Non-extruded activated carbon honeycomb structures

Patent metadata

Field	Value
Publication number	US-10046264-B2
Application number	US-201514870992-A
Country	US
Kind code	B2
Filing date	Sep 30, 2015
Priority date	Oct 6, 2014
Publication date	Aug 14, 2018
Grant date	Aug 14, 2018

Abstract

A non-extruded filter article, including:
an activated carbon honeycomb substrate having a plurality of flow-through channels and porous walls, and the activated carbon substrate comprises a carbon in from 90 to 99.9 wt. % of the article, and the porous walls have a percentage porosity of from 40% to 65%. Also disclosed is a non-extrusion method of making the article and a method of using the article.

First claim

What is claimed is:

1. A non-extruded filter article, comprising an activated carbon honeycomb substrate having a plurality of flow-through channels and porous walls, wherein:
the activated carbon honeycomb substrate comprises from 95 to 99.9 wt % of activated carbon, and
the porous walls have a porosity ranging from 40% to 65%.

2. The article of claim 1 , wherein the activated carbon honeycomb substrate further comprises at least one performance enhancing additive selected from a zero valent iron nanoparticle, activated alumina, a cerium oxide, or combinations thereof.

3. The article of claim 1 , wherein the porosity of the porous walls ranges from 43% to 60%.

4. The article of claim 1 , wherein the flow-through channels are in a parallel relation, are in a monolith structure, are in a roll structure, or combinations thereof.

5. The article of claim 1 , wherein the flow-through channels have an end face geometry comprising a “U” shape, an “S” shape, a sine wave shape, a square, a triangle, a hexagon, an ellipse, a rectangle, or combinations thereof.

6. A method of making the article of claim 1 , comprising: contacting a shaped cellulosic substrate and an activating agent to form a treated substrate, wherein the shaped cellulosic substrate has porous walls and a plurality of flow-through channels; heating the treated substrate to from 500.degree. C. to 850.degree. C. in an inert atmosphere to form the carbon substrate; and removing at least some of the activating agent from the carbon substrate to form the article.

7. The method of claim 6 , further comprising contacting the outer surface of the shaped cellulosic substrate with a binder prior to heating the treated substrate.

8. The method of claim 6 , further comprising contacting the substrate with a carbon source material prior to heating the treated substrate.

9. The method of claim 8 , wherein the carbon source material is selected from at least one of: a phenolic resin, a cellulose powder, an activated carbon, a charcoal, a coal-based material, an organic char, or combinations thereof.

10. The method of claim 6 , further comprising contacting the treated substrate with a zero valent iron nanoparticle, a gamma-alumina, a ceria oxide, or combinations thereof.

11. The method of claim 6 , wherein removing at least some of the activating agent removes from 90 wt. % to 99.9 wt. % of the activating agent, and the cellulosic substrate is from 90 to 99.9 vol % paper.

12. The method of claim 6 , wherein removing at least some of the activating agent is accomplished by washing the carbon substrate with an acid.

13. The method of claim 6 , wherein the activating agent is selected from at least one of an alkali metal, a transition metal salt, or combinations thereof.

14. The method of claim 6 , wherein the activating agent is selected from at least one of KOH, NaOH, K 2 CO 3 , ZnCl 2 , and combinations thereof.

15. The method of claim 8 , wherein the organic char material is selected from at least one of: a wheat flour, a coconut shell, a pecan flour, a cherry pit flour, a rice hull, sawdust, or combinations thereof.

16. The method of claim 6 , wherein heating the treated substrate is accomplished in from 2 to 10 hours.

17. The method of claim 6 , further comprising coating a thermoset polymer on the exterior of cellulosic substrate prior to contacting with a carbon source material or an activating agent, the thermoset polymer being selected from at least one of: a phenolic resin, an aromatic polyamide, a urea, a polyimide, a melamine resin, an epoxide, a carboxymethyl cellulose, or combinations thereof.

18. A method of using the article of claim 1 , comprising: contacting the carbon honeycomb filter and a fluid having a contaminant.

19. The method of claim 18 , wherein the fluid is a liquid, a gas, a suspension, a solution, or combinations thereof; the contaminant is selected from the group consisting of a heavy metal, a volatile organic compound, and combinations thereof.

20. The method of claim 19 , wherein the heavy metal is at least one of: arsenic, cadmium, chromium, copper, selenium, lead, mercury, or combinations thereof, and the volatile organic compound is at least one of: benzene, formaldehyde, methylene chloride, perchloroethylene, or combinations thereof.

Assignees

• Corning Inc

Inventors

• House Keith Leonard
• Johnson Benedict Yorke

Classifications

• B01D2253/3425

  Honeycomb shape · CPC title

• B01D2257/102

  Nitrogen · CPC title

• B01D2257/7027

  Aromatic hydrocarbons · CPC title

• B01D53/02

  by adsorption, e.g. preparative gas chromatography {(solid sorbent compositions B01J20/00, preparation of inorganic compounds or elements C01)} · CPC title

• B01J20/3231

  characterised by the coating or impregnating layer · CPC title