BR112021007686A2 - catalyst adsorbent filters, catalyst adsorbent composition and method of forming a catalyst adsorbent filter - Google Patents

Abstract

CATALYSING ADSORBING FILTERS, CATALYSING ADSORBING COMPOSITION AND METHOD FOR FORMING A CATALYSING ADSORBING FILTER. In certain embodiments, catalyst adsorbent compositions are disclosed which include a metal oxide catalyst adapted to convert gaseous pollutants to chemically benign species and an adsorbent adapted to adsorb the chemically benign species along with other gaseous species and volatile organic compounds.

Description

"ADSORBENT CATALYST FILTERS, COMPOSITION ADSORBENT CATALYST AND METHOD TO FORM AN ADSORBENT CATALYST FILTER" CROSS REFERENCE TO RELATED ORDERS

[001] This application claims the priority benefit of the International Application in PCT/CN2018/111425, filed on October 23, 2018, the disclosure of which is incorporated herein by reference in its entirety.

FIELD OF TECHNIQUE

[002] The present disclosure relates to compositions, devices and methods for air purification. More particularly, the disclosure relates to adsorbent catalyst compositions, devices and systems, methods for their preparation and methods for their use in removing, at room temperature, gaseous pollutants from the air.

BACKGROUND

[003] Air pollution is a concern of increasing importance as levels of various air pollutants continue to rise. Formaldehyde, nitrogen oxides, sulfur dioxide and ammonia are considered to be the main pollutants, for which various absorbent systems and materials are used to remove them from indoor environments.

[004] Traditional systems for treating pollutants and absorbent materials still face many challenges, including improving long-term performance, increasing the efficiency of manufacturing operations and reducing production costs. Many absorbent materials are generally adapted for one type of adsorption application, although they are incapable of removing other types of pollutants. Current cathodic air purification technology, for example, requires two separate layers to remove acidic and basic chemical contaminants, thus requiring a more complex design. Additionally, non-woven filter systems using carbon pellets result in high back pressure, which has a detrimental effect on performance.

[005] Thus, there is still a need for devices, methods and compositions that can effectively remove multiple pollutants simultaneously.

DISCLOSURE SUMMARY

[006] The following is a simplified summary of various aspects of the present disclosure in order to provide a basic understanding of those aspects. This summary is not a comprehensive overview of the disclosure. It is not intended to identify key or critical elements of the disclosure, nor to delineate any scope of the particular modalities of disclosure or any scope of claims. Its sole purpose is to present some concepts of the disclosure in a simplified form as a prelude to the more detailed description that is presented later.

[007] In one aspect of the present disclosure, an adsorbent catalyst filter comprises: a filter body comprising a material selected from polymeric foam, polymeric fiber, non-woven cloth, a ceramic, and pulp products (e.g., paper); and a coating formed on the filter body. The coating comprises: a manganese oxide catalyst adapted to convert gaseous pollutants into chemically benign species; and an adsorbent adapted to adsorb chemically benign species and other gaseous species which the manganese oxide catalyst is not adapted to convert.

[008] In certain embodiments, the adsorbent is selected from a group consisting of: silica gel, activated carbon, faujasite, chabazite, clinoptilolite, mordenite, silicalite, zeolite X, zeolite Y, ultrastable zeolite Y, zeolite ZSM, ofretite, beta zeolite, organic metal structures, metal oxide,

polymers, resins and combinations thereof.

[009] In certain embodiments, the adsorbent comprises activated carbon.

[010] In certain embodiments, activated carbon is synthetic activated carbon or is based on or derived from one or more of wood, peat coal, coconut husk, lignite, petroleum pitch, petroleum coke, petroleum tar pitch. charcoal, fruit kernels, nuts, husks, sawdust, wood flour, synthetic polymer or natural polymer.

[011] In certain embodiments, a Brunauer-Emmett-Teller (BET) surface area of the adsorbent is from about 20 m2/g to about 3,000 m2/g.

[012] In certain embodiments, a weight:weight ratio of manganese oxide to adsorbent is 1:5 to 7:1.

[013] In certain embodiments, the coating further comprises a polymeric binder, and the polymeric binder is selected from the group consisting of: polyethylene, polypropylene, polyolefin copolymer, polyisoprene, polybutadiene, polybutadiene copolymer, chlorinated rubber , nitrile rubber, polychloroprene, ethylene-propylene-diene elastomer, polystyrene, polyacrylate, polymethacrylate, polyacrylonitrile, poly(vinyl ester), poly(vinyl halide), polyamide, cellulosic polymer, polyimide, acrylic polymer, vinyl acrylic polymer , styrene acrylic polymer, polyvinyl alcohol, thermoplastic polyester, thermosetting polyester, poly(phenylene oxide), poly(phenylene sulfide), fluorinated polymer, poly(tetrafluoroethylene) polyvinylidene fluoride, chlorine/poly(fluoride) copolymer of vinyl), ethylene chlorotrifluoroethylene copolymer, polyamide, phenolic resin, epoxy resin, polyurethane, acrylic/styrene acrylic copolymer, there tex, silicone polymer and combinations thereof.

[014] In certain embodiments, the polymeric binder is present from about 5% by weight to about 30% by weight relative to the total weight of the coating.

[015] In certain embodiments, the coating further comprises a dispersing agent. In certain embodiments, the dispersing agent comprises one or more of an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, or a nonionic surfactant.

[016] In certain embodiments, the filter body comprises a polymeric foam comprising polyurethane.

[017] In certain embodiments, the filter body has alveolar shape.

[018] In another aspect of the present disclosure, an adsorbent catalyst composition comprises: an adsorbent comprising activated carbon; a catalyst comprising manganese oxide; a polymeric binder; and a surface-active dispersing agent.

