Apparatus and methods for treating exhaust gases
The present invention, in some embodiments, provides catalyst modules and/or catalytic reactors having increased effective catalyst cross-sectional areas. In some embodiments, a catalyst module comprises a fluid stream inlet side comprising a plurality of first catalyst bodies and a plurality of first ducts and a fluid stream outlet side comprising a plurality of second catalyst bodies and a plurality of second ducts, wherein the first ducts are a fluid stream inlet to the second catalyst bodies and the second ducts are a fluid stream outlet for the first catalyst bodies.
1. A catalyst module comprising:
a fluid stream inlet side comprising at least one first catalyst body and at least one first duct; and
a fluid stream outlet side comprising at least one second catalyst body and at least one second duct, wherein the at least one first duct is a fluid stream inlet to the at least one second catalyst body and the at least one second duct is a fluid stream outlet of the at least one first catalyst body.
2. The catalyst module of claim 1 , wherein the fluid stream inlet side further comprises a plurality of first catalyst bodies and a plurality of first ducts and the fluid stream outlet side further comprises a plurality of second catalyst bodies and a plurality of second ducts wherein the first ducts are a fluid stream inlet to the second catalyst bodies and the second ducts are a fluid stream outlet of the first catalyst bodies.
3. The catalyst module of claim 2 comprising at least one row of the first catalyst bodies.
4. The catalyst module of claim 3 comprising a plurality of rows of the first catalyst bodies.
5. The catalyst module of claim 4 comprising a plurality of rows of the second ducts.
6. The catalyst module of claim 2 comprising at least one row of the second catalyst bodies.
7. The catalyst module of claim 6 comprising a plurality of rows of the second catalyst bodies.
8. The catalyst module of claim 7 comprising a plurality of rows of the first ducts.
9. The catalyst module of claim 2 , wherein at least one of the first ducts and second ducts is tapered.
10. The catalyst module of claim 2 further comprising posts at least partially defining openings of the first ducts.
11. The catalyst module of claim 1 , wherein the module satisfies the equation:
x
<
[
total
inlet
facial
catalyst
area
]
[
(
total
inlet
facial
area
of
first
catalyst
)
+
(
total
inlet
facial
duct
area
)
]
wherein x is 1.
12. The catalyst module of claim 1 , wherein the module satisfies the equation:
x
<
[
total
inlet
facial
catalyst
area
]
[
(
total
inlet
facial
area
of
first
catalyst
)
+
(
total
inlet
facial
duct
area
)
]
wherein x is 1.1.
13. The catalyst module of claim 1 , wherein the module satisfies the equation:
x
<
[
total
inlet
facial
catalyst
area
]
[
(
total
inlet
facial
area
of
first
catalyst
)
+
(
total
inlet
facial
duct
area
)
]
wherein x is 1.4.
14. The catalyst module of claim 1 , wherein the first catalyst body and the second catalyst body comprise monolithic structural catalyst bodies.
15. The catalyst module of claim 1 , wherein at least one of the first catalyst body and the second catalyst body comprises a plate catalyst body, packed bed catalyst body or corrugated catalyst body.
16. The catalyst module of claim 1 , wherein at least one of the first catalyst body and the second catalyst body is a used catalyst body.
17. The catalyst module of claim 1 further comprising at least one additional catalyst body positioned between the inlet side and the outlet side of the module.
18. The catalyst module of claim 2 further comprising a plurality of additional catalyst bodies positioned between the inlet side and the outlet side of the module.
19. The catalyst module of claim 17 further comprising at least one additional fluid stream inlet duct to the at least one additional catalyst body and at least one additional fluid stream outlet duct of the at least one additional catalyst body.
20. The catalyst module of claim 18 further comprising a plurality of additional fluid stream inlet ducts to the additional catalyst bodies and a plurality of additional fluid stream outlets of the additional catalyst bodies.
21. A catalyst module comprising:
a fluid stream inlet side comprising a plurality of rows of first structural catalyst bodies and a plurality of rows of first ducts; and
a fluid stream outlet side comprising a plurality of rows of second structural catalyst bodies and a plurality of rows of second ducts, wherein the first ducts are a fluid stream inlet to the second catalyst bodies and the second ducts are a fluid stream outlet of the first catalyst bodies and wherein the module satisfies the following equation:
x
<
[
total
inlet
facial
catalyst
area
]
[
(
total
inlet
facial
area
of
first
catalyst
)
+
(
total
inlet
facial
duct
area
)
]
wherein x is 1 or 1.1.
22. The catalyst module of claim 21 , wherein at least one of the first structural catalyst bodies and the second structural catalyst bodies comprises used structural catalyst bodies.
23. A catalytic reactor comprising:
at least one catalyst module, the at least one catalyst module comprising:
a fluid stream inlet side comprising a plurality of first catalyst bodies and a plurality of first ducts; and
a fluid stream outlet side comprising a plurality of second catalyst bodies and a plurality of second ducts, wherein the first ducts are a fluid stream inlet to the second catalyst bodies and the second ducts are a fluid stream outlet of the first catalyst bodies.
