate solids contaminated with PFAS, the method comprising: enclosing particulate solids contaminated with PFAS in a vessel; generating microwave radiation of pre-determined frequency or frequencies and power level or levels; directing the microwave radiation to the particulate solids in the vessel, thereby heating the particulate solids and promoting vaporisation of the PFAS from the particulate solids; creating a partial vacuum at a location where at least a portion of the heated particulate solids are located, thereby further promoting vaporization of the PFAS from the particulate solids; transferring vapour from the vessel to a treatment stage; and treating in the treatment stage the vapour transferred from the vessel, thereby at least partially converting the vaporized PFAS into at least one safer substance.
2. The method according to claim 1, wherein: the step of creating a partial vacuum is performed by creating the partial vacuum in the vessel while the particulate solids are located therein; and wherein the step of directing the microwave radiation comprises directing the microwave radiation into the particulate solids below a surface level of the particulate solids in the vessel, whereby a significant proportion of available energy of the microwave radiation is absorbed into the particulate solids before that energy reaches a gas space above the surface level of the particulate solids, thereby reducing a chance of plasma formation in the gas space above the particulate solids.
3. The method according to claim 1, wherein: the step of directing the microwave radiation is discontinued after a period of heating time; and wherein the step of creating the partial vacuum is performed substantially simultaneously with or after the discontinuation of the step of directing microwave radiation, thereby creating the partial vacuum in the vessel.
4. The method according to claim 1, wherein; the step of directing the microwave radiation is discontinued after a period of heating time; and wherein after the step of directing the microwave radiation is ended, the heated particulate solids are transferred from the vessel to an extraction stage, thereby enabling further contaminated particulate solids contaminated with PFAS to be located in the vessel and to be heated therein, and wherein the step of creating the partial vacuum is performed in the extraction stage.
5. The method according to claim 1, further comprising a plasma inhibition step that inhibits formation of plasma in a gas space above a level of the particulate solids during the step of directing the microwave radiation into the particulate solids.
6. The method according to claim 5 wherein the plasma inhibition step includes directing the microwave radiation to the body of particulate solids in stages comprising: (i) a higher power microwave heating stage during which higher power microwave energy is applied to the particulate solids while simultaneously a pressure within the vessel greater than atmospheric pressure (101 kPa) is maintained; and (ii) a lower power microwave heating stage during which a lower power microwave energy is applied to the particulate solids and simultaneously a partial vacuum is created in the vessel in which the lower power microwave energy is being applied and during which PFAS are being vaporized for removal from the particulate solids, the higher power microwave energy being higher in power than the lower power microwave energy.
7. The method according to claim 6, wherein the higher power microwave heating stage and the lower power microwave heating stage are alternated, thereby improving an effectiveness of PFAS extraction by higher power heating and higher vacuum extraction.
8. The method according to claim 5, wherein the plasma inhibition step includes increasing an amount of inert gas in a gas atmosphere mixed with and surrounding the particulate solids while they are undergoing the heating by the microwave radiation, thereby inhibiting creation of plasma in the gas space above the level of particulate solids in the vessel during the step of directing the microwave radiation into the particulate solids.
9. A method of remediating particulate solids contaminated with PFAS, the method comprising: locating particulate solids contaminated with PFAS in a vessel; generating microwave radiation of pre-determined frequency or frequencies and power level or levels; directing the microwave radiation to the particulate solids in the vessel, thereby heating the particulate solids and promoting vaporisation of the PFAS; transferring vapour from the vessel to a treatment stage; and treating in the treatment stage the transferred vapour, thereby at least partially converting the vapourized PFAS into at least one safer substance; the step of treating the transferred vapour in the treatment stage comprising exposing the transferred vapour to a plasma within a treatment zone, whereby PFAS molecules in the vapour are subject to at least partial dissociation while entering and passing through the treatment zone.
10. The method according to claim 9, wherein the plasma in the treatment zone is created and/or is maintained by directing to the treatment zone microwave radiation from a secondary microwave generator that is operatively associated with the treatment zone.
11. The method according to claim 9, wherein the particulate solids that are contaminated with PFAS and located in the vessel are mixed either intermittently or continuously while the microwave radiation is directed to the particulate solids in the vessel, thereby promoting heating of the particulate solids and vaporisation of the PFAS.
