WO1995028279A1 - Corps alveolaires en charbon actif presentant des capacites d'adsorption variables et procede pour leur fabrication - Google Patents

Corps alveolaires en charbon actif presentant des capacites d'adsorption variables et procede pour leur fabrication Download PDF

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Publication number
WO1995028279A1
WO1995028279A1 PCT/US1995/007438 US9507438W WO9528279A1 WO 1995028279 A1 WO1995028279 A1 WO 1995028279A1 US 9507438 W US9507438 W US 9507438W WO 9528279 A1 WO9528279 A1 WO 9528279A1
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Prior art keywords
resin
fugitive
channels
combinations
continuous
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Application number
PCT/US1995/007438
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English (en)
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WO1995028279A9 (fr
Inventor
Kishor Purushottam Gadkaree
Joseph Frank Mach
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Corning Incorporated
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Publication date
Application filed by Corning Incorporated filed Critical Corning Incorporated
Priority to MX9604865A priority Critical patent/MX9604865A/es
Priority to AU28248/95A priority patent/AU2824895A/en
Priority to BR9507382A priority patent/BR9507382A/pt
Priority to KR1019960705783A priority patent/KR970702153A/ko
Priority to EP95923816A priority patent/EP0755328A4/fr
Priority to JP7527195A priority patent/JPH09511982A/ja
Publication of WO1995028279A1 publication Critical patent/WO1995028279A1/fr
Publication of WO1995028279A9 publication Critical patent/WO1995028279A9/fr

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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
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/52—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
    • C04B35/524—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite obtained from polymer precursors, e.g. glass-like carbon material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C04B35/83—Carbon fibres in a carbon matrix

