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

Patent metadata

Field	Value
Publication number	US-2016175815-A1
Application number	US-201514953648-A
Country	US
Kind code	A1
Filing date	Nov 30, 2015
Priority date	Dec 23, 2014
Publication date	Jun 23, 2016
Grant date	—

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 cpsi; and a coating on the substrate, 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 have an axis ratio of at least 1.2.

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

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

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

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

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

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

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

12 . The structured adsorbent bed of claim 1 , wherein the binder comprises SiO 2 .

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

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

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

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

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

18 . The structured adsorbent bed of claim 1 , wherein the substrate is a porous solid selected from the group consisting of a metal oxide, a mixed-metal oxide, a ceramic and a zeolite.

19 . The structured adsorbent bed of claim 18 , wherein the substrate has a porosity of about 6% or less.

20 . The structured adsorbent bed of claim 1 , wherein the substrate is a non-porous solid selected from the group consisting of a metal, a glass and a plastic.

21 . The structured adsorbent bed of claim 20 , wherein the metal is stainless steel.

22 . The structured adsorbent bed of claim 1 further comprising a zirconium-containing layer on the substrate.

23 . A method of preparing the structured adsorbent bed of claim 1 , the method comprising:
pretreating the substrate; preparing an aqueous slurry comprising the adsorbent particles and the binder; and applying the aqueous slurry to the substrate to form the coating on the substrate.

24 . The method of claim 23 , wherein pretreating the substrate comprises: (i) applying the zirconium-containing layer to the substrate; or (ii) heating the substrate and applying the zirconium-containing layer to the substrate.

25 . The method of claim 24 , wherein (ii) heating the substrate is performed at about 600° C. to about 1100° C.

26 . The method of claim 24 , wherein the zirconium-containing layer comprises zirconium oxide, zirconium silicate or a combination thereof.

27 . The method of claim 23 , wherein the binder is SiO 2 .

28 . The method of claim 23 , wherein the weight ratio of the adsorbent particles to the binder is from about 70:30 w/w to about 90:10 w/w.

29 . The method of claim 23 , further comprising:
removing excess coating from the coated substrate; drying the coated substrate; and heating the coated substrate.

30 . The method of claim 29 , 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.

31 . The method of claim 29 , 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.

32 . The method of claim 23 , wherein the coating has about 10% to about 40% macroporosity.

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

34 . The process of claim 33 , wherein the gas mixture comprises CH 4 .

35 . The process of claim 33 , wherein the at least one contaminant is selected from the group consisting CO 2 , H 2 O, H 2 S, NO x and SO x .

36 . The gas separation process of claim 33 , 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 Res & Eng Co

Inventors

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

Classifications

• B01J20/3042

  Use of binding agents; addition of materials ameliorating the mechanical properties of the produced sorbent · CPC title

• B01J20/103

  comprising silica · CPC title

• B01J20/183

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

• B01J20/28004

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

• B01J20/3204

  Inorganic carriers, supports or substrates · CPC title