US20170157589A1 - Method for making a carbonaceous sponge-like sorbent - Google Patents
Method for making a carbonaceous sponge-like sorbent Download PDFInfo
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- US20170157589A1 US20170157589A1 US14/958,901 US201514958901A US2017157589A1 US 20170157589 A1 US20170157589 A1 US 20170157589A1 US 201514958901 A US201514958901 A US 201514958901A US 2017157589 A1 US2017157589 A1 US 2017157589A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
- B01J20/20—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising free carbon; comprising carbon obtained by carbonising processes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/22—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising organic material
- B01J20/26—Synthetic macromolecular compounds
- B01J20/261—Synthetic macromolecular compounds obtained by reactions only involving carbon to carbon unsaturated bonds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
- B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
- B01J20/28042—Shaped bodies; Monolithic structures
- B01J20/28045—Honeycomb or cellular structures; Solid foams or sponges
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/3007—Moulding, shaping or extruding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
- B01J20/30—Processes for preparing, regenerating, or reactivating
- B01J20/3042—Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent
Definitions
- the present invention relates to the manufacture of sorbents, and particularly to the manufacture of a carbonaceous sponge-like sorbent.
- Fly ash is one of the residues generated by coal combustion, and is composed of the fine particles that are driven out of the boiler with the flue gases.
- fly ash produced from coal combustion was simply entrained in flue gases and dispersed into the atmosphere. This, however, created environmental and health concerns that prompted laws that have reduced fly ash emissions to less than 1% of ash produced.
- the method for making a carbonaceous sponge-like sorbent includes drying carbon-rich fly ash and then mixing the dried fly ash with a binder, such as a polyvinyl acetate emulsion, preferably with a polyvinyl acetate concentration in the emulsion of 18 wt %.
- a binder such as a polyvinyl acetate emulsion, preferably with a polyvinyl acetate concentration in the emulsion of 18 wt %.
- the binder and the volume of fly ash can be mixed in a hopper by a mechanical stirrer or the like to form a carbonaceous mixture, preferably with a binder to fly ash ratio of 1:1 by weight.
- the carbonaceous mixture can be conveyed from the hopper to the press for pressing the carbonaceous mixture into blocks or briquettes of the carbonaceous sponge-like sorbent.
- the produced carbonaceous sponge-like sorbent is then dried.
- the carbonaceous sponge-like sorbent has a high degree of permeability (on the order of 1,200 m 2 /g), thus forming a carbonaceous “sponge” (i.e., a porous, sponge-like structure) with a high degree of permeability.
- FIG. 1 is a perspective view of an exemplary system for making a carbonaceous sponge-like sorbent according to the present invention.
- FIG. 2A is a partial perspective view of a press of the system for making the carbonaceous sponge-like sorbent, shown in a state of partial compaction.
- FIG. 2B is a partial perspective view of the press of the system for making the carbonaceous sponge-like sorbent, shown post-compaction.
- FIGS. 3A, 3B, 3C and 3D are scanning electron microscope (SEM) images showing the microstructure of the carbonaceous sponge-like sorbent, shown at magnifications of 750 ⁇ , 1500 ⁇ , 3000 ⁇ and 7500 ⁇ , respectively.
- a method for making a carbonaceous sponge-like sorbent includes mixing carbon-rich fly ash with a polyvinyl acetate emulsion to form the carbonaceous sponge-like sorbent.
- the carbon-rich fly ash can be collected from a desalination plant or the like. Prior to mixing with the polyvinyl acetate, the carbon-rich fly ash is dried. For example, the carbon rich fly ash can first be air dried, and then further dried at a temperature of approximately 100° C. for a period of approximately two hours in an electric oven, or by drying with a solar collector at a temperature of approximately 70° C. for a period of approximately six hours.
- the carbonaceous sponge-like sorbent has a high degree of permeability, on the order of 1,200 m 2 /g (measured by the N 2 -gas method).
- the present carbonaceous sponge-like sorbent can be used instead of traditional activated charcoal for sorption of pollutants from water.