[019] In another aspect of the present disclosure, a method for forming an adsorbent catalyst filter comprises: forming a slurry comprising a metal oxide catalyst and an adsorbent; coating the slurry in a filter body comprising a material selected from polymeric foam, polymeric fiber, non-woven cloth, a ceramic, and pulp products (eg, paper); and drying the slurry to form the catalyst adsorbent filter.

[020] In certain embodiments, drying takes place at a temperature of about 80 °C to about 250 °C.

[021] In certain embodiments, the adsorbent comprises activated carbon and a BET surface area of the adsorbent is from about 20 m2/g to about 3000 m2/g.

[022] In certain embodiments, the metal oxide catalyst comprises manganese oxide, a weight:weight ratio of manganese oxide to adsorbent that is 1:5 to 7:1.

[023] In certain embodiments, the slurry further comprises a polymeric binder. In certain embodiments, the polymeric binder is present from about 5% by weight to about 30% by weight based on the total weight of the coating. In certain embodiments, the polymeric binder is selected from the group consisting of: polyethylene, polypropylene, polyolefin copolymer, polyisoprene, polybutadiene, polybutadiene copolymer, chlorinated rubber, nitrile rubber, polychloroprene, ethylene-propylene elastomer- diene, polystyrene, polyacrylate, polymethacrylate, polyacrylonitrile, poly(vinyl ester), poly(vinyl halide), polyamide, cellulosic polymer, polyimide, acrylic polymer, vinyl acrylic polymer, styrene acrylic polymer, polyvinyl alcohol, thermoplastic polyester, thermosetting polyester, poly(phenylene oxide), poly(phenylene sulfide), fluorinated polymer, poly(tetrafluoroethylene) polyvinylidene fluoride, poly(vinyl fluoride) chlorine/fluorine copolymer, ethylene chlorotrifluoroethylene copolymer, polyamide, resin phenolic, epoxy resin, polyurethane, acrylic/styrene acrylic copolymer, latex, silicone polymer and combinations thereof.

[024] In certain modalities, the slurry also comprises a dispersing agent, and the dispersing agent comprises one or more of an anionic surfactant, a cationic surfactant, a zwitterionic surfactant or a nonionic surfactant.

[025] In certain embodiments, the filter body comprises a polymeric foam comprising polyurethane.

[026] In another aspect of the present disclosure, an adsorbent catalyst filter comprises: a filter body comprising a material selected from polymeric foam, polymeric fiber, non-woven cloth, a ceramic and pulp products (e.g., paper); and a coating formed on the filter body. The coating comprises: a manganese oxide catalyst adapted to convert gaseous pollutants into chemically benign species; an adsorbent adapted to adsorb the chemically benign species along with other gaseous species and volatile organic compounds; a polymeric binder; and a dispersing agent.

[027] In another aspect of the present disclosure, a volatile organic compound (VOC) scrubbing system comprises any modalities of the aforementioned catalyst adsorbent arranged to be placed in contact with the air received in the VOC scrubbing system. In one embodiment, the VOC scrubbing system comprises one or more filtration cartridges with catalyst adsorbent disposed therein and arranged to be contacted with a stream of air received in the VOC scrubbing system.

[028] Any modalities of the aforementioned catalyst adsorbent can be arranged within one or more filtration cartridges.

[029] In another aspect of the present disclosure, a method for treating air comprises a pollutant selected from SO 2 , NH 3 , NO 2 , NO and formaldehyde, the method comprising flowing a first volume of air into an air treatment chamber that comprises any embodiments of the adsorbent catalyst mentioned above, wherein the first volume of air has a first concentration of the pollutant and places the sorbent in contact with the first volume of air, wherein a second concentration of the pollutant of the first volume of air is less or equal to the first concentration after contact.

In certain embodiments, the first volume of air comprises air recirculated from an interior of a building. In certain embodiments, the method further comprises flowing a second volume of air into the air handling chamber, wherein the second volume of air has a third concentration of the pollutant and contacting the sorbent with the second volume of air, wherein a fourth concentration of the second volume of air pollutant is greater than or equal to the third concentration after contact. In certain embodiments, the second volume of air comprises air from outside the building.

[030] In another aspect of the present disclosure, an automobile ventilation system comprises a component (e.g., a filter, filter unit, container, air duct, etc.) comprising any modalities of the aforementioned catalyst adsorbent disposed within of the component.

[031] In another aspect of the present disclosure, an aircraft environmental control system comprises a filter unit comprising any modalities of the aforementioned catalyst adsorbent disposed within the filter unit.

[032] In another aspect of the present disclosure, a cathodic air filter for a fuel cell system comprises a filter unit comprising any modalities of the aforementioned catalyst adsorbent disposed within the filter unit. Such a cathode air filter system can be incorporated, for example, in fuel cell systems for vehicles, homes or for industrial use.

[033] In another aspect of the present disclosure, an air control system for removing a pollutant from atmospheric air comprises a filter unit comprising any modalities of the aforementioned sorbent disposed within the filter unit.

[034] As used in this document, the term “adsorbent material” refers to a material that can adhere gas molecules, ions or other species within its structure (eg, removing CO 2 from the air).

Specific materials include, but are not limited to, clays, metal organic structure, activated alumina, silica gel, activated carbon, molecular sieve carbon, zeolites (eg, molecular sieve zeolite), polymers, resins, and any of these such components or others that have a gas adsorbent material supported thereon (for example, such as the various sorbent modalities described herein). Certain adsorbent materials can, preferentially or selectively, adhere to particular species.

[035] Also as used in this document, the term "catalyst adsorbent" refers to a material that has dual catalytic and adsorptive properties. For example, an adsorbent catalyst layer, upon contact with a molecular species, can catalyze the conversion of the molecular species into one or more by-products and may also be capable of adsorbing the molecular species and/or one or more by-products. The adsorbent catalyst layer may also be capable of adsorbing other molecular species that cannot be catalytically reacted through the adsorbent catalyst layer.