Definitions

  • This invention relates to activated carbon bodies in the shape of honeycomb structures.
  • the honeyconibs are made by contacting a crosslinkable resin with channel-forming material and optionally with pore-forming and/or support fillers, shaping, curing, carbonizing, and activating.
  • the channel-forming material breaks down into low molecular weight components in inert atmosphere at high temperatures, leaving behind the honeycomb channels.
  • These bodies are strong and are not subject to attrition as are granulated carbon beds.
  • the bodies have continuous flow paths for minimizing pressure drop in a flow stream.
  • the configuration of the channels, and hence the adsorption capacity can be controlled by selection of suitable size and shape channel-forming material as well as percentage of pore-forming and support fillers. Therefore the bodies can be suited to a wide variety of adsorption applications.
  • Activated carbon materials in the form of granules or powders are used for a variety of pollution control applications. Pollutants in liquid or gas streams are removed by contacting the stream with activated carbon in granulated or powdered form.
  • the fine angstrom size pore structure of activated carbon enables adsorption of the impurities out of the process streams.
  • the pores in activated carbon which impart the unique ability to adsorb the pollutants even at very low concentrations (eg., as low as 1 ppm) are in the 5 to 20 angstrom range. Pores above about 50 angstroms do not contribute significantly to adsorption at low concentrations.
  • activated carbon is used in many pollution control applications, in the form of pellets or powder, a major disadvantage with this form of carbon is the high pressure drop associated with packed beds of pellets or powder. Another problem is that of entrainment of the powder in the flow stream and attrition of the granules.
  • One way around this problem is to form the activated carbon in the shape of a honeycomb.
  • the honeycomb geometry has the advantage of high geometric surface area available for contact and low pressure drop across the bed. In some industrial processes honeycomb geometries are necessary.
  • Resins have been used in making carbon bodies both as binders and as carbon precursors. For example, phenolic resins are extruded into honeycomb shapes as in U.S. patent 4,399,052. The resin is cured, carbonized, and activated.
  • a major difficulty with such a product is that during carbonization when about 50 wt. % is lost, such bodies distort and crack in many cases.
  • adsorption capacity per unit volume can be controlled so that it can be made to fit the requirements of a specific application and at the same time exhibit properties in the body of no attrition, minimized pressure drop, and high surface area in a given volume.
  • the present invention provides such a carbon structure and a method of making it.
  • an activated carbon body having flow-through channels.
  • the channels can be straight, curved or crisscrossed.
  • a method for making an activated carbon body having flow-through channels involves combining and shaping channel-forming material and optionally fugitive pore-forming material and non-fugitive support material, a crosslinkable resin into a green body and curing the resin.
  • the temperature at which the channel-forming material begins to distort is greater than the curing temperature of the resin.
  • the resin is carbonized and at the same time the channel-forming material is vaporized out to form a carbon body having flow through channels in the configuration of the fugitive material.
  • the carbon body is then activated- Brief Description of the Drawings
  • Figure 1 shows an array of channel forming elements in the form of straight solid filaments.
  • Figure 2 shows an array of channel forming elements in the form of curved solid filaments.
  • Figure 4 shows a honeycomb body shaped from a mixture of resin and loose solid fibers or filaments, for example of the types shown in Figures 1 or 2.
  • Figure 5 shows the honeycomb of Figure 4 after carbonization.
  • Figure 6 shows a carbonized honeycomb body made using hollow tubular filaments, for example of the type shown in Figure 3.
  • Figure 8 shows channel-forming material in the form of a woven screen.
  • Figure 9 shows resin in contact with a screen in the dried and still formable state.
  • the present invention relates to carbon bodies or structures for which the adsorption capacity per unit volume can be controlled, that is, can be made to be low, intermediate or high depending on what the specific application requires.
  • the structure also eliminates problems such as attrition associated with granulated beds, and the pressure drop is lower than in granulated beds.
  • the carbon body is characterized by a honeycomb structure, that is, having flow-through channels for optimum flowability of a work stream therethrough; and angstrom sized pores (about 5 to about 50 angstroms for adsorption) .
  • the channels can be straight and/or curved.
  • the channels can be essentially parallel, and/or non- parallel, and/or crisscrossing.
  • the structure exhibits high strength.
  • Examples of such applications include residential water purification, volatile organic compound emission control, natural gas fuel storage for gas-powered vehicles or equipment, indoor air purification, industrial respirators, automotive cabin air filters, ventless hoods, chemical separations, NO x and SO x control, and exhaust traps for automotive cold start applications.