- Crude carbon-rich fly ash used to make the present carbonaceous sponge-like sorbent was found to have a fixed carbon content of 79.79 wt %, an ash content of 7.03 wt %, a volatile matter content of 5.83 wt % and a moisture content of 7.23 wt %. This may be compared against a sample of conventional activated charcoal derived from coconut shell, which has a fixed carbon content of 84.79 wt %, an ash content of 6.43 wt %, a volatile matter content of 7.99 wt % and a moisture content of 6.11 wt %.
- FIG. 1 A system for making the carbonaceous sponge-like sorbent 10 is shown in FIG. 1 .
- the volume of fly ash is placed in a hopper 12 of the system for making the carbonaceous sponge-like sorbent 10 .
- a binder is added to the volume of fly ash by spraying or the like.
- the binder can be a polyvinyl acetate (PVA) emulsion.
- sprayer 16 is shown positioned directly over a substantially conical hopper 12 for spraying the PVA emulsion on the fly ash.
- the PVA emulsion is formed from PVA in water, with the concentration of PVA in the overall PVA/water emulsion being 18 wt %, although it should be understood that any suitable concentration of PVA may be used.
- the PVA emulsion binder and the volume of fly ash are mixed in the hopper 12 by a mechanical stirrer 18 or the like to form a carbonaceous mixture.
- mechanical stirrer 18 is shown being driven by a conventional motor 14 , although it should be understood that any suitable type of stirrer or mixer may be used and that mechanical stirrer 18 is shown for exemplary purposes only. Additionally, it should be understood that any suitable type of motor or other drive may be used for driving stirrer 18 .
- the PVA to fly ash ratio is 1:1 by weight, although it should be understood that any suitable ratio may be used.
- a hollow tube 22 may extend between hopper 12 and a press 50 , with the hollow tube 22 being in open communication with hopper 12 and a molding tube 30 of press 50 .
- a worm gear 24 inside hollow tube 22 which may be driven to rotate via linkage with motor 14 , is used to transfer the carbonaceous mixture from hopper 12 to press 50 .
- the overall conveyer 20 is shown in FIG. 1 as being formed from worm gear 24 inside hollow tube 22 , it should be understood that conveyer 20 is shown for exemplary purposes only and that any suitable type of conveyer or transfer device may be used to transfer the carbonaceous mixture from hopper 12 to press 50 .
- the press 50 includes a vertically-oriented molding tube 30 in communication with the conveyer 20 for receiving the carbonaceous mixture C, along with a vertical piston 28 which is slidably received within the molding tube 30 .
- the molding tube 30 is shown as being substantially cylindrical for formation of a substantially cylindrical briquette or block of a carbonaceous sponge-like sorbent B. It should be understood that molding tube 30 may have any desired contouring and relative dimensions for formation of the carbonaceous sponge-like sorbent of any desired size and shape.
- the lower end 38 of the vertical piston 28 which slidably seals the molding tube 30 , above the carbonaceous mixture C, for compacting the carbonaceous mixture C, may also have any suitable contouring and dimensions, dependent on the selected contouring and relative dimensions of molding tube 30 .
- an axial passage 52 may be formed through vertical piston 28 (and the lower end 38 thereof) for delivering pressurized air or the like therethrough. Following compaction of the carbonaceous mixture C, the pressurized air may be used to ensure that each of the formed blocks of carbonaceous sponge-like sorbents B are easily released from lower end 38 and the interior of molding tube 30 .
- the axial passage 52 is relatively small in diameter.
- the axial passage 52 could have a diameter on the order of 2 mm, thus providing ample volume for delivery of the pressurized air but without interfering with the molding of the briquettes or blocks of carbonaceous sponge-like sorbents B.
- molding tube 30 is shown filled with the carbonaceous mixture C.
- piston 28 is driven downwardly (by any suitable type of drive system, such a linear actuator, a pneumatic cylinder or the like) such that lower end 38 of vertical piston 28 compresses the carbonaceous mixture.
- the upper end 40 of a vertical stand 32 selectively seals a lower end 44 of the molding tube 30 .
- the upper end 40 of vertical stand 32 may have any suitable contouring and dimensions, dependent on the selected contouring and relative dimensions of molding tube 30 .