[036] As used herein, the term "adsorption capacity" refers to a working capacity for an amount of a chemical species that an adsorbent material can adsorb under specific operating conditions (eg, temperature and pressure). Adsorption capacity units, when presented in mg/g units, correspond to milligrams of adsorbed gas per gram of sorbent.

[037] Also as used in this document, the term “particles” refers to a collection of distinct portions of a material, each with a larger dimension being in the range of 0.1 µm to 50 mm. The morphology of the particles can be crystalline, semi-crystalline or amorphous. The size ranges disclosed in this document may be medium/regular or medium in size, unless otherwise noted. It is also noted that the particles need not be spherical, but can be in the form of cubes, cylinders, disks or any other suitable shape, as would be noted by a person skilled in the art. "Powders" and "granules" can be types of particles.

[038] Also as used in this document, the term "monolith"

refers to a single unitary block of a specific material. The single unitary block can be in the form of, for example, a brick, a disk or a rod and can contain channels for increased gas flow/distribution. In certain embodiments, multiple monoliths can be arranged together to form a desired shape.

In certain embodiments, a monolith may have a honeycomb shape with multiple parallel channels, each with a square shape, a hexagonal shape, or another shape.

[039] Also as used herein, the term "dispersing agent" refers to a compound that helps maintain solid particles in a suspended state in a fluid medium and inhibit or reduce agglomeration or sedimentation of particles in the fluid medium.

[040] Also as used in this document, the term "binder" refers to a material that, when included in a coating, layer, or film (eg, a layer, layer, or film-coated coating on a substrate), promotes formation of a continuous or substantially continuous structure from an outer surface of the coating, layer or film to the opposite outer surface, is homogeneously or semi-homogeneously distributed in the coating, layer or film and promotes adhesion to a surface on which the coating, layer or film is formed and the cohesion between the surface and the coating, layer or film.

[041] Also as used in this document, the terms "stream" or "flow" refer broadly to any gas stream that may contain solids (eg, particles), liquids (eg, steam) and/or gas mixtures.

[042] Also as used in this document, the terms "volatile organic compounds" or "VOCs" refer to organic chemical molecules with a high vapor pressure at room temperature. These chemical molecules have a low boiling point and a large number of molecules evaporate and/or sublime at room temperature, thus transitioning from a liquid or solid phase to a gaseous phase. Common VOCs include, but are not limited to, formaldehyde, benzene, toluene, xylene, ethylbenzene, styrene, propane, hexane, cyclohexane, limonene, pinene, acetaldehyde, hexaldehyde, ethyl acetate, butanol, and the like.

[043] Also as used in this document, the terms "unpurified air" or "unpurified air stream" refer to any stream that contains one or more pollutants at a concentration or content equal to or greater than a perceived level. as a nuisance, which is considered to have adverse effects on human health (including short- and/or long-term effects) and/or cause adverse effects on the operation of the equipment. For example, in certain embodiments, a stream that contains formaldehyde at a concentration greater than 0.5 part formaldehyde per parts per million air stream calculated as an eight hour weighted average concentration, according to the “level of action” established by the Occupational Safety & Health Administration, is an unpurified air flow. In certain embodiments, a flux that contains formaldehyde at a concentration greater than 0.08 part formaldehyde per parts per million of airflow calculated as an eight-hour weighted average concentration, according to national standards in China, is a flux of unpurified air. Unpurified air may include, but is not limited to, formaldehyde, ozone, carbon monoxide (CO), VOCs, methyl bromide, water, amine-containing compounds (eg, ammonia), sulfur oxides, hydrogen sulfide and nitrogen oxides.

[044] Also as used in this document, the terms "purified air" or "purified air stream" refer to any stream that contains one or more pollutants in a concentration or content less than the concentration or content of one or more pollutants in the which would be considered a stream of unpurified air.

[045] Also as used in this document, the term "substrate" refers to a material (eg, a metal, semimetal, semimetal oxide, metal oxide, polymeric, ceramic, paper, pulp/semi-pulp products, etc.) on or on which the catalyst is placed. In certain embodiments, the substrate can be in the form of a solid surface with an overlay layer that contains a plurality of catalytic particles and/or adsorbent particles. An overlay layer is formed by preparing a slurry that contains a specified solids content (eg, 30% to 50% by weight) of catalyst particles and/or adsorbent particles, which are then coated. onto a substrate and dried to provide an overlay layer. In certain embodiments, the substrate can be porous and the overlay layer can be deposited outside and/or inside the pores.

[046] Also as used herein, the term "nitrogen oxide" refers to compounds containing nitrogen and oxygen including, but not limited to, nitric oxide, nitrogen dioxide, nitrous oxide, nitrosilazide, ozatetrazol, trioxide of dinitrogen, dinitrogen tetroxide, dinitrogen pentoxide, trinitramide, nitrite, nitrate, nitronium, nitroson, peroxynitrite or combinations thereof.

[047] Also as used herein, the term "sulfur compounds" refers to compounds that contain sulfur including, but not limited to, sulfur oxides (sulfur monoxide, sulfur dioxide, sulfur trioxide, sulfur monoxide. disulfide, disulfide dioxide), hydrogen sulfide or combinations thereof.

[048] As used herein, the term "about" in connection with a measured quantity refers to the normal variations in that measured quantity as expected by the person skilled in the art of performing the measurement and exercising a compatible level of care with the purpose of measuring and the accuracy of the measuring equipment. For example, when “about” modifies a value, it can be interpreted to mean that the value can vary by ±1%.

[049] The surface area, as discussed in this document, is determined by the Brunauer-Emmett-Teller (BET) method according to DIN ISO 9277:2003-05 (which is a revised version of DIN 66131), which is referred to as “BET surface area”. The specific surface area is determined by a multipoint BET measurement in the relative pressure range of 0.05 to 0.3 p/p0.