  • Other potential applications include use as ozone filters, mercury collection from municipal incinerators, radon adsorption, automotive gas tank or intake manifold emissions, sewer pump vents, oil-air separations, or any other application wherein adsorption of a component or components from a fluid stream containing multiple components is desired.
  • the method for making the structures involves contacting a continuous fugitive material or channel- forming material with a crosslinkable resin and optionally with what will be called fillers.
  • the fillers can be non- fugitive or support material to enhance strength of the body, and/or non-continuous fugitive or pore-forming material which forms wall porosity during carbonization.
  • the mixture is then shaped into a form by a non-extrusion process.
  • the form is then dried, and the resin is cured and carbonized to produce a carbon body. After the drying step, the form can be further shaped if necessary.
  • the fugitive materials vaporize.
  • the channel-forming material leaves behind channels which are essentially in the same shape as they were in the pre- carbonized form.
  • the pore-forming material if present leaves behind wall porosity.
  • the carbonized body is then activated to produce the final activated carbon body.
  • the resin content determines the total amount of carbon in the body structure.
  • the size, shape and weight percent of channel-forming and pore-forming material determines the surface area of the carbon available for activation which in turn determines the adsorption capacity.
  • Support material controls the strength and cost of the body.
  • the adsorption capacity is controlled by the amount of carbon present in the final body structure and the percentage of this carbon available for activation.
  • the percentage of carbon available for activation is determined by the available surface area for the activation reaction.
  • the available surface area in turn is determined by the channel-forming and pore-forming material. If surface area is increased excessively then the structure can become weak.
  • the support fillers enhance strength and allow maximization of surface area.
  • the method of the present invention allows control of surface area available for adsorption for a given weight of carbon.
  • the resin A critical characteristic of the resin is that it be crosslinkable. These resins form three-dimensional network structures extending throughout the final body. The final body is stable to heat and cannot be made to melt or flow.
  • resins that can be considered suitable to the practice of the present invention are the thermosetting resins such as phenolics, furan, epoxies, and thermoplastic polymers such as polyacrylonitrile, polyvinyl chloride, etc., which although not thermosetting, can be crosslinked by high temperature oxidation. It is desirable that the resin give a high carbon yield on carbonization, that is, for example at least about 25%, and preferably at least about 40% based on the amount of cured resin. Thermosetting resins normally give these high yields.
  • Thermosetting resins are the preferred resins.
  • thermosetting resins that can be used in the practice of the present invention are phenolics, furan, epoxies, and combinations of these.
  • Preferred resins are phenolics, furan, and combinations of these because of their high carbon yield and low viscosities at room temperature. Normally, the viscosities can vary from about 50 cps to about 1000 cps. The preferred viscosities are about 100 to about 500 cps.
  • the resins can be provided as solids, liquids, solutions, or suspensions.
  • One resin that is especially suited to the practice of the present invention is phenolic resole.
  • the phenolic resoles are solutions of phenolics in water.
  • a higher viscosity suspension of solid phenolic powder in liquid resin can be used to increase the amount of resin in the support material (when used) and thus the final carbon yield.
  • One especially suited resin is a phenolic resole resin available from Occidental Chemical Corporation, Niagara Falls, N.Y. under the product name of Plyophen 43290. According to OxyChem® Material Safety Data Sheet No.
  • Plyophen 43290 is a liquid one step phenolic resin containing phenol, formaldehyde, and water, having a specific gravity of 1.22-1.24, a boiling point >100°C and a pH of 7.5-7.7 @ 100 gm/1.
  • Furan resins are available as liquids.
  • One furan that is suitable to the practice of the present invention is supplied by QO Chemicals, Inc. under the name of Furcarb® LP.
  • Furcarb® LP resins preparations of phenol (4% max) in furfuryl alcohol and have a specific gravity of 1.2, and a boiling point of 170°C. The viscosity is 300 cps.
  • the channel-formin ⁇ material volatilizes and leaves very low or no residue at the temperatures of the present invention. For example, the material breaks down into low molecular weight volatile compounds during firing in an inert atmosphere leaving very little or no residue.
  • the channel-forming material must have a heat distortion temperature point which is greater than the curing temperature of the resin that is used so that it does not distort during the curing process. This is typically but not necessarily at least about 150°C which is the cure temperature for phenolic resins.
  • the channel-forming material is continuous, that is, filament or fiber-like and is of sufficient length to provide on its volatilization, low pressure drop paths or channels through which a work stream can pass in continuous uninterrupted flow through the body; as opposed to wall porosity.
  • the channel-forming material can be in any form that will provide these low pressure drop paths, such as fibers.
