Sorbent-loaded fibers for high temperature adsorption processes

Patent metadata

Field	Value
Publication number	US-10525399-B2
Application number	US-201715858807-A
Country	US
Kind code	B2
Filing date	Dec 29, 2017
Priority date	Apr 17, 2017
Publication date	Jan 7, 2020
Grant date	Jan 7, 2020

Abstract

A composite fiber comprising sorbent particles (at 50 wt %) in a polymeric matrix that comprises a polymer or blend of polymers including at least one thermoplastic polymer, the extrudates being produced by thermal-induced phase separation or diffusion-induced phase separation from a dope suspension of the thermoplastic polymer, an optional solvent and the sorbent particles. The polymer or blend of polymers is able to withstand exposure to temperatures at or above 220° C. without experiencing significant detrimental effects upon the sorbent capacity of the sorbent particles. The fiber exhibits an elongation at break of at least 5%.

First claim

What is claimed is:

1. Composite fiber for sorbent-based fluid separations each of which comprises sorbent particles in a polymeric matrix, wherein:
the polymeric matrix comprises a polymeric binder or blend of polymeric binders;
the polymeric binder or blend of polymeric binders comprises at least one thermoplastic polymer;
the polymeric binder or blend of polymeric binders is able to withstand exposure to temperatures at or above 220° C. without significant detrimental effect upon the sorbent capacity of the sorbent particles;
the fiber exhibits an elongation at break of at least 5% (preferably of at least 7% more preferably of at least 10% and even more preferably of at least 15%);
said fiber having been produced by temperature-induced phase separation (TIPS) or diffusion-induced phase inversion (DIPS) from a polymer dope suspension that comprises the thermoplastic polymer, optionally dissolved in a solvent in the case of DIPS, and the sorbent particles either suspended in the solvent in the case of DIPS or suspended in thermoplastic polymer while in the molten state in the case of TIPS;
the sorbent is an adsorbent or absorbent; and
the sorbent particles are present in the extrudates at a concentration of at least 50 wt %.

2. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a Vicat softening temperature or a heat deflection temperature of at least 220° C.

3. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a Vicat softening temperature or a heat deflection temperature of at least 240° C.

4. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a Vicat softening temperature or a heat deflection temperature of at least 250° C.

5. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a Vicat softening temperature or a heat deflection temperature of at least 270° C.

6. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a Vicat softening temperature or a heat deflection temperature of at least 300° C.

7. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a Vicat softening temperature or a heat deflection temperature of at least 330° C.

8. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a Vicat softening temperature or a heat deflection temperature of at least 360° C.

9. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a Vicat softening temperature or a heat deflection temperature of at least 400° C.

10. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 220° C.

11. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 240° C.

12. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 250° C.

13. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 260° C.

14. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 270° C.

15. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 300° C.

16. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 330° C.

17. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 360° C.

18. The fiber of claim 1 , wherein the polymeric binder or blend of polymeric binders has a glass transition temperature(s) of at least 400° C.

19. The fiber of claim 1 , wherein the adsorbent is selected from the group consisting of zeolite, activated carbon, carbon molecular sieve, activated alumina, silica gel, metalorganic frameworks, and amines in solid form.

20. The fiber of claim 1 , wherein the thermoplastic polymer is selected from the group consisting of polyetherimides, polyimides, polyamides, polyamide-imides, polyaramids, ladder-type polymers, polybenzimidazole (PBI), polybenzoxazole (PBO), and polybenzothiazole (PBT).

21. The fiber of claim 1 , wherein the thermoplastic polymer is selected from the group consisting of polybenzimidazole, polybenzoxazole, and polybenzothiazole.

22. The fiber of claim 1 , wherein the polymer dope suspension further comprises one or more types of cross-linking agents, and after formation by diffusion-induced phase separation, the polymeric matrix is caused to be cross-linked with the cross-linking agent(s).

23. The fiber of claim 1 , wherein after formation by diffusion-induced phase separation, the fiber are impregnated with one or more types of cross-linking agents and the polymeric matrix is caused to be cross-linked with the cross-linking agent(s).

24. The fiber of claim 1 , wherein the polymer dope suspension further comprises one or more polymers insoluble in the solvent.

25. The fiber of claim 24 , wherein the soluble thermoplastic polymer and the insoluble polymer(s) have a same molecular formula but the insoluble polymer(s) has a higher molecular weight or degree of crystallinity.

26. The fiber of claim 1 , further comprising one or more inorganic fillers incorporated in the polymeric matrix.

27. The fiber of claim 26 , wherein the one or more inorganic fillers are selected from carbon fibers and glass fibers.

28. The fiber of claim 1 , wherein the polymeric matrix includes a one or more polyaramids and derivatives thereof.

29. The fiber of claim 1 , wherein the polymeric matrix includes a one or more polyaramids selected from MPD-I, MPD-IT, DAM-IT, and derivatives thereof.

30. A method for activation of the fiber of claim 1 , comprising the step of heating the fiber to a predetermined activation temperature of the sorbent.

31. The method of claim 30 , wherein the predetermined activation temperature is at least 220 C.

32. The method of claim 30 , wherein the predetermined activation temperature is at least 240 C.

33. The method of claim 30 , wherein the predetermined activation temperature is at least 250 C.

34. The method of claim 30 , wherein the predetermined activation temperature is at least 270 C.

35. An adsorbent bed for adsorption-based fluid separations comprising one or more of the fiber activated by the method of claim 30 .

36. Method for adsorption-based gas separation, comprising the step of separating a feed gas, including at least first and second gases, with one or more of the adsorbent beds of claim 35 to produce a first stream of gas that is enriched in the first gas in comparison to the feed gas and a second stream of gas that is enriched in the second gas in comparison to the feed gas, wherein the feed gas is separated by said one or more adsorbent beds by pressure swing adsorption, pressure-temperature swing adsorption, temperature swing adsorption, vacuum swing adsorption, vacuum-pressure swing adsorption, or electro swing

Assignees

• Air Liquide
• Air Liquide Advanced Tech Us Llc

Inventors

• Coignet Philippe A
• Kratzer Dean W
• Kulkarni Sudhir S
• Sanders Jr Edgar S

Classifications

• B01D2253/204

  Metal organic frameworks (MOF's) · CPC title

• B01D2253/34

  Specific shapes · CPC title

• B01D2253/116

  Molecular sieves other than zeolites · CPC title

• B01D2256/10

  Nitrogen · CPC title

• B01D2257/104

  Oxygen · CPC title