Structured adsorbent beds, methods of producing the same and uses thereof

Patent metadata

Field	Value
Publication number	US-10512893-B2
Application number	US-201715661562-A
Country	US
Kind code	B2
Filing date	Jul 27, 2017
Priority date	Dec 23, 2014
Publication date	Dec 24, 2019
Grant date	Dec 24, 2019

Abstract

Structured adsorbent beds comprising a high cell density substrate, such as greater than about 1040 cpsi, and a coating comprising adsorbent particles, such as DDR and a binder, such as SiO 2 are provided herein. Methods of preparing the structured adsorbent bed and gas separation processes using the structured adsorbent bed are also provided herein.

First claim

What is claimed is:

1. A structured adsorbent bed for purification of a gas feedstream comprising:
a substrate having a cell density greater than 1040 cells per square inch (cpsi), wherein the substrate is a non-porous solid selected from a metal;
a metal oxide layer that has been formed on the surface of the substrate by heating the substrate to a temperature from about 900° C. to about 1050° C.;
a primer layer on the metal oxide layer, wherein the primer layer is a zirconium-containing layer; and
a coating on the zirconium-containing layer, wherein the coating comprises adsorbent particles and a binder.

2. The structured adsorbent bed of claim 1 , wherein the adsorbent particles have an average diameter of about 2 μm to about 40 μm.

3. The structured adsorbent bed of claim 1 , wherein the adsorbent particles have an average diameter greater than about 20 μm.

4. The structured adsorbent bed of claim 1 , wherein the adsorbent particles comprise a microporous material.

5. The structured adsorbent bed of claim 4 , wherein the microporous material comprises a zeolite.

6. The structured adsorbent bed of claim 5 , wherein the zeolite is DDR.

7. The structure adsorbent bed of claim 6 , wherein the zeolite is selected from the group consisting of Sigma-1 and ZSM-58.

8. The structured adsorbent bed of claim 1 , wherein the binder comprises particles having an average diameter of about 25 nm to about 200 nm.

9. The structured adsorbent bed of claim 1 , wherein the binder comprises particles having an average diameter of about 100 nm to about 200 nm.

10. The structured adsorbent bed of claim 1 , wherein the binder has a pH greater than 7.

11. The structured adsorbent bed of claim 1 , wherein the binder comprises SiO2.

12. The structured adsorbent bed of claim 1 , wherein the substrate has a cell density of about 1500 cpsi to about 4000 cpsi.

13. The structured adsorbent bed of claim 1 , wherein the substrate has a cell density of about 1400 cpsi or greater.

14. The structured adsorbent bed of claim 1 , wherein the coating on the substrate has a thickness of about 30 μm to about 200 μm.

15. The structured adsorbent bed of claim 1 , wherein the coating on the substrate has a thickness of at least 100 μm or greater.

16. The structured adsorbent bed of claim 1 , wherein the coating comprises one or more layers of adsorbent particles and binder particles.

17. The structured adsorbent bed of claim 1 , wherein the metal is stainless steel.

18. A method of preparing the structured adsorbent bed of claim 1 , the method comprising:
pretreating the substrate wherein the substrate is a non-porous solid selected from a metal by heating the substrate to a temperature from about 900° C. to about 1050° C., thereby forming a metal oxide layer;
applying a primer layer onto the metal oxide layer, wherein the primer layer is a zirconium-containing layer;
preparing an aqueous slurry comprising the adsorbent particles and the binder; and
applying the aqueous slurry to the zirconium-containing layer to form the coating on the zirconium-containing layer.

19. The method of claim 18 , wherein the zirconium-containing layer comprises zirconium oxide, zirconium silicate or a combination thereof.

20. The method of claim 18 , wherein the binder is SiO2.

21. The method of claim 18 , wherein the weight ratio of the adsorbent particles to the binder is from about 70:30 w/w to about 90:10 w/w.

22. The method of claim 18 , further comprising:
removing excess coating from the coated substrate;
drying the coated substrate; and
heating the coated substrate.

23. The method of claim 22 , wherein the excess coating is removed from the substrate by flowing a gas through the coated substrate at a rate equal to or greater than 100 L/min.

24. The method of claim 22 , wherein drying the coated substrate comprises flash drying the coated substrate wherein a gas purge heated from about 50° C. to about 60° C. is flowed through the coated substrate at rate of at least about 100 L/min.

25. The method of claim 18 , wherein the coating has about 10% to about 40% macroporosity.

26. A gas separation process comprising contacting a gas mixture containing at least one contaminant with the structured adsorbent bed of claim 1 .

27. The process of claim 26 , wherein the gas mixture comprises CH4.

28. The process of claim 26 , wherein the at least one contaminant is selected from the group consisting CO2, H2O, H2S, NOx and SOx.

29. The gas separation process of claim 26 , wherein the process comprises PSA, TSA, PPSA, PTSA, RCPSA, RCTSA, RCPPSA or RCPTSA.

Assignees

• Brody John F
• Leta Daniel P
• Fowler Tracy Alan
• Freeman Stephanie A
• Cutler Joshua I
• Exxonmobil Upstream Res Co

Inventors

• Brody John F
• Leta Daniel P
• Fowler Tracy Alan
• Freeman Stephanie A
• Cutler Joshua I

Classifications

• B01D2253/25

  Coated, impregnated or composite adsorbents · CPC title

• B01J20/183

  Physical conditioning without chemical treatment, e.g. drying, granulating, coating, irradiation · CPC title

• B01J20/103

  comprising silica · CPC title

• B01J20/28004

  Sorbent size or size distribution, e.g. particle size · CPC title

• B01J20/3238

  containing any type of zeolite · CPC title