  • the fibers can be in the form of a plurality or array of loose fibers or filaments, or in the form of a very long monofilament which is wound in a given configuration with the length and diameter being chosen depending on the amount and configuration of porosity that is desired.
  • the fibers can range typically from about 1 micrometer or less in diameter to as much as 1/2 centimeter or 1 centimeter or more in diameter depending on the application.
  • the fibers can be solid or hollow with commercial plastic straws being one example of the latter.
  • the fibers can also be preformed into a shape such as woven or non-woven (fused) mats or screens, etc.
  • Figures 1, 2, 3, 7, and 8 show some common shapes of channel-forming materials used in the practice of the present invention and hence, the configurations of channels in the bodies of the present invention.
  • Figures 1, 2, and 3 show fiber-like materials.
  • An array of channel forming elements in the form of loose straight solid filaments is shown in Figure 1.
  • Figure 3 An array of channel forming elements in the form of loose straight hollow tubes is shown in Figure 3.
  • Figure 7 and 8 show preformed shapes.
  • Figure 7 shows a fused screen (70) in which after carbonization the openings (72) between the screen area (74) will be the carbon while area (74) will form the channels.
  • Figure 8 shows a woven screen (80) in which after carbonization the openings (82) between the screen area (84) will be the carbon while area (84) will form the channels.
  • the fugitive material is preferably non-wettable by the resin liquid, solution or suspension in order that channels of clean and defined shape will form on vaporization. Therefore, the nature, amount, size, and shape of the continuous fugitive material are chosen depending on the desired degree and configuration of channels desired in the final body. The above factors also determine surface area of carbon available for adsorption.
  • Some materials that are especially suited as fugitive materials are thermoplastics. Examples of thermoplastics are polymers which on carbonization in inert atmosphere break down into low molecular compounds and disappear without leaving any residue. Examples of these materials are polyester, polypropylene. One such thermoplastic polymer is a polypropylene which is supplied in the form of a monofilament by Glassmaster Inc., Lexington, S.C.
  • One suitable continuous fugitive material is polypropylene which can be in the form of fibers or screens. Fibers are supplied by Glassmaster, Lexington, S.C. Screens of various mesh sizes are supplied by Tetko, Inc. Briarcliff Manor, N.Y.
  • a body is produced having a honeycomb structure which is formed from an array of fibers or a screen of channel-forming material.
  • filler material can be contacted with the resin and channel-forming material.
  • the filler material can be pore-forming or support or combinations of the two types.
  • Pore-forming material is essentially the same as far as chemical composition as channel-forming material but the relative sizes and shapes of the two types vary. Material that will form flow thru-channels in a given size body is termed channel-forming for that body. Material that is not large enough in size to form channels in a given size body, but will form porosity is termed pore- forming material.
  • the pore-forming material is preferably non-wettable so that pores of clean and defined shape form on vaporization.
  • One material that is especially suited for use as pore-forming material in the practice of the present invention is finely powdered polymer fibers such as polyester flock supplied by International Filler Corp., North Tonawanda, N.Y., under the designation 31 PF. Flock is formed by grinding continuous fibers of thermoplastic material to very small size so that the material appears to be powdery. The fiber lengths in flock materials are typically less than about 150 micrometers.
  • non-fugitive or support is meant that the material is non-reactive, non-volatile, and remains essentially unchanged throughout the steps of the process and intact as part of the final product body, as opposed to fugitive or burnout materials.
  • the non-fugitive material serves as a support for the carbon and contributes to the strength of the body.
  • Some support materials are cordierite, eg., cordierite powder, clays, glass powders, alumino-silicate, sand, and combinations of these.
  • Some preferred support materials are cordierite, clays, glass powders, alumino- silicate and combinations of these. Especially preferred is cordierite powder because of its low cost when a casting process is used.
  • the support material can be in the form of a mat for especially good facility in shaping and to provide a closely knit or strong support for the resin and subsequently the carbon.
  • the mat is made preferably from short fibers but in some cases longer fibers can be used to attain a given configuration in the final product body. Also for forming mats, it is preferred that the fibers be about 1-50 and more preferably about 2-10 micrometers in diameter.
  • the mats are of low bulk density (high void volume) .
  • the void volume can vary from about 50% to about 98%. Preferred void volumes are about 75-95%.
  • the support mat be. capable of absorbing at least about three times its weight and more preferably at least about five times its weight in resin when contacted therewith.
  • One preferred support mat is of alumino-silicate fibers, especially in the form of short fibers, such as Fiberfax 970 fiber mat supplied by Carborundum Co., Niagara Falls, N.Y.
