Porous material and method for preparing the same

Patent metadata

Field	Value
Publication number	US-11767271-B2
Application number	US-202017026471-A
Country	US
Kind code	B2
Filing date	Sep 21, 2020
Priority date	Jan 17, 2020
Publication date	Sep 26, 2023
Grant date	Sep 26, 2023

Abstract

A porous material including a composite oxide body containing calcium oxide, iron oxide, and silica, and a plurality of inter-connecting microchannel structures is provided. A preparing method of porous material is further provided. With the inter-connecting microchannel structures of the porous material and the advantages of high porosity and large specific surface area, the porous material has a bright prospect in the fields of catalysts, filters, adsorption materials, and fuel carriers.

First claim

What is claimed is:

1. A porous material, comprising:
a composite oxide body comprising calcium oxide, iron oxide and silica; and
a plurality of microchannel structures formed in the composite oxide body and extending to a surface of the composite oxide body, wherein each of the microchannel structures comprises main channels and branched channels extending from the main channels in a lateral direction and connecting thereto, wherein the main channels have an average channel diameter larger than those of the branched channels.

2. The porous material of claim 1 , wherein the main channels have an average channel diameter between 1 micron and 20 microns, and the branched channels have an average channel diameter between 50 nm and 150 nm.

3. The porous material of claim 1 , wherein the main channels have an aspect ratio of from 3 to 20.

4. The porous material of claim 1 , wherein the main channels have an average depth of from 20 microns to 250 microns.

5. The porous material of claim 1 , which has a porosity between 40% and 80%.

6. The porous material of claim 1 , wherein the composite oxide body further comprises an iron alloy, and the iron alloy further comprises at least one element selected from the group consisting of calcium, silicon, magnesium, aluminum, titanium, carbon, sulfur, potassium, sodium and manganese.

7. The porous material of claim 6 , wherein the iron alloy is an iron-silicon alloy.

8. The porous material of claim 1 , wherein the calcium oxide is from 30 wt % to 50 wt %, the iron oxide is from 10 wt % to 35 wt %, and the silica is from 5 wt % to 20 wt %, on a basis of a total weight of the porous material.

9. The porous material of claim 1 , wherein the composite oxide body further comprises at least one metal oxide selected from the group consisting of alumina, magnesium oxide, titanium oxide, and manganese oxide.

10. The porous material of claim 9 , wherein the magnesium oxide is from 2 wt % to 10 wt %, the alumina is from 2 wt % to 10 wt %, the titanium oxide is from 0.1 wt % to 5 wt %, and the manganese oxide is from 1 wt % to 5 wt %, on a basis of a total weight of the porous material.

11. The porous material of claim 1 , wherein a weight ratio of the calcium oxide to the iron oxide is from 3:1 to 1:1, and a weight ratio of the calcium oxide to the silica is from 5:1 to 3:1.

12. A method for preparing a porous material of claim 1 , comprising:
performing a pore-forming process for at least once, the pore-forming process comprising a reduction reaction on composite oxide powder comprising calcium oxide, iron oxide and silica at a temperature of 1,000° C. or below 1,000° C., wherein the reduction reaction is carried out by contacting the composite oxide powder with a reducing gas stream to form the porous material.

13. The method of claim 12 , wherein the composite oxide powder is an industrial byproduct.

14. The method of claim 13 , wherein the industrial byproduct is blast-furnace slag, basic-oxygen-furnace slag, electric-arc-furnace slag, or a combination thereof.

15. The method of claim 12 , wherein the reducing gas stream has a reducing gas selected from hydrogen gas, methane, ethane, propane, carbon monoxide, or a combination thereof.

16. The method of claim 12 , wherein the reduction reaction is performed at a temperature of 400° C. to 1,000° C. for 0.3 hours to 24 hours.

17. The method of claim 12 , wherein the pore-forming process further comprises subjecting the composite oxide powder to an oxidation reaction before or after the reduction reaction, and the oxidation reaction is carried out by contacting the composite oxide powder with an oxidizing gas stream.

18. The method of claim 17 , wherein the oxidizing gas stream has a gas hourly space velocity of 1 hr −1 to 3,200 hr −1 , and the reducing gas stream has a gas hourly space velocity of 1 hr −1 to 800 hr −1 .

19. The method of claim 17 , wherein the oxidation reaction is performed at a temperature of 400° C. to 1,000° C. for 0.3 hours to 24 hours.

20. The method of claim 17 , further comprising repeating a pore-forming process cycle of the oxidation reaction and the reduction reaction, wherein a number of the pore-forming process cycle is not beyond five.

Assignees

• Ind Tech Res Inst

Inventors

• Chang Ming-Hui
• Yu sheng-min
• Lee Hsiu-Hsia
• Hsu Chien-Chung

Classifications

• C04B38/0032 Primary

  one of the precursor materials being a monolithic element having approximately the same dimensions as the final article, e.g. a paper sheet which after carbonisation will react with silicon to form a porous silicon carbide porous body · CPC title

• C04B38/0009

  characterised by features relating to the cell walls, e.g. wall thickness or distribution of pores in the walls · CPC title

• C04B38/0054

  the pores being microsized or nanosized · CPC title

• C21B3/04

  Recovery of by-products, e.g. slag · CPC title

• C04B38/0025 Primary

  starting from inorganic materials only, e.g. metal foam; Lanxide type products · CPC title