12. The method according to claim 9, wherein: the particulate solids that are contaminated with PFAS are progressively fed into the vessel, either by continuous feeding of the particulate solids or by intermittent feeding of charges of the particulate solids; and the heated particulate solids that have yielded up PFAS by vaporisation are progressively removed from the vessel; the particulate solids being progressively moved from a soil feed location of the vessel to a soil removal location of the vessel while being exposed to the microwave irradiation.
13. The method according to claim 12, wherein the vessel in which the microwave radiation is directed to the particulate solids includes a microwave-transparent wall or window composed of a microwave-transparent material through which the particulate solids are exposed to the microwave radiation.
14. The method according to claim 9, wherein: a batch of the particulate solids contaminated with PFAS is located in the closed vessel, and during the direction of the microwave radiation to the body of particulate solids, the batch is mixed either intermittently or continuously, thereby exposing the batch of particulate solids substantially throughout its volume to the microwave radiation for a vaporisation period during which no further particulate solids are added to the vessel; and wherein the vapour containing the PFAS that is yielded up by the batch is removed from the vessel and treated prior to discharge of the treated particulate solids from the vessel.
15. The method according to claim 9, wherein the particulate solids are subjected to a two-stage heating process comprising: a first lower energy preheating stage in which the particulate solids are heated to vaporize water in the particulate solids and thereby dry the particulate solids to a pre-determined reduced moisture content; and a second higher energy heating stage in which the microwave radiation is directed to the particulate solids in the vessel having the reduced moisture content, thereby promoting vaporization of the PFAS.
16. The method according to claim 9, wherein the vapour containing PFAS yielded by the particulate solids is drawn from the vessel during the directing of the microwave radiation to the particulate solids in the vessel, and wherein the vapour containing PFAS is continuously drawn from the vessel and transferred into the treatment stage during the directing of the microwave radiation to the particulate solids in the vessel by creating a negative pressure downstream of the treatment stage which thereby draws the vapours from the vessel into and through the treatment stage.
17-18. (canceled)
19. The method according to claim 1, wherein; the microwave radiation directed to the particulate solids is generated by a microwave generator; and wherein the microwave radiation is transferred by a waveguide to the vessel through a microwave transparent wall of, or window in, the vessel, the waveguide incorporating a tuner operative to match an impedance of the microwave generator and associated waveguide to an impedance of the particulate solids in the vessel, thereby improving a microwave energy transfer efficiency to the particulate solids.
20. (canceled)
21. An apparatus constructed and operative to perform the method of claim 1, thereby remediating particulate solids contaminated with PFAS, the apparatus comprising: a vessel suitable for enclosure therein of particulate solids contaminated with PFAS; a microwave radiation generator suitable for generating microwave radiation of pre-determined frequency or frequencies and power level or levels; a coupling mechanism enabling the microwave radiation to be directed to the particulate solids in the vessel, thereby heating the particulate solids and promoting vaporisation of the PFAS from the particulate solids; a vacuum apparatus suitable for creating a partial vacuum at a location where at least a portion of the heated particulate solids are located, thereby further promoting vaporization of the PFAS from the particulate solids; a treatment stage; a vapour interconnection suitable for transferring the vapourized PFAS from the vessel to the treatment stage; and a vapour treatment apparatus suitable for treating in the treatment stage the vapourized PFAS transferred from the vessel to the treatment stage, thereby at least partially converting the vaporized PFAS into at least one safer substance.
22. The method of claim 13, wherein the vessel comprises a tube into which particulate solids to be treated are fed, the tube being inclined and being continuously or intermittently vibrated and/or rotated as the solids are fed therethrough, thereby causing the particulate solids to progressively travel by gravity down the inclined tube to an exit therefrom.
23. The method according to claim 9, wherein; the microwave radiation directed to the particulate solids is generated by a microwave generator; and wherein the microwave radiation is transferred by a waveguide to the vessel through a microwave transparent wall of, or window in, the vessel, the waveguide incorporating a tuner operative to match an impedance of the microwave generator and associated waveguide to an impedance of the particulate solids in the vessel, thereby improving a microwave energy transfer efficiency to the particulate solids.