  • the resin is contacted with the channel-forming materials and with any fillers that are being used and the material is shaped into a green body.
  • green body is meant the shaped body before any curing of the resin.
  • the contacting can be done by any technique designed to bring the materials together and form into the desired shape, such as for example dipping the solid components as the screens and fibers into the resin in static or continuous processing. Conventional molding techniques are well suited for the purposes of the present invention.
  • the green body is heated to dry and cure the resin.
  • the drying is done to remove the liquid phases, eg., solvents, etc., therefrom.
  • the drying advances the resin to a non-tacky but still flexible state, commonly called the "B stage".
  • B stage a non-tacky but still flexible state
  • partial crosslinking in the resin takes place.
  • the drying conditions of temperature and time are chosen depending on the combination and amounts of resin and support material although typical drying temperatures are in the range of about 80°C-110°C. The drying conditions can be adjusted as necessary to achieve the "B" stage.
  • the solvent is removed by drying at about 80°C-85°C, and then at about 100°C-110°C for a total time of up to about 3 hours.
  • the drying time is about 1.5-2 hours at about 80°C-85°C and then about 20-30 minutes at about 100°C-110°C to obtain the flexible non-tacky state.
  • screens or mats both fugitive and non-fugitive are used or made, they can be further shaped if desired. For example the screens can then be cut, stacked, and the cut pieces pressed together to further shape the dried body, or they can be rolled, etc.
  • One technique is to form a wet mixture of all the components: resin, channel-forming material in the form of loose fibers, and optionally the fillers: pore-forming and/or support.
  • the mixture can then be shaped by introducing the components into a mold.
  • FIG. 9 shows a dried body (90) having a screen (92) such as of the type shown in Figures 7 or 8 in contact with resin (94) which has been dried to the B stage.
  • the dried resin and screen can be further shaped.
  • Figure 10 shows the further shaping of this dried body into a roll.
  • the resin can be mixed with a support material eg., cordierite powder, and this mix poured into a mold in which has been placed a structure of channel-forming material such as a screen. 4)
  • the support material can be pre-shaped and then contacted with the resin.
  • Channel-forming material can be pressed into the preshaped material.
  • resin can be contacted with a support mat eg., of alumino- silicate, and dried, after which channel-forming fibers are pressed into the resin-support mat.
  • Channel-forming material can be pre-shaped and then contacted with the resin.
  • Support material can be pressed into the preshaped material.
  • Channel-forming material in the form of a monofilament eg., made from a thermoplastic polymer as polypropylene can be pulled through a resin bath, eg., a phenolic resin bath to coat the monofilament with the resin.
  • a resin bath eg., a phenolic resin bath
  • filler material pore-forming and/or support material and/or solid resin can be included in the resin bath.
  • the resulting coated monofilament can optionally be passed through a die with a cylindrical hole to remove excess resin on the monofilament.
  • the coated monofilament is then wound onto a drum with a flat or round cross section. In this way, layers of the monofilament can be built up on the drum by continuous winding.
  • the winding operation is discontinued and the layers are taken off the drum and can be further shaped such as by pressing, into the shaped green body.
  • the green body dried and the resin cured. Alternately, the drying can be done on the drum. The dried form can then be further shaped if desired.
  • the support material if used, can be first impregnated with a catalyst which is known to accelerate the curing reaction, and then mixed with the resin. On pouring into the mold, the resin becomes rigid and a cured body can be formed.
  • a catalyst which is known to accelerate the curing reaction
  • the resin On pouring into the mold, the resin becomes rigid and a cured body can be formed.
  • An example of this process is the case of furan resin cured with catalysts such as ZnCl 2 , PTSA (para-toluene sulfonic acid) , citric acid, or some other catalyst.
  • the mold with the green body is heated to dry the green body and cure the resin.
  • the resin is then finally cured in the shaped form by heating under the specific temperature and time conditions required for the specific resin.
  • This can be found in the manufacturer's literature. For example, for phenolic resole 43290 from Occidental Chemical Co. the body is heated in air to about 140-155°C. The final temperature is attained slowly so that the body does not distort. For example, the body is first heated to about 90°C-100°C, then to about 120°C-130°C and held at this temperature for about 1-2 hours. It is then heated to about 140°C-155°C and held for about 30 minutes-2 hours for final cure.
  • Figure 4 shows a honeycomb body (40) shaped from a mixture of resin (42) and loose solid fibers or filaments (44) for example of the types shown in Figures 1 or 2.
  • the resulting cured resin shaped body is then carbonized and activated to convert the resin to activated carbon.
  • the carbonization also results in removal of the fugitive materials to form the respective shapes of channels and wall porosity.