- the vertical stand 32 is selectively vertically adjustable such that, following compaction, the produced carbonaceous sponge-like sorbents B may be lowered out of molding tube 30 , exiting the open lower end 44 of the molding tube 30 . It should be understood that vertical stand 32 is selectively driven upward and downward by any suitable type of drive system, such a linear actuator, a pneumatic cylinder or the like.
- the pneumatic piston 34 horizontally transfers the produced carbonaceous sponge-like sorbents B from beneath the molding tube 30 to a dryer 36 , which is preferably in the form of an infrared conveyer, as shown in FIG. 1 , which irradiates the carbonaceous sponge-like sorbents B with infrared (IR) radiation as they pass therealong.
- IR infrared
- any suitable type of pneumatic piston driven by any suitable type of pneumatic controller 26 , may be utilized or, alternatively, the pneumatic piston 34 may be replaced by any suitable type of linear actuator or the like.
- any suitable type of dryer may be utilized for drying and curing the binder in the carbonaceous sponge-like sorbent B.
- infrared drying is used, as application of the IR radiation causes the polyvinyl acetate binder to rearrange its chemical structure to form a polycyclic aromatic.
- FIGS. 3A, 3B, 3C and 3D are scanning electron microscope (SEM) images showing the microstructure of the produced carbonaceous sponge-like sorbent B at magnifications of 750 ⁇ , 1500 ⁇ , 3000 ⁇ and 7500 ⁇ , respectively.
- the diameters of agglomerated carbonaceous balls found on the surfaces of the samples of the carbonaceous sponge-like sorbent B produced by the above method vary widely between samples, ranging between 34.44 ⁇ m and 65.08 ⁇ m. Additionally, pore diameters within the agglomerated carbonaceous balls differed between 0.75 ⁇ m and 8.04 ⁇ m.
- the SEM images also indicate that the carbonaceous sponge-like sorbents have a vast permeable structure which would be suitable for sorption of fluids in water treatment and industrial purification.
Abstract
Description
- 1. Field of the Invention
- The present invention relates to the manufacture of sorbents, and particularly to the manufacture of a carbonaceous sponge-like sorbent.
- 2. Description of the Related Art
- Fly ash is one of the residues generated by coal combustion, and is composed of the fine particles that are driven out of the boiler with the flue gases. In the past, fly ash produced from coal combustion was simply entrained in flue gases and dispersed into the atmosphere. This, however, created environmental and health concerns that prompted laws that have reduced fly ash emissions to less than 1% of ash produced. Worldwide, more than 65% of fly ash produced from coal power stations is disposed of in landfills and ash ponds. The recycling of fly ash has become increasing important in recent years due to increasing landfill costs and current interest in sustainable development.
- Thus, a method for making a carbonaceous sponge-like sorbent from fly ash solving the aforementioned problems is desired.
- The method for making a carbonaceous sponge-like sorbent includes drying carbon-rich fly ash and then mixing the dried fly ash with a binder, such as a polyvinyl acetate emulsion, preferably with a polyvinyl acetate concentration in the emulsion of 18 wt %. The binder and the volume of fly ash can be mixed in a hopper by a mechanical stirrer or the like to form a carbonaceous mixture, preferably with a binder to fly ash ratio of 1:1 by weight. The carbonaceous mixture can be conveyed from the hopper to the press for pressing the carbonaceous mixture into blocks or briquettes of the carbonaceous sponge-like sorbent. The produced carbonaceous sponge-like sorbent is then dried. The carbonaceous sponge-like sorbent has a high degree of permeability (on the order of 1,200 m2/g), thus forming a carbonaceous “sponge” (i.e., a porous, sponge-like structure) with a high degree of permeability.
- These and other features of the present invention will become readily apparent upon further review of the following specification and drawings.