Description
INTRODUCTION TO THE DRAWINGS
[0038] Possible and preferred features of the present invention will now be described with particular reference to the accompanying drawings. However it is to be understood that the features illustrated in and described with reference to the drawings are not to be construed as limiting on the scope of the invention. In the drawings:
[0039]
[0040]
[0041]
[0042]
DESCRIPTION OF EMBODIMENTS
[0043] Referring to
[0044] The microwave radiation is generated by a microwave generator [7] and a waveguide [21] transfers the microwave radiation to the treatment zone [6] through a microwave transparent wall of, or window in, the treatment zone which is comprised by the quartz tube walls in
[0045] It is known that microwave electric fields of sufficient strength can induce an ionised gas, also known as a plasma. Under atmospheric conditions air will break down forming a plasma when the electric field stress is in the vicinity of 30 kV/cm. The specific electric field strength to initiate a plasma will depend on many parameters such is temperature, gas ionisation energy and pressure.
[0046] Microwave plasmas are typically initiated in single mode cavities where their resonant nature gives rise to very high field strengths, however plasma can form in non-resonant multimode applicators provided there is sufficient electric field strength. The field strength is proportional to the square root of the applied power level.
[0047] The dimensions and configuration of suitable microwave applicators for plasma processing is very much dependent upon the frequency of operation which can be anywhere between 800 MHz to 30 GHz, however the most likely frequencies are 896 MHz, 915 MHz, 922 MHz and 2.45 GHz as these are commercially used in industry.
[0048] The power levels required will be dependent upon frequency, gas throughput and pressure and could be as low as 1 kW and as high as 300 kW.
[0049] The unique ability of a plasma to cause molecule disassociation into fundamental components is largely due to a combination of the average bulk ion temperature and extremely high individual ion temperatures. Free electrons in the plasma can have very high energy and hence very high individual ion temperatures. The bulk temperatures required are expected to be in the order of 800-1200° C. and the individual ion temperatures may be in the order of 1000 to 10,000° K.
[0050] In each of
[0051] Referring to
[0052] The input [3] and output [4] screw conveyors are lined with microwave chokes [3, 4] to prevent electromagnetic radiation from escaping the treatment chamber.
[0053] The treatment chamber [2] rotates to provide mixing of the soil which helps produce a homogeneous heating profile and release vapours (including PFAS). The treatment chamber [2] is angled to allow a gravity assisted flow of product from input to output assisted by the rotation of the chamber and the input [3] and output [4] screw conveyors. The tubular chamber [2] may also be either continuously or intermittently vibrated as well as rotated so that the soil progressively travels by gravity down the inclined tube to the exit [4] therefrom.
[0054] Vapours are drawn out of the chamber through the gas output [5] and passed through a microwave plasma treatment stage [6] to destroy the PFAS via thermal oxidation and/or dissociation.
[0055] The plasma is produced using a microwave generator [7] operating within the frequency spectrum of 300 MHz to 5 GHz and requires a tuning system [8] in the waveguide [21] for impedance matching.
[0056] The neutralised gases and particulates from the gas stream are then filtered [9] or adsorbed or otherwise processed to render them safe.
[0057] A pump [10] is used to extract the gasses from the treatment chamber and lower the pressure of the system.
[0058] An impedance matching tuner [11] is utilised in the waveguide [22] before the microwave input port, on the generator side, to maximise the amount of electromagnetic energy being absorbed by the soil. Tuning and impedance matching by tuner [11] can help to avoid a need or desirability of using a catalyst (high dielectric loss) in the particulate solids although such use of a catalyst can be possible if desired.
[0059] Electromagnetic energy from a microwave generator [12] operating within the frequency spectrum of 300 MHz to 5 GHz, is delivered to the treatment chamber [2] via waveguide [22].
[0060] Microwave transparent windows between the tuner [11] and treatment chamber [2] prevents soil and gases from entering the microwave waveguide [22].
[0061] Temperature probes [15, 16, 17, 18] are used at both ends of the treatment chamber [2] as well as at each input and output in order monitor the soil and vapour temperatures and enable process control.
[0062] The treatment chamber [2] is insulated with TBD material to maintain required internal temperatures.
[0063] The remediated soil is removed via the output screw conveyor and choke [4].
[0064] Energy levels, heating rates, input and output speed, rotation speed, temperatures and other monitored and controllable inputs and outputs are controlled, monitored and recorded via Touch Screen Computer Control System [19].
