Porous bodies with enhanced pore architecture

Patent metadata

Field	Value
Publication number	US-10751699-B2
Application number	US-201916725418-A
Country	US
Kind code	B2
Filing date	Dec 23, 2019
Priority date	Jun 2, 2015
Publication date	Aug 25, 2020
Grant date	Aug 25, 2020

Abstract

A porous body is provided with enhanced fluid transport properties that is capable of performing or facilitating separations, or performing reactions and/or providing areas for such separations or reactions to take place. The porous body includes at least 80 percent alpha alumina and has a pore volume from 0.3 mL/g to 1.2 mL/g and a surface area from 0.3 m 2 /g to 3.0 m 2 /g. The porous body further includes a pore architecture that provides at least one of a tortuosity of 7.0 or less, a constriction of 4.0 or less and a permeability of 30 mdarcys or greater. The porous body can be used in a wide variety of applications such as, for example, as a filter, as a membrane or as a catalyst carrier.

First claim

What is claimed is:

1. A method for producing a porous body, the method comprising:
providing a precursor mixture comprising (i) milled alpha alumina powder having a particle size of 0.1 to 6 microns, (ii) a non-silicate binder, and (iii) a principle burnout material having a particle size of 1-10 microns;
forming a predetermined shape; and
subjecting the shape to a heat treatment step in which the shape is sintered to produce the porous body.

2. The method of claim 1 , wherein the porous body comprises at least 80 percent alpha alumina and having a pore volume from 0.3 mL/g to 1.2 mL/g, a surface area from 0.3 m 2 /g to 3.0 m 2 /g, and a pore architecture that provides at least one of a tortuosity of 7 or less, a constriction of 4 or less and a permeability of 30 mdarcys or greater.

3. The method of claim 1 , wherein the providing the precursor mixture comprises providing a homogeneous mixture of the milled alpha alumina powder, the non-silicate binder, and the principle burnout material.

4. The method of claim 1 , wherein the principle burnout material is a granulated polyolefin.

5. The method of claim 4 , wherein the granulated polyolefin is one of polyethylene and polypropylene.

6. The method of claim 1 , wherein the precursor mixture further comprises at least one of an unmilled alpha alumina powder and an auxiliary burnout material.

Assignees

• Scient Design Co

Inventors

• Suchanek Wojciech L

Classifications

• B01J35/56

  Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional [3D] monoliths · CPC title

• B01J23/04 Primary

  Alkali metals · CPC title

• Y02P20/52

  using catalysts, e.g. selective catalysts · CPC title

• C07D301/22

  by oxidation of saturated compounds with air or molecular oxygen (of mixtures of unsaturated and saturated compounds C07D301/04) · CPC title

• C04B41/88

  Metals · CPC title