BRIEF DESCRIPTION OF THE DRAWINGS

[050] The present disclosure is illustrated, by way of example and not by way of limitation, in the Figures of the accompanying drawings, in which: Figure 1 represents an illustrative airflow system according to an embodiment of the disclosure; Figure 2A depicts a cross-section of a filter body with a catalyst adsorbent coating formed thereon in accordance with an embodiment of the disclosure; Figure 2B depicts a cross-section of a catalyst adsorbent coating formed on a surface of a filter body in accordance with an embodiment of the disclosure; and Figure 3 is a flowchart illustrating a method of forming a catalyst adsorbent filter sorbent in accordance with an embodiment of the disclosure.

DETAILED DESCRIPTION

[051] The modalities described in this document refer to adsorbent catalyst compositions and systems for the removal of pollutants from the air. More specifically, catalyst adsorbent compositions can be incorporated into indoor air, cabin air and cathodic air purification systems, which can be designed to remove toxic chemical pollutants such as formaldehyde, ozone, carbon monoxide, nitrogen oxides, carbon dioxide. sulfur, amines (including ammonia), sulfur compounds (including thiols), chlorinated hydrocarbons and other alkaline or acidic chemicals.

[052] In certain embodiments, a high surface area adsorbent (eg, activated carbon) mixed with a metal oxide catalyst (eg, manganese oxide) and other functional additives produces a catalyst adsorbent composition that serves as a complete solution for the removal of gaseous pollutions, described in this document, with high efficiency. The catalyst adsorbent composition can be coated onto a filter body, such as an open-pore foam, alveo or non-woven filter body, to increase filtration efficiency and facilitate acceptable back pressure.

[053] The modalities of the present disclosure allow the purification of air at low temperatures (for example, the ambient temperature varies from 20 °C to 25 °C) without the need for heating the unpurified air or the adsorbent catalyst filter. In addition, the relatively low materials and temperatures used in forming the catalyst adsorbent composition allow for a broader range of filters, such as polymeric foam materials, which would otherwise be incompatible with the higher temperature processes used to coat metallic filters .

[054] The modalities of the present disclosure further allow an effective catalysis without the use of ultraviolet (UV) radiation or electricity and are free of photocatalytic chemistry.

[055] The modalities of this disclosure also allow the formation of adsorbent catalyst filters that are free of detectable odors, even after long-term operation.

[056] Figure 1 represents an illustrative airflow system 100 according to an embodiment of the disclosure. System 100 includes a filter unit 104 and an HVAC system 106 installed as part of a building.

102. As shown in Figure 1, filter scrubber unit 104 and HVAC system 106 are fluidly coupled to each other and to the building's internal air space 102 such that a recirculating air flow path 108 is established. As various pollutants, such as VOCs, accumulate within the indoor air space of building 102, the indoor air is recirculated through the filter unit 104 to catalyze and/or adsorb the pollutants with the use of a catalytic adsorbent filter, as described in this document. The purified air then passes through the HVAC 106 system, which can be further filtered (eg to remove dust and other particles) and can be heated or cooled before being recirculated back to the building.

102.

[057] The modality of system 100 is merely illustrative and it should be understood that the modalities of adsorbent catalyst filters described in this document can be incorporated into other systems for air treatment, such as an automobile ventilation system and environmental control system of aircraft, an air control system for the treatment of atmospheric air, humidification/dehumidification systems, odor removal systems, VOC scrubbing systems, systems for the treatment of cathodic air in fuel cell systems for cars, homes or for industrial use, and other systems.

[058] Figures 2A and 2B represent cross-sections of a catalyst adsorbent filter 200 formed according to an embodiment of the disclosure. Catalyst adsorbent filter 200 includes a filter body 210, which is illustrated in the form of a honeycomb filter with air passages 215 formed therethrough. It should be understood that the honeycomb filter is for illustrative purposes only and that other filter formats can be used. Catalyst adsorbent filter 200 further includes a catalyst adsorbent composition coated on the inner walls of filter body 200.

[059] In certain embodiments, the filter body may be in the form of an open-pore foam, a honeycomb or a non-woven filter body. In certain embodiments, a filter body material can be ceramic (e.g., porous ceramic), metallic, polymeric foam, plastic, paper, fibrous (e.g., polymeric fiber) or combinations thereof. For example, in certain embodiments, the filter body can be formed from polyurethane fibers or a polyurethane foam. In certain embodiments, the filter body can be a metallic monolithic filter body, a ceramic monolithic filter body, a paper filter body, a polymer filter body, or a monolithic ceramic fiber substrate. In certain embodiments, the filter body can be an HVAC duct, an air filter, or a louvered surface. In certain embodiments, the filter body can be a portable air filter or a filter disposed on a vehicle, such as a motor vehicle, rail vehicle, vessel, aircraft, or spacecraft.

[060] In certain embodiments, the catalyst adsorbent composition can be formulated as a slurry and covered with layer on the filter body. In certain embodiments, a loading of the catalyst adsorbent composition on the filter body can range from about 0.5 g/16.38 cm3 to about 4 g/16.38 cm3 (about 0.5 g/in3 to about 4 g/in3) in relation to a volume of the filter body. In certain embodiments, the catalyst adsorbent composition may be coated on the filter body and may form a single catalyst adsorbent layer on the solid substrate or a plurality of catalyst adsorbent layers. If a plurality of adsorbent catalyst layers are coated on the solid substrate, the layers may vary in their composition or, alternatively, all of the adsorbent catalyst layers may have the same composition.

[061] In certain embodiments, the catalyst of the catalyst adsorbent composition may comprise a catalytic metal oxide. The catalytic metal oxide can include one or more of manganese oxide, cobalt oxide, molybdenum oxide, chromium oxide, copper oxide or cerium oxide.