[0065] In
[0066] In the particular apparatus in
[0067] The pump [10] which creates suction to draw PFAS out of the treatment chamber [2] and through the treatment stage constituted by the plasma applicator [6] can reduce the vapour pressure in the treatment chamber and hence assist vaporisation of PFAS, although the function of the pump is also to draw the PFAS vapour from the chamber through the treatment stage. Thus the vapour containing PFAS is continuously drawn from the chamber [2] and transferred into the treatment stage [6] during the treatment of the particulate solids in the vessel by creating a negative pressure downstream of the treatment stage which thereby draws vapours from the vessel into and through the treatment stage. However it is also possible that vapour containing PFAS yielded by the soil [30] is drawn from the vessel after the irradiation of the soil in the vessel.
[0068] Because removal of water from the soil [30] being treated which occurs under the effects of the microwave irradiation generally increases the permeability of the soil to microwave energy, the process and apparatus may have a two-stage (or more than two-stage) operation. In particular, in a first-stage, the microwave irradiation is primarily conducted using parameters for vaporising water in the soil. This increases the microwave permeability of the progressively drying soil so that, in a second stage, the power of the microwave radiation generated and transmitted into the treatment chamber [2] is increased to more effectively vaporise PFAS in the at least partially dried soil.
[0069] In a further possible embodiment of the invention, the chamber [2] in which the soil is irradiated may include (or may consist of) a microwave transparent enclosure, e.g. composed of quartz or ceramic or other microwave transparent material, in which the soil resides during the irradiation. The enclosure may comprise for example a quartz or ceramic tube into which soil to be treated is fed, the tube being inclined and either continuously or intermittently vibrated so that the soil progressively travels by gravity down the inclined tube to an exit therefrom. The vibration will promote penetration of the microwave radiation (and heating effects) and/or direct exposure of the soil surfaces and interstices as the soil particles are agitated and loosened and separated and as they mix and migrate. A suitable apparatus may be a vibrator coupled to the tube and used to promote granular flow e.g. of the type in the mining industry or other industries where flow of particulates in a tube or pipe or the like is required. The vibration frequency and amplitude, and the angle of inclination of the tube, will be parameters that affect the soil movement speed through the irradiation zone, and these parameters may be selectively variable and may be empirically determined to optimise the process.
[0070] In both of the particular embodiments of
[0071] In both of the particular embodiments of
[0072] In a first possible arrangement the means for creating a partial vacuum is performed by creating the partial vacuum in the closed vessel while the soil [30] is located therein and, unlike
[0073] In a second possible arrangement having the means for creating a partial vacuum, the directing of microwave radiation into the soil is discontinued after a period of heating time, and substantially simultaneously with or after the discontinuation of the step of directing microwave radiation the partial vacuum is created in the closed vessel. This also reduces the likelihood of plasma formation and arcing occurring in the gas space when the suction step is performed to lower the vapour pressure.
[0074] In a third possible arrangement having the means for creating a partial vacuum, and applicable to the batch system of
[0075] Also in both of the particular embodiments of
[0076] Alternatively, to the two stage heating, or in conjunction therewith, the plasma inhibition may include substantially increasing the amount of inert gas, particularly helium or neon or argon, in the gas atmosphere mixed with and surrounding the soil [30] undergoing heating by microwave radiation so as to thereby inhibit the creation of a plasma in the gas space above the level of soil [30] in the chamber [2] of the vessel where microwave irradiation is occurring. The high ionization temperature of helium particularly inhibits the creation of a plasma in the gas.
[0077] In both of the particular embodiments of
[0078] The diagram of
[0082] In
[0083] It will be seen that the particular preferred embodiments of possible apparatus embodying the present invention described and illustrated herein can be used to effectively remediate soil contaminated with PFAS. The processed soil may be of better quality for re-introduction to the environment since lower temperatures are used in the PFAS extraction compared to prior soil heating systems. The apparatus can be sufficiently small scale to be transported to a site where the contaminated soil to be treated is located and the apparatus can be set up and operated at the site by systematically collecting soil throughout the site and processing it according to the method and apparatus of the invention for immediate return.
[0084] It is to be understood that various alterations, modifications and/or additions may be made to the features of the possible and preferred embodiment(s) of the invention as herein described without departing from the spirit and scope of the invention.