Catalytic Extraction Processing:  An Elemental Recycling Technology

Abstract

Catalytic Extraction Processing (CEP) is an innovative Elemental RecyclingTM technology that converts organic, organometallic, and inorganic waste, byproduct, or process streams into marketable commercial products: industrial gases, metal alloys, and ceramics (e.g., inorganic oxides, halides, sulfides). Feed materials are injected into a molten metal bath where dissociation of molecular entities to their respective elements and reaction of these dissolved elemental intermediates to form products occur. Process chemistry is driven by reaction thermodynamics, solution equilibria, and metal catalysis, which allow specific partitioning of elements and conversion of feed materials to the desired products as predicted. Experimental results demonstrate CEP's capabilities for waste minimization (e.g., product formation) and environmental performance (e.g., minimum emissions). Examples include the processing of highly toxic toluene diisocyanate production wastes (EPA RCRA listed waste K027), chlorinated organics (EPA RCRA listed waste F024), and mixed metallic, plastic, and inorganic wastes (weapon componentry). Synthesis gas, hydrogen chloride, ceramic, and metal products were manufactured from these waste materials. CEP consistently demonstrates destruction removal efficiencies (DREs) exceeding 99.9999%, NO x and SO x below detection limits (typically 1 ppm to 100 ppm), and dioxins/furans nondetectable to the targeted regulatory limit of 0.1 ng/Nm3 2,3,7,8 TCDD toxicity equivalent (TEQ). Condensed-phase environmental quality was verified by ceramic phases passing toxicity characteristic leaching procedure (TCLP) and the absence of hazardous organic constituents in both metal and ceramic phases. CEP's environmental performance has been validated by the U.S. EPA's best demonstrated available technology (BDAT) equivalency designations, while its manufacturing capabilities have been confirmed by Massachusetts Department of Environmental Protection (MADEP) recycling certifications.

Iron and copper catalysis of PCDD/F formation

“…Ryan studied dioxin formation from an unusual thermal process, Catalytic Extraction Processing (CEP), a technology that converts organic, organometallic and inorganic waste streams into marketable commercial products (Nagel et al 1996). The CEP uses a bath of molten iron to process waste, including chlorinated compounds.…”

Argon Scattering off the Surface of Liquid Indium: Exit Angle and Energy Dependence

“…Many physical and chemical phenomena involve collisions and reactions at gas−liquid interfaces. These processes include desiccation, stratospheric ozone depletion via sulfuric acid areosols, , and the destruction of toxic compounds in molten metals . A key step in many gas−liquid reactions is the initial energy transfer between gas and surface molecules, since this brings the gas species into longtime contact with the liquid. − …”

“…These processes include desiccation, stratospheric ozone depletion via sulfuric acid areosols, 1,2 and the destruction of toxic compounds in molten metals. 3 A key step in many gas-liquid reactions is the initial energy transfer between gas and surface molecules, since this brings the gas species into longtime contact with the liquid. [4][5][6] This paper describes a theoretical and experimental investigation of argon scattering off the surface of liquid indium.…”

A High-Level Computational Study on the Thermochemistry and Thermal Decomposition of Sulfur Mustard (2,2‘-Dichloroethyl Sulfide): A Chemical Warfare Agent

“…Metal catalysis can also greatly facilitate thermal rearrangement/degradation processes. Decomposition of organic waste in liquid metals has been recently developed as an industrial process …”