Porous ceramic supports for resistively heated hybrid gas sorbents

Patent metadata

Field	Value
Publication number	US-2022401917-A1
Application number	US-202117349574-A
Country	US
Kind code	A1
Filing date	Jun 16, 2021
Priority date	Jun 16, 2021
Publication date	Dec 22, 2022
Grant date	—

Abstract

A porous sorbent ceramic product includes a three-dimensional structure having an electrically conductive ceramic material, wherein the conductive ceramic material has an open cell structure with a plurality of intra-material pores, a sorbent additive primarily present in the intra-material pores of the conductive ceramic material for adsorption of a gas, and at least two electrodes in electrical communication with the conductive ceramic material.

First claim

What is claimed is:

1 . A porous sorbent ceramic product comprising:