-
FIG. 1 is a perspective view of an exemplary system for making a carbonaceous sponge-like sorbent according to the present invention. -
FIG. 2A is a partial perspective view of a press of the system for making the carbonaceous sponge-like sorbent, shown in a state of partial compaction. -
FIG. 2B is a partial perspective view of the press of the system for making the carbonaceous sponge-like sorbent, shown post-compaction. -
FIGS. 3A, 3B, 3C and 3D are scanning electron microscope (SEM) images showing the microstructure of the carbonaceous sponge-like sorbent, shown at magnifications of 750×, 1500×, 3000× and 7500×, respectively. - Similar reference characters denote corresponding features consistently throughout the attached drawings.
- A method for making a carbonaceous sponge-like sorbent includes mixing carbon-rich fly ash with a polyvinyl acetate emulsion to form the carbonaceous sponge-like sorbent. The carbon-rich fly ash can be collected from a desalination plant or the like. Prior to mixing with the polyvinyl acetate, the carbon-rich fly ash is dried. For example, the carbon rich fly ash can first be air dried, and then further dried at a temperature of approximately 100° C. for a period of approximately two hours in an electric oven, or by drying with a solar collector at a temperature of approximately 70° C. for a period of approximately six hours. The carbonaceous sponge-like sorbent has a high degree of permeability, on the order of 1,200 m2/g (measured by the N2-gas method).
- The present carbonaceous sponge-like sorbent can be used instead of traditional activated charcoal for sorption of pollutants from water. Crude carbon-rich fly ash used to make the present carbonaceous sponge-like sorbent was found to have a fixed carbon content of 79.79 wt %, an ash content of 7.03 wt %, a volatile matter content of 5.83 wt % and a moisture content of 7.23 wt %. This may be compared against a sample of conventional activated charcoal derived from coconut shell, which has a fixed carbon content of 84.79 wt %, an ash content of 6.43 wt %, a volatile matter content of 7.99 wt % and a moisture content of 6.11 wt %.
- A system for making the carbonaceous sponge-like sorbent 10 is shown in
FIG. 1 . As shown inFIG. 1 , following drying, the volume of fly ash is placed in ahopper 12 of the system for making the carbonaceous sponge-like sorbent 10. Inside thehopper 12, a binder is added to the volume of fly ash by spraying or the like. The binder can be a polyvinyl acetate (PVA) emulsion. InFIG. 1 ,sprayer 16 is shown positioned directly over a substantiallyconical hopper 12 for spraying the PVA emulsion on the fly ash. It should be understood that the relative positioning and configurations of bothsprayer 16 andhopper 12 are shown for exemplary purposes only, and that any suitable type of sprayer (or any other suitable type of applicator) may be used in combination with any suitable type of hopper or receptacle. The PVA emulsion is formed from PVA in water, with the concentration of PVA in the overall PVA/water emulsion being 18 wt %, although it should be understood that any suitable concentration of PVA may be used. - The PVA emulsion binder and the volume of fly ash are mixed in the
hopper 12 by amechanical stirrer 18 or the like to form a carbonaceous mixture. InFIG. 1 ,mechanical stirrer 18 is shown being driven by aconventional motor 14, although it should be understood that any suitable type of stirrer or mixer may be used and thatmechanical stirrer 18 is shown for exemplary purposes only. Additionally, it should be understood that any suitable type of motor or other drive may be used for drivingstirrer 18. Preferably, the PVA to fly ash ratio is 1:1 by weight, although it should be understood that any suitable ratio may be used. - As shown, a
hollow tube 22 may extend betweenhopper 12 and apress 50, with thehollow tube 22 being in open communication withhopper 12 and amolding tube 30 ofpress 50. A worm gear 24 insidehollow tube 22, which may be driven to rotate via linkage withmotor 14, is used to transfer the carbonaceous mixture fromhopper 12 to press 50. Although theoverall conveyer 20 is shown inFIG. 1 as being formed from worm gear 24 insidehollow tube 22, it should be understood thatconveyer 20 is shown for exemplary purposes only and that any suitable type of conveyer or transfer device may be used to transfer the carbonaceous mixture fromhopper 12 to press 50. - As shown, the