In certain embodiments, the metal oxide can be a rare earth metal oxide.

[062] In certain embodiments, the catalytic metal oxide is manganese oxide. In certain embodiments, the manganese oxide is amorphous or at least partially amorphous. In certain embodiments, the manganese oxide is semi-crystalline. In certain embodiments, the manganese oxide can comprise cryptomelane, birnessite, vernadite, polymorph I manganese oxide, weakly crystalline cryptomelane, amorphous manganese oxide, polymorphs thereof, amorphous manganese oxide or mixtures thereof.

[063] In certain embodiments, the metal oxide catalyst is present from about 10% by weight to about 90% by weight, from about 20% by weight to about 90% by weight, from about 30% by weight to about 90% by weight, from about 30% by weight to about 80% by weight, from about 40% by weight to about 80% by weight or about 40% by weight to about 70% by weight based on the total weight of the catalyst adsorbent composition.

[064] In certain embodiments, the adsorbent of the catalyst adsorbent composition comprises an adsorbent selected from silica gel, activated carbon, faujasite, chabazite, clinoptilolite, mordenite, silicalite, zeolite X, zeolite Y, ultrastable zeolite Y, zeolite ZSM (for example , ZSM-5, ZSM-11), ophrite, beta zeolite, organic metal structures, metal oxide, polymers, resins and combinations thereof.

[065] In certain embodiments, the adsorbent may include an adsorbent material which may include a primary adsorbent (such as one or more of those discussed above) on a support material such as carbon, an oxide (eg, alumina, silica) or zeolite.

[066] In certain embodiments, the adsorbent comprises activated carbon. Activated carbon can be synthetic activated carbon or based on or derived from wood, peat coal, coconut husk, lignite, petroleum pitch, petroleum coke, coal tar pitch, fruit kernels, nuts, bark, sawdust , wood flour, synthetic polymer, natural polymer and combinations thereof.

[067] In certain embodiments, the adsorbent includes a plurality of porous particles in powder form. In certain embodiments, an average particle/powder size ranges from about 1.0 µm to about 100 µm. In certain embodiments, the average size ranges from about 5.0 µm to about 50 µm. In certain embodiments, a BET surface area of the adsorbent is from about 20 m 2 /g to about 3000 m 2 /g or more.

[068] In certain embodiments, the BET surface area of the adsorbent is from about 50 m2/g to about 3000 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 100 m 2 /g to about 3000 m 2 /g. In certain embodiments, the BET surface area of the adsorbent is from about 250 m2/g to about 3000 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 500 m 2 /g to about 3000 m 2 /g. In certain embodiments, the BET surface area of the adsorbent is from about 600 m2/g to about 3000 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 700 m2/g to about 3000 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 800 m2/g to about 3000 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 900 m2/g to about 3000 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1000 m2/g to about 3000 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1000 m2/g to about 2750 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1000 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1100 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1,200 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1300 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1400 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1500 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1600 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1700 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1800 m2/g to about 2,500 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1800 m2/g to about 2400 m2/g. In certain embodiments, the BET surface area of the adsorbent is from about 1800 m2/g to about 2300 m2/g.

[069] In certain embodiments, the adsorbent is activated carbon with a BET surface area of about 1000 m2/g to about 2,500 m2/g. In certain embodiments, the adsorbent is activated carbon with a BET surface area of about 1800 m2/g to about 2300 m2/g.

[070] In order to increase the capacity of the porous support used in the modalities of this disclosure, the adsorbent can be activated. Activation may include subjecting the adsorbent (eg, particles) to various conditions, including, but not limited to, room temperature, vacuum, an inert gas stream, or any combination thereof, for a time sufficient to activate the adsorbent. In certain embodiments, the adsorbent can be activated by calcination.

[071] In certain embodiments, a weight:weight ratio of manganese oxide to adsorbent is 1:1 to 7:1. In certain sports, the weight:weight ratio is 2:1 to 5:1. In certain modalities, the weight:weight ratio can be 1:1, 2:1, 3:1, 4:1, 5:1, 6:1, 7:1 or any combination of subranges defined in between. In certain modalities, the weight:weight ratio can be from 1:1 to 1:5.

In certain modalities, the weight:weight ratio can be 1:1, 1:2, 1:3, 1:4, 1:5 or any combination of subranges defined in between.

[072] In certain embodiments, the catalyst adsorbent composition can further comprise a binder. Examples of suitable binders may include, but are not limited to: polyethylene, polypropylene, polyolefin copolymers, polyisoprene, polybutadiene, polybutadiene copolymers, chlorinated rubber, nitrile rubber, polychloroprene, ethylene-propylene-diene elastomers, polystyrene, polyacrylate , polymethacrylate, polyacrylonitrile, poly(vinyl esters), poly(vinyl halides), polyamides, cellulosic polymers, polyimides, acrylics, vinyl acrylics, styrene acrylics, polyvinyl alcohols, thermoplastic polyesters, thermosetting polyesters, poly(oxide of phenylene), poly(phenylene sulfide), fluorinated polymers such as polytetrafluoroethylene, polyvinylidene fluoride, poly(vinylidene fluoride) and chlorine/fluorine copolymers such as ethylene chlorotrifluoroethylene copolymer, polyamide, phenolic resins, polyurethane, latex of acrylic/styrene acrylic copolymer and silicone polymers.