  • the carbonization is carried out by heating the body in an inert or reducing atmosphere such as nitrogen or argon or forming gas.
  • Forming gas is a mixture of nitrogen and hydrogen. Typical mixtures by volume are 92:8 or 94:6 N 2 :H 2 , although any mixtures can be used.
  • Carbonization temperatures are about 600°C-1000°C or more typically about 700-1000°C for a length of time of usually about 1-20 hours. While the body is in the temperature range of about 300-600°C, the fugitive materials vaporize.
  • low molecular weight compounds separate out and carbon atoms form graphitic structures. For example for phenolic resole resin 43290 from Occidental Chemical Co.
  • carbonization is done by heating at a rate of about 150°C/hr in N 2 .
  • the temperature is held at about 900°C for about 6-10 hours to complete the carbonization.
  • the temperature is then reduced to 25°C at a cooling rate of about 150°C/hr.
  • the body contains random three dimensional oriented graphitic platelets with amorphous carbon between the platelets.
  • Figure 5 shows the honeycomb of Figure 4 after carbonization (50) .
  • the channel forming material has burned out to leave flow through channels (52) in the carbon structure (54) .
  • the carbon in the body is then activated by partially oxidizing in a suitable oxidant such as C0 2 , steam, air, or a combination of these, etc.
  • a suitable oxidant such as C0 2 , steam, air, or a combination of these, etc.
  • Activation can be carried out at temperatures between about 700°C-1000°C.
  • Activation conditions depend on type and amount of resin, flow rate of gas, etc. For example for phenolic resole and Furcab resins activation conditions are at about 900°C for about 1 hour in C0 2 at a flow rate of about 14.2 1/hr. (about 0.5 CFH (cubic feet per hour) ) .
  • the partial oxidation during activation causes the removal of the amorphous carbon and the formation of molecular size porosity between the graphitic platelets.
  • the activated carbon body of the present invention is a continuous carbon structure and thus is high in strength.
  • Continuous polypropylene fibers were introduced into liquid phenolic resole and the resulting mixture was then dried and cured at about 80°C for about 2 hours, about 100°C for about 1 hour, and about 150°C for about 30 minutes.
  • the compact solid was then carbonized at about 900°C for about 6 hours in nitrogen.
  • the compact was a honeycomb structure with continuous paths in place of the polypropylene fibers.
  • the carbon was then activated at about 900°C for about 1 hour in carbon dioxide.
  • the 1" (2.54 cm) diameter x 1" (2.54 cm) long honeycomb had a butane adsorption capacity of about 800 mg.
  • a mixture of phenolic resole resin 43290 from Occidental Chemical Co., a solid phenolic powder from the same company No. 7716, and polyester flock (finely powdered polymer fiber 31WPF from International Filler Corp), in the weight ratio of 77.4%, 15.5%, and 7.2% respectively was made and poured into a mold containing continuous polypropylene fibers.
  • the mold was then heated to about 80°C and dried and then slowly heated to about 125°C and held for about 1 hour and then heated in nitrogen to about 900°C and held at that temperature for about 6 hours.
  • both the polypropylene and the polyester fibers disintegrated and disappeared leaving holes behind.
  • a honeycomb shape with straight parallel channels was thus formed.
  • Example 4 A mixture of about 13.8% aluminosilicate Fiberfrax fiber from Carborundum Corp., about 14% Polyflock 31WPF from international Filler Corp., about 20.4% 7716, and about 51.8% 43290 phenolic resin from Occidental Chemical was poured into a mold containing polypropylene fiber of about 1 mm in diameter. The resin was cured at about 150°C as in Example 2 and carbonized and activated as before to obtain a carbon honeycomb structure the same size as that of example 1. The butane adsorption capacity of this body was about 525 mg.
  • Example 4 A mixture of about 13.8% aluminosilicate Fiberfrax fiber from Carborundum Corp., about 14% Polyflock 31WPF from international Filler Corp., about 20.4% 7716, and about 51.8% 43290 phenolic resin from Occidental Chemical was poured into a mold containing polypropylene fiber of about 1 mm in diameter. The resin was cured at about 150°C as in Example 2 and carbonized and
  • Fiberfrax 970 mat from Carborundum Co. was dipped in resin and then allowed to dry at about 80°C for about 2 hours and about 100°C for about 1 hour.
  • Polypropylene monofilaments as in Example 3 were then pressed into soft flexible mat and a preform was made by laying several mats together and pressing and heating to cure.
  • the preform was carbonized and activated to obtain a honeycomb structure the same size as in the previous examples with adsorption capacity of about 829 mg of butane.
  • a mixture of about 11% finely ground cordierite powder having an average particle size of about 10 micrometers in diameter, about 6% polyflock, about 13.6% 7716 resin and about 69.4% 43290 resin from Occidental Chemical was poured into a mold containing a 25 mesh polypropylene screen from Tetko Inc. The mold was heated to cure, carbonize, and activate the resin as in the previous examples.
  • the body having the same size as in the previous examples had a butane adsorption capacity of about 565 mg.
  • the examples show that carbon structures with parallel flow paths can be made with controlled adsorption capacities. Depending on the requirements for the product and the economic considerations, carbon structures produced can be made to have different adsorption capacities.