press 50 includes a vertically-orientedmolding tube 30 in communication with theconveyer 20 for receiving the carbonaceous mixture C, along with avertical piston 28 which is slidably received within themolding tube 30. InFIG. 1 , themolding tube 30 is shown as being substantially cylindrical for formation of a substantially cylindrical briquette or block of a carbonaceous sponge-like sorbent B. It should be understood thatmolding tube 30 may have any desired contouring and relative dimensions for formation of the carbonaceous sponge-like sorbent of any desired size and shape. Similarly, thelower end 38 of thevertical piston 28, which slidably seals themolding tube 30, above the carbonaceous mixture C, for compacting the carbonaceous mixture C, may also have any suitable contouring and dimensions, dependent on the selected contouring and relative dimensions ofmolding tube 30. As best seen inFIG. 1 , anaxial passage 52 may be formed through vertical piston 28 (and thelower end 38 thereof) for delivering pressurized air or the like therethrough. Following compaction of the carbonaceous mixture C, the pressurized air may be used to ensure that each of the formed blocks of carbonaceous sponge-like sorbents B are easily released fromlower end 38 and the interior ofmolding tube 30. Theaxial passage 52 is relatively small in diameter. For purposes of illustration, for acylindrical molding tube 30 with an interior diameter of 3 cm (and, correspondingly, avertical piston 28 with a diameter of approximately 3 cm), theaxial passage 52 could have a diameter on the order of 2 mm, thus providing ample volume for delivery of the pressurized air but without interfering with the molding of the briquettes or blocks of carbonaceous sponge-like sorbents B. - In
FIG. 1 ,molding tube 30 is shown filled with the carbonaceous mixture C. In the configuration ofFIG. 2A ,piston 28 is driven downwardly (by any suitable type of drive system, such a linear actuator, a pneumatic cylinder or the like) such thatlower end 38 ofvertical piston 28 compresses the carbonaceous mixture. As further shown inFIG. 2A , during the compaction process, theupper end 40 of avertical stand 32 selectively seals a lower end 44 of themolding tube 30. Theupper end 40 ofvertical stand 32 may have any suitable contouring and dimensions, dependent on the selected contouring and relative dimensions ofmolding tube 30. - As shown in
FIG. 2B , thevertical stand 32 is selectively vertically adjustable such that, following compaction, the produced carbonaceous sponge-like sorbents B may be lowered out ofmolding tube 30, exiting the open lower end 44 of themolding tube 30. It should be understood thatvertical stand 32 is selectively driven upward and downward by any suitable type of drive system, such a linear actuator, a pneumatic cylinder or the like. - Once the blocks of carbonaceous sponge-like sorbents B have been lowered out of
molding tube 30, they are positioned on table 42, adjacent apneumatic piston 34. Thepneumatic piston 34 horizontally transfers the produced carbonaceous sponge-like sorbents B from beneath themolding tube 30 to adryer 36, which is preferably in the form of an infrared conveyer, as shown inFIG. 1 , which irradiates the carbonaceous sponge-like sorbents B with infrared (IR) radiation as they pass therealong. The infrared radiation dries and cures the binder in the blocks of carbonaceous sponge-like sorbents B. It should be understood that any suitable type of pneumatic piston, driven by any suitable type ofpneumatic controller 26, may be utilized or, alternatively, thepneumatic piston 34 may be replaced by any suitable type of linear actuator or the like. Similarly, it should be understood that any suitable type of dryer may be utilized for drying and curing the binder in the carbonaceous sponge-like sorbent B. Preferably, infrared drying is used, as application of the IR radiation causes the polyvinyl acetate binder to rearrange its chemical structure to form a polycyclic aromatic. -
FIGS. 3A, 3B, 3C and 3D are scanning electron microscope (SEM) images showing the microstructure of the produced carbonaceous sponge-like sorbent B at magnifications of 750×, 1500×, 3000× and 7500×, respectively. The diameters of agglomerated carbonaceous balls found on the surfaces of the samples of the carbonaceous sponge-like sorbent B produced by the above method vary widely between samples, ranging between 34.44 μm and 65.08 μm. Additionally, pore diameters within the agglomerated carbonaceous balls differed between 0.75 μm and 8.04 μm. The SEM images also indicate that the carbonaceous sponge-like sorbents have a vast permeable structure which would be suitable for sorption of fluids in water treatment and industrial purification. - It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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