[073] In certain embodiments, the binder is a polymeric binder selected from: polyethylene, polypropylene, polyolefin copolymer, polyisoprene, polybutadiene, polybutadiene copolymer, chlorinated rubber, nitrile rubber, polychloroprene, ethylene-propylene elastomer- diene, polystyrene, polyacrylate, polymethacrylate, polyacrylonitrile, poly(vinyl ester), poly(vinyl halide), polyamide, cellulosic polymer, polyimide, acrylic polymer, vinyl acrylic polymer, styrene acrylic polymer, polyvinyl alcohol, thermoplastic polyester , thermosetting polyester, poly(phenylene oxide), poly(phenylene sulfide), fluorinated polymer, polytetrafluoroethylene, polyvinylidene fluoride, poly(vinyl fluoride) chloro/fluoro copolymer, ethylene chlorotrifluoroethylene copolymer, polyamide, phenolic resin, epoxy resin, polyurethane, acrylic/styrene acrylic copolymer, latex, silicone polymer and combinations thereof. In certain embodiments, the binder comprises an acrylic/styrene copolymer latex and a polyurethane dispersion.

[074] In certain embodiments, the binder, or mixture of binders, is present from about 5% by weight to about 30% by weight with respect to the total weight of the catalyst adsorbent composition when dried and deposited in the body of filter. In certain embodiments, the polymeric binder is present from about 10% by weight to about 30% by weight, from about 15% by weight to about 30% by weight, from about 5% by weight to about from 25% by weight, from about 5% by weight to about 20% by weight, from about 10% by weight to about 20%, or from about 15% by weight to about 20% by weight.

[075] In certain embodiments, the catalyst adsorbent composition includes a dispersing agent. The dispersing agent can include one or more of an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, or a nonionic surfactant. In certain embodiments, the dispersing agent is a nonionic acrylic copolymer.

[076] Figure 3 is a flowchart illustrating a method 300 of forming a catalyst adsorbent filter sorbent according to an embodiment of the disclosure. Method 300 begins at block 302, in which a slurry is formed. The slurry comprises a metal oxide catalyst and an adsorbent, which can be formed by dissolving the metal oxide catalyst and the adsorbent in an aqueous solution.

[077] In certain embodiments, the slurry further comprises a polymeric binder. In certain embodiments, the polymeric binder is selected from: polyethylene, polypropylene, polyolefin copolymer, polyisoprene, polybutadiene, polybutadiene copolymer, chlorinated rubber, nitrile rubber, polychloroprene, ethylene-propylene-diene elastomer, polystyrene, polyacrylate, polymethacrylate, polyacrylonitrile, poly(vinyl ester), poly(vinyl halide), polyamide, cellulosic polymer, polyimide, acrylic polymer, vinyl acrylic polymer, styrene acrylic polymer, polyvinyl alcohol, thermoplastic polyester, thermosetting polyester, poly( phenylene oxide), poly(phenylene sulfide), fluorinated polymer, poly(tetrafluoroethylene), polyvinylidene fluoride, poly(vinyl fluoride) chloro/fluoro copolymer, ethylene chlorotrifluoroethylene copolymer, polyamide, phenolic resin, epoxy resin, polyurethane, acrylic/styrene acrylic copolymer, latex, silicone polymer and combinations thereof.

[078] In certain embodiments, the slurry further comprises a dispersing agent. The dispersing agent can include one or more of an anionic surfactant, a cationic surfactant, a zwitterionic surfactant, or a nonionic surfactant.

[079] In certain embodiments, the slurry also includes an oxidizer, which can improve the efficiency of removal of nitrogen oxides. The oxidant can be selected from nitric acid, hypochlorite, a persulfate, a peroxide, permanganate or a chlorate.

[080] In certain embodiments, the slurry also includes an alkaline component, such as a hydroxide, ammonia or a carbonate, which can improve the stabilization of the slurry. In certain embodiments, a pH of the slurry can be adjusted between 2 and 12 or between 4 and 10.

[081] In block 304, the slurry is coated on a filter body. The filter body may comprise a material selected from polymeric foam, polymeric fiber, non-woven cloth, a ceramic or a pulp product (e.g., paper). In certain embodiments, the filter body comprises a polymeric foam comprising polyurethane. In certain embodiments, the filter body is honeycomb in shape.

[082] In block 306, the slurry is dried to form the adsorbent catalyst filter. In certain embodiments, drying is carried out at a temperature of from about 80°C to about 250°C. The polymeric binder can be present from about 5% by weight to about 30% by weight relative to the total weight of the coating.

[083] Note that the blocks of method 300 are not limiting and that, in certain modalities, some or all of the blocks of their respective methods can be performed. In certain embodiments, one or more of the blocks can be performed substantially simultaneously. Some blocks can be completely omitted or repeated.

ILLUSTRATIVE EXAMPLES

[084] The following examples are set forth to assist in understanding the disclosure and should not, of course, be construed as specifically limiting the modalities described and claimed in this document. Such variations of the modalities, including the replacement of all equivalents now known or later developed, which would be within the reach of persons skilled in the art and formulation changes or small changes to the experimental design, should be considered as being within the scope of the modalities incorporated into this document.

EXAMPLE 1

[085] A mixture of 5.9 g of a dispersing agent, 27.4 g of potassium hydroxide (KOH) and 737 g of water was prepared, and 297.6 g of powder of

MnO2 and 59.5 g of activated carbon powder were then dispersed into the mixture to form a slurry having 32 wt% solids content based on the total slurry weight. A final slurry was achieved by adding 31.2 g of a polyacrylic latex and 31.2 g of polyurethane latex binder to the slurry.

The final slurry had a solids content of about 35% by weight, a pH of about 10 and a maximum viscosity of 0.72 Pa·s (720 centipoise).

EXAMPLE 2

[086] A test sample was prepared using a polyurethane foam core as a filter body. The polyurethane foam core had a diameter of 2.54 cm (1 inch) and a length of 40 millimeters. The polyurethane foam core was coated with the final slurry obtained from Example 1. The coated polyurethane foam core was dried at 110°C and held at 110°C for 1 hour. A dry gain of overlay layer of the coated polyurethane core was 1.8 g. An additional rectangular polyurethane foam sample measuring 408 by 283 millimeters and a 5 millimeter thick square polyurethane foam was coated by the same procedure, resulting in a dry cover layer gain of 49.3 g, which was tested using the GB/T 32085 standard.