Abstract

Son décrit un corps en charbon actif (54) présentant des canaux de circulation (52), ainsi qu'un procédé de fabrication de ce corps. Ce procédé consiste à associer et façonner un matériau formant des canaux et un matériau porogène éventuellement volatil ainsi qu'un matériau de support non volatil et une résine réticulable pour obtenir un corps vert, et à durcir la résine. La température à laquelle le matériau formant des canaux commence à se déformer est supérieure à la température de durcissement de la résine. La résine est carbonisée et le matériau formant des canaux est simultanément vaporisé pour former un corps en carbone (54) possédant des canaux de circulation (52) présentant la configuration du matériau volatil. Ce corps en carbone (54) est ensuite activé. Entre autres formes, les canaux (52) peuvent être droits, incurvés ou entrecroisés.
PCT/US1995/007438 1994-04-15 1995-04-11 Corps alveolaires en charbon actif presentant des capacites d'adsorption variables et procede pour leur fabrication WO1995028279A1 (fr)

Priority Applications (6)

Application Number Priority Date Filing Date Title
MX9604865A MX9604865A (es) 1995-04-11 1995-04-11 Estructuras en forma de panal de carbon activado que tienen capacidades de adsorcion variables y metodo para hacer las mismas.
AU28248/95A AU2824895A (en) 1994-04-15 1995-04-11 Activated carbon honeycombs having varying adsorption capacities and method of making same
BR9507382A BR9507382A (pt) 1994-04-15 1995-04-11 Processo para fabricação de um corpo de carboso ativado tendo canais de fluxo direto e corpode carbono ativado assim obtido
KR1019960705783A KR970702153A (ko) 1994-04-15 1995-04-11 다양한 흡착능을 가진 활성화된 카본 벌집형 몸체 및 이를 제조하는 방법
EP95923816A EP0755328A4 (fr) 1994-04-15 1995-04-11 Corps alveolaires en charbon actif presentant des capacites d'adsorption variables et procede pour leur fabrication
JP7527195A JPH09511982A (ja) 1994-04-15 1995-04-11 吸着能力の変化する活性炭ハニカムおよびその製造方法

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US22826594A 1994-04-15 1994-04-15
US08/228,265 1994-04-15
CA002188222A CA2188222A1 (fr) 1994-04-15 1996-10-18 Alveoles au charbon active possedant des capacites variees d'adsorption et methode de fabrication de ces alveoles

Publications (2)

Publication Number Publication Date
WO1995028279A1 true WO1995028279A1 (fr) 1995-10-26
WO1995028279A9 WO1995028279A9 (fr) 1995-12-21

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US1995/007438 WO1995028279A1 (fr) 1994-04-15 1995-04-11 Corps alveolaires en charbon actif presentant des capacites d'adsorption variables et procede pour leur fabrication

Country Status (6)

Country Link
EP (1) EP0755328A4 (fr)
JP (1) JPH09511982A (fr)
AU (1) AU2824895A (fr)
BR (1) BR9507382A (fr)
CA (1) CA2188222A1 (fr)
WO (1) WO1995028279A1 (fr)

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WO2004021491A1 (fr) * 2002-08-27 2004-03-11 The Morgan Crucible Company Plc Plaques bipolaires a canaux de refroidissement
WO2007031876A2 (fr) * 2005-06-29 2007-03-22 Philip Morris Products S.A. Tubes monolithiques de carbone a gabarits comprenant des microcanaux façonnes et procede de fabrication de ces tubes
WO2008080028A2 (fr) 2006-12-25 2008-07-03 Carbon Ceramics Company, Llc Matériau de carbone vitreux et procédé de production associé
DE102005032345B4 (de) * 2004-07-23 2009-09-17 Helsa-Automotive Gmbh & Co. Kg Adsorptiver Formkörper mit anorganischer amorpher Stützstruktur, Verfahren zur Herstellung desselben sowie dessen Verwendung
US7759276B2 (en) 2004-07-23 2010-07-20 Helsa-Automotive Gmbh & Co. Kg Adsorptive formed body having an inorganic amorphous supporting structure, and process for the production thereof
FR2957276A1 (fr) * 2010-03-15 2011-09-16 Francois Parmentier Monolithe multicapillaire
WO2013064754A1 (fr) 2011-09-15 2013-05-10 Parmentier Francois Monolithe multicapillaire en silice amorphe et/ou en alumine activee
EP3081292A1 (fr) * 2015-04-15 2016-10-19 Air Products And Chemicals, Inc. Particules adsorbantes perforées
US9579628B2 (en) 2015-04-15 2017-02-28 Air Products And Chemicals, Inc. Perforated adsorbent particles
WO2022003307A1 (fr) * 2020-07-03 2022-01-06 Separative Procédé de fabrication d'un garnissage multicapillaire

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US8728218B2 (en) * 2011-09-15 2014-05-20 Corning Incorporated Sorbent substrates for CO2 capture and methods for forming the same
US20200254394A1 (en) * 2017-10-30 2020-08-13 Shinshu University Method for manufacturing molded filter body

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US4923843A (en) * 1986-09-25 1990-05-08 Aluminum Company Of America Peptized activated carbon/alumina composite
US5225081A (en) * 1989-09-07 1993-07-06 Exxon Research And Engineering Co. Method for removing polynuclear aromatics from used lubricating oils
US5213895A (en) * 1990-09-11 1993-05-25 Daiso Co., Ltd. Particle-bearing composite and a method for producing the same