24. The catalytic reactor of claim 23 , wherein at least one of the first catalyst bodies and the second catalyst bodies comprises monolithic structural catalyst bodies.
25. The catalytic reactor of claim 23 , wherein at least one of the first catalyst bodies and the second catalyst bodies comprises plate catalyst bodies, packed bed catalyst bodies or corrugated catalyst bodies.
26. The catalytic reactor of claim 23 further comprising at least one additional catalyst body positioned between the inlet side and the outlet side of the module and at least one additional fluid stream inlet duct to the at least one additional catalyst body and at least one additional fluid stream outlet duct of the at least one additional catalyst body.
27. The catalytic reactor of claim 23 further comprising a plurality of additional catalyst bodies positioned between the inlet side and the outlet side of the module and a plurality of additional fluid stream inlets ducts to the additional catalyst bodies and a plurality of additional fluid stream outlet ducts of the additional catalyst bodies.
28. A catalytic reactor comprising:
at least one catalyst module having dimensions suitable for treating a flue gas stream from a gas turbine, a gas boiler or a coal-fired boiler, the at least one catalyst module comprising:
a flue gas stream inlet side comprising a plurality of rows of first structural catalyst bodies and a plurality of rows of first ducts; and
a flue gas stream outlet side comprising a plurality of rows of second structural catalyst bodies and a plurality of rows of second ducts, wherein the first ducts are a flue gas stream inlet to the second catalyst bodies and the second ducts are a flue gas stream outlet of the first catalyst bodies and wherein the module satisfies the following equation:
x
<
[
total
inlet
facial
catalyst
area
]
[
(
total
inlet
facial
area
of
first
catalyst
)
+
(
total
inlet
facial
duct
area
)
]
wherein x is 1 or 1.1.
29. The catalytic reactor of claim 28 , wherein at least one of the first structural catalyst bodies and the second structural catalyst bodies comprises used structural catalyst bodies.
30. The catalytic reactor of claim 28 , wherein the gas turbine is upstream of a heat recovery steam generator.
31. A catalytic reactor comprising:
a fluid stream inlet side comprising a plurality of first catalyst modules and a plurality of first ducts; and
a fluid stream outlet side comprising a plurality of second catalyst modules and a plurality of second ducts, wherein the first ducts are a fluid stream inlet to the second catalyst modules and the second ducts are a fluid stream outlet of the first catalyst modules.
32. The catalytic reactor of claim 31 , wherein at least one of the first catalyst modules and the second catalyst modules comprises a plurality of catalyst bodies.
33. The catalytic reactor of claim 31 further comprising at least one additional catalyst module positioned between the inlet side and the outlet side of the catalytic reactor and at least one additional fluid stream inlet duct to the at least one additional catalyst module and at least one additional fluid stream outlet duct of the at least one additional catalyst module.
34. A method of treating a fluid stream comprising:
providing at least one catalyst module comprising a fluid stream inlet side comprising a plurality of first catalyst bodies and a plurality of first ducts and a fluid stream outlet side comprising a plurality of second catalyst bodies and a plurality of second ducts, wherein the first ducts are a fluid stream inlet to the second catalyst bodies and the second ducts are a fluid stream outlet of the first catalyst bodies; and
passing a first portion of the fluid stream through the first catalyst bodies and out of the module through the second ducts.
35. The method of claim 34 further comprising passing a second portion of the fluid stream through the second catalyst bodies via the first ducts.
36. The method of claim 34 , wherein the at least one catalyst module further comprises at least one additional catalyst body positioned between the fluid stream inlet side and fluid stream outlet side wherein a portion of the fluid stream is passed through the at least one additional catalyst body.
37. The method of claim 34 , wherein the fluid stream is a flue gas stream generated by a gas turbine, a gas boiler or a coal-fired boiler.
38. The method of claim 37 , wherein the gas turbine is upstream of a heat recovery steam generator.
39. A chemical species capture apparatus comprising:
a fluid stream inlet side comprising a first capture body and a first duct; and
a fluid stream outlet side comprising a second capture body and a second duct, wherein the first duct is a fluid stream inlet to the second capture body and the second duct is a fluid stream outlet of the first capture body.
40. The catalyst module of claim 39 , wherein the fluid stream inlet side further comprises a plurality of first capture bodies and a plurality of first ducts and the fluid stream outlet side further comprises a plurality of second capture bodies and a plurality of second ducts wherein the first ducts are a fluid stream inlet to the second capture bodies and the second ducts are a fluid stream outlet of the first capture bodies.
41. The chemical species capture apparatus of claim 39 further comprising at least one additional capture body positioned between the inlet side and the outlet side of the apparatus.
42. The chemical capture apparatus of claim 40 further comprising a plurality of additional catalyst bodies positioned between the inlet side and the outlet side of the apparatus.