COMPARATIVE EXAMPLE 1

[087] A mixture of 13.2 g of a dispersing agent, 6.6 g of KOH, 99.3 g of polyacrylic latex and 1,127 g of water was prepared, and 331 g of activated carbon powder was then prepared. dispersed in the mixture to form a slurry having 26% by weight solids content based on the total slurry weight, a pH of about 8, and a maximum viscosity of 1,206 Pa·s (1,026 centipoise).

COMPARATIVE EXAMPLE 2

[088] A test sample was prepared using a polyurethane foam core as a filter body. The polyurethane foam core had a diameter of 2.54 cm (1 inch) and a length of 40 millimeters. The polyurethane foam core was coated with the slurry obtained from Comparative Example 1. The coated polyurethane foam core was dried at 110°C and held at 110°C for 1 hour. A dry gain of overlay layer of the coated polyurethane core was 1.0 g.

RESULTS

[089] Table 1 below summarizes the results obtained by placing the coated polyurethane foam cores in a piston flow reactor. During testing, the unpurified air stream included SO 2 , NOx and NH 3 each present at 30 ppm. Other airflow parameters include a temperature of 25±0.5 °C, 18% relative humidity, 10% O 2 and a space velocity of 150,000 h-1 and a total flow time of 1 hour. Table 1 demonstrates that Example 2 is able to adsorb more pollutants than Comparative Example 2, with higher SO 2 adsorption capacity. Furthermore, Example 2 exhibited improved overlay layer adhesion compared to Comparative Example 2.

TABLE 1 Sample Capacity Capacidad Capacity Capacidity Layer de and adhesion adsorption adsorption adsorption NO NO2 NH3 SO2 adsorption overcoat (mg/g) (mg/g) (mg/g) (mg/g) nt Example 2 79.2 7.7 43.1 5.2 Good Example 49.5 10.1 85.9 Not Bad Comparative 2 activity

[090] In the foregoing description, numerous specific details, such as materials, dimensions, specific process parameters, etc., are presented to provide a complete understanding of the embodiments of the present disclosure. Particular features, structures, materials or characteristics can be combined in any suitable way in one or more modalities. The words “example” or “exemplary” are used in this document to mean that it serves as an example, situation or illustration. Any aspect or design described in this document as “exemplary” or “exemplary” should not necessarily be interpreted as preferential or advantageous over other aspects or designs. Instead, the use of the words “example” or “exemplary” is intended to present concepts in a concrete way.

As used in this application, the term “or” is intended to mean an inclusive “or” rather than an exclusive “or”. That is, unless otherwise specified or clear from the context, "X includes A or B" is intended to mean any of the natural inclusive permutations. That is, if X includes A; X includes B; or X includes A and B, then “X includes A or B” is satisfied in either of the above situations. In addition, the use of the terms "a", "an", "the", and similar references in the context of describing the materials and methods discussed in this document (especially in the context of the following claims) shall be interpreted as covering the either the singular or the plural, unless otherwise indicated herein or clearly contradicted by context.

[091] The recitation of ranges of values in this document is only intended to be a shorthand method of referring individually to each separate value within the range, unless otherwise indicated in this document, and each value separate is incorporated into the descriptive report as if it were recited in this document individually. All methods described in this document may be performed in any suitable order unless otherwise indicated in this document or otherwise clearly contradicted by context.

[092] Reference throughout this descriptive report to “one (1) modality”, “certain modalities”, “one or more modalities”, “a modality” or “some modalities” means that a particular feature, structure, material or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. So the aspects of the sentences,

such as "in one or more modalities", "in certain modalities", "in one (1) modality" or "in a modality", in several places throughout this descriptive report, are not necessarily referring to the same modality of the present disclosure. In addition, particular features, structures, materials or characteristics can be combined in any suitable way in one or more modalities.

[093] It should be understood that the above description is intended to be illustrative and not restrictive. Many other modalities will be evident to persons skilled in the art after reading and understanding the above description. The scope of disclosure must, therefore, be determined by reference to the appended claims, together with the full scope of equivalents to which those claims are entitled. The use of any and all examples, or exemplary language (eg, "as/as") provided in this document is merely intended to further clarify the materials and methods and does not represent a limitation on the scope of the claims, unless it is otherwise indicated.

No language in the descriptive report should be construed as indicative of any element not claimed to be essential to the practice of the disclosed materials and methods.

[094] Although the modalities disclosed in this document have been described with reference to particular modalities, it should be understood that these modalities are merely illustrative as to the principles and applications of the present disclosure. It will be apparent to those skilled in the art that various modifications and variations can be made to the method and apparatus of the present disclosure without departing from the spirit and scope of the disclosure. Thus, it is intended that the present disclosure include modifications and variations that are within the scope of the appended claims and their equivalents and that the embodiments described above are presented for purposes of illustration and not limitation.