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Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2004021491A1 (fr) * 2002-08-27 2004-03-11 The Morgan Crucible Company Plc Plaques bipolaires a canaux de refroidissement
DE102005032345B4 (de) * 2004-07-23 2009-09-17 Helsa-Automotive Gmbh & Co. Kg Adsorptiver Formkörper mit anorganischer amorpher Stützstruktur, Verfahren zur Herstellung desselben sowie dessen Verwendung
US7759276B2 (en) 2004-07-23 2010-07-20 Helsa-Automotive Gmbh & Co. Kg Adsorptive formed body having an inorganic amorphous supporting structure, and process for the production thereof
US7767134B2 (en) 2005-06-29 2010-08-03 Philip Morris Usa Inc. Templated carbon monolithic tubes with shaped micro-channels and method for making the same
KR101334430B1 (ko) * 2005-06-29 2013-11-29 필립모리스 프로덕츠 에스.에이. 형상화된 미세-채널을 가지는 주형을 이용한 탄소 일체형튜브 및 그것의 제조방법
WO2007031876A2 (fr) * 2005-06-29 2007-03-22 Philip Morris Products S.A. Tubes monolithiques de carbone a gabarits comprenant des microcanaux façonnes et procede de fabrication de ces tubes
EA013275B1 (ru) * 2005-06-29 2010-04-30 Филип Моррис Продактс С.А. Шаблонные угольные монолитные трубки с формованными микроканалами и способ их изготовления
WO2007031876A3 (fr) * 2005-06-29 2007-07-26 Philip Morris Prod Tubes monolithiques de carbone a gabarits comprenant des microcanaux façonnes et procede de fabrication de ces tubes
WO2008080028A2 (fr) 2006-12-25 2008-07-03 Carbon Ceramics Company, Llc Matériau de carbone vitreux et procédé de production associé
EP2094607A2 (fr) * 2006-12-25 2009-09-02 Carbon Ceramics Company, LLC Matériau de carbone vitreux et procédé de production associé
EP2094607A4 (fr) * 2006-12-25 2013-12-25 Carbon Ceramics Company Llc Matériau de carbone vitreux et procédé de production associé
US10137431B2 (en) 2010-03-15 2018-11-27 Francois Parmentier Multicapillary Monolith
FR2957276A1 (fr) * 2010-03-15 2011-09-16 Francois Parmentier Monolithe multicapillaire
WO2011114017A3 (fr) * 2010-03-15 2011-11-17 Parmentier Francois Monolithe multicapillaire
EP2547440A2 (fr) * 2010-03-15 2013-01-23 François Parmentier Monolithe multicapillaire
US9314769B2 (en) 2010-03-15 2016-04-19 Francois Parmentier Multicapillary monolith
EP2547440B1 (fr) * 2010-03-15 2022-09-14 François Parmentier Monolithe multicapillaire
WO2013064754A1 (fr) 2011-09-15 2013-05-10 Parmentier Francois Monolithe multicapillaire en silice amorphe et/ou en alumine activee
US10981147B2 (en) 2011-09-15 2021-04-20 Francois Parmentier Multi-capillary monolith made from amorphous silica and/or activated alumina
US9579628B2 (en) 2015-04-15 2017-02-28 Air Products And Chemicals, Inc. Perforated adsorbent particles
EP3081293A3 (fr) * 2015-04-15 2016-11-16 Air Products And Chemicals, Inc. Particules adsorbantes perforées
EP3081292A1 (fr) * 2015-04-15 2016-10-19 Air Products And Chemicals, Inc. Particules adsorbantes perforées
WO2022003307A1 (fr) * 2020-07-03 2022-01-06 Separative Procédé de fabrication d'un garnissage multicapillaire
FR3112083A1 (fr) * 2020-07-03 2022-01-07 François PARMENTIER Procédé de fabrication d’un garnissage multicapillaire

Also Published As

Publication number Publication date
AU2824895A (en) 1995-11-10
BR9507382A (pt) 1997-09-23
JPH09511982A (ja) 1997-12-02
EP0755328A4 (fr) 1997-11-12
CA2188222A1 (fr) 1998-04-18
EP0755328A1 (fr) 1997-01-29

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