Heat Exchange Media For Managing Silica Build-Up In A Regenerative Thermal Oxidizer

Abstract

A heat-exchange medium for use in a regenerative thermal oxidizer has a coating of potassium aluminum silicate which prevents the build-up of silicon dioxide from processed gas on the surface of the ceramic heat-exchange media.

1 . A ceramic heat-exchange medium having a coating of potassium aluminum silicate. 
   
   
       2 . The ceramic heat-exchange medium as recited in  claim 1 , wherein said coating covers substantially all of the exterior surface of said heat exchange medium. 
   
   
       3 . The ceramic heat-exchange medium recited in  claim 1 , wherein said heat-exchange medium is a ceramic saddle. 
   
   
       4 . The ceramic heat-exchange medium recited in  claim 1 , wherein said heat-exchange medium is a ceramic ring. 
   
   
       5 . The ceramic heat-exchange medium recited in  claim 1 , wherein said heat-exchange medium is a ceramic sphere. 
   
   
       6 . The ceramic heat-exchange medium recited in  claim 1 , wherein said heat-exchange medium is a ceramic pellet. 
   
   
       7 . The ceramic heat-exchange medium recited in  claim 1 , wherein said heat-exchange medium is a monolith. 
   
   
       8 . The ceramic heat-exchange medium recited in  claim 1 , wherein said potassium aluminum silicate coating has a thickness of from about 0.2 to about 0.4 mm. 
   
   
       9 . The ceramic heat-exchange medium recited in  claim 1 , wherein said heat-exchange medium is a corrugated layered ceramic media. 
   
   
       10 . The ceramic heat-exchange medium recited in  claim 1 , wherein said heat-exchange medium is a layered structured ceramic media. 
   
   
       11 . A method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer, which comprises the steps of:
 providing clay;   shaping said clay into a plurality of preforms suitable for use in a regenerative thermal oxidizer;   contacting substantially the entire outer surface of said preforms with potassium aluminum silicate; and   firing said coated performs to form said ceramic media.   
   
   
       12 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 11 , wherein the clay contains from about 45 to about 48 percent by weight SiO 2 . 
   
   
       13 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 12 , wherein the clay contains from about 29 to about 38 percent by weight Al 2 O 3 . 
   
   
       14 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 13 , wherein the clay contains from about 1.6 to about 2.2 percent by weight K 2 O. 
   
   
       15 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 14 , wherein the clay contains up to about 2 percent by weight Fe 2 O 3 . 
   
   
       16 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 11  wherein said preforms are in the shape of ceramic saddles. 
   
   
       17 . The method of making a corrugated layered ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 11  wherein said preforms are in the shape of ceramic rings. 
   
   
       18 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 11  wherein said preforms are in the shape of ceramic spheres. 
   
   
       19 . The method of making a layered structured ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 11  wherein said preforms are in the shape of ceramic pellets. 
   
   
       20 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 11  wherein said preforms are in the shape of ceramic monoliths. 
   
   
       21 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 11  wherein said potassium aluminum silicate is applied using a liquid. 
   
   
       22 . The method of making a ceramic media for a heat-exchanger in a regenerative thermal oxidizer recited in  claim 21 , wherein said liquid is water.