Claims (20)

1. CATALYST ADSORBENT FILTER, the catalyst adsorbent filter being characterized by comprising: a filter body comprising a material selected from polymeric foam, polymeric fiber, non-woven fabric, ceramic and pulp products; and a coating formed on the filter body, the coating comprising: a manganese oxide catalyst adapted to convert gaseous pollutants into chemically benign species; and an adsorbent adapted to adsorb chemically benign species and other gaseous species which the manganese oxide catalyst is not adapted to convert. 2. ADSORBENT CATALYST FILTER, according to claim 1, characterized in that the adsorbent is selected from a group consisting of: silica gel, activated carbon, faujasite, chabazite, clinoptilolite, mordenite, silicalite, zeolite X, zeolite Y, ultrastable Y zeolite, ZSM zeolite, ofretite, beta zeolite, organic metal structures, metal oxide, polymers, resins and combinations thereof. 3. ADSORBENT CATALYST FILTER, according to claim 1, characterized in that the adsorbent comprises activated carbon. 4. ADSORBENT CATALYST FILTER, according to claim 3, characterized in that the activated carbon is synthetic activated carbon or based on or derived from one or more of wood, peat coal, coconut husk, lignite, petroleum rosin, coke petroleum, coal tar pitch, fruit kernels, nuts, husks, sawdust, wood flour, synthetic polymer or natural polymer. 5. ADSORBENT CATALYST FILTER, according to claim 1, characterized in that a Brunauer-Emmett-Teller (BET) surface area of the adsorbent is from about 20 m2/g to about 3,000 m2/g. 6. ADSORBENT CATALYST FILTER, according to claim 1, characterized in that the weight:weight ratio of manganese oxide to the adsorbent is from 1:5 to 7:1. 7. ADSORBENT CATALYST FILTER, according to claim 1, characterized in that the coating further comprises a polymeric binder and in which the polymeric binder is selected from a group consisting of: polyethylene, polypropylene, polyolefin copolymer, poly- isoprene, polybutadiene, polybutadiene copolymer, chlorinated rubber, nitrile rubber, polychloroprene, ethylene-propylene-diene elastomer, polystyrene, polyacrylate, polymethacrylate, polyacrylonitrile, poly(vinyl ester), poly(vinyl halide), polyamide, cellulosic polymer, polyimide, acrylic polymer, vinyl acrylic polymer, styrene acrylic polymer, polyvinyl alcohol, thermoplastic polyester, thermosetting polyester, poly(phenylene oxide), poly(phenylene sulfide), fluorinated polymer, polytetrafluoroethylene, polyvinylidene fluoride, copolymer of chloro/poly(vinyl fluoride) fluoro, ethylene chlorotrifluoroethylene copolymer, polyamide, phenolic resin, resin epoxy, polyurethane, acrylic/styrene acrylic copolymer, latex, silicone polymer and combinations thereof. 8. CATALYST ADsorbent FILTER, according to claim 7, characterized in that the polymeric binder is present from approximately 5% by weight to approximately 30% by weight relative to the total weight of the coating. 9. ADSORBENT CATALYST FILTER, according to claim 1, characterized in that the coating further comprises a dispersing agent, and in which the dispersing agent comprises one or more of an anionic surfactant, a cationic surfactant, a zwitterionic surfactant or a non- ionic. 10. ADSORBENT CATALYST FILTER, according to claim 1, characterized in that the filter body comprises a polymeric foam comprising polyurethane. 11. CATALYST ADSORBENT FILTER, according to claim 1, characterized in that the filter body has alveolar shape. 12. ADSORBENT CATALYST COMPOSITION characterized by comprising: an adsorbent comprising activated carbon; a catalyst comprising manganese oxide; a polymeric binder; and a surface-active dispersing agent. 13. METHOD FOR FORMING AN ADSORBENT CATALYST FILTER, the method comprising: forming a slurry comprising a metal oxide catalyst and an adsorbent; coating the slurry in a filter body comprising a material selected from polymeric foam, polymeric fiber, non-woven cloth, a ceramic and pulp products; and drying the slurry to form the catalyst adsorbent filter. 14. METHOD according to claim 13, characterized in that drying takes place at a temperature of about 80 °C to about 250 °C. 15. The method according to claim 13, characterized in that the adsorbent comprises activated carbon and in which a BET surface area of the adsorbent is from about 20 m2/g to about 3,000 m2/g. 16. The method according to claim 13, characterized in that the metal oxide catalyst comprises manganese oxide, and in which a weight:weight ratio of the manganese oxide to the adsorbent is from 1:5 to 7:1. 17. The METHOD according to claim 13, characterized in that the slurry further comprises a polymeric binder, and in which the polymeric binder is present from about 5% by weight to about 30% by weight with respect to the total coating weight, and wherein the polymeric binder is selected from a group consisting of: polyethylene, polypropylene, polyolefin copolymer, polyisoprene, polybutadiene, polybutadiene copolymer, chlorinated rubber, nitrile rubber, polychloroprene, elastomer ethylene-propylene-diene, polystyrene, polyacrylate, polymethacrylate, polyacrylonitrile, poly(vinyl ester), poly(vinyl halide), polyamide, cellulosic polymer, polyimide, acrylic polymer, vinyl acrylic polymer, styrene acrylic polymer, alcohol polyvinyl, thermoplastic polyester, thermosetting polyester, poly(phenylene oxide), poly(phenylene sulfide), fluorinated polymer, polytetrafluoroethylene, polyvinylidene fluoride, copolymer of chloro/poly(vinyl fluoride) fluoro), ethylene chlorotrifluoroethylene copolymer, polyamide, phenolic resin, epoxy resin, polyurethane, acrylic/styrene acrylic copolymer, latex, silicone polymer and combinations thereof. 18. METHOD according to claim 13, characterized in that the slurry further comprises a dispersing agent, and in which the dispersing agent comprises one or more of an anionic surfactant, a cationic surfactant, a zwitterionic surfactant or a nonionic surfactant . 19. METHOD according to claim 13, characterized in that the filter body comprises a polymeric foam comprising polyurethane. 20. ADSORBENT CATALYST FILTER, wherein the adsorbent catalyst filter is characterized by comprising: a filter body comprising a material selected from polymeric foam, polymeric fiber, non-woven fabric, ceramic and pulp products; and a coating formed on the filter body, wherein the coating comprises: a manganese oxide catalyst adapted to convert gaseous pollutants into chemically benign species; an adsorbent adapted to adsorb the chemically benign species along with other gaseous species and volatile organic compounds; a polymeric binder; and a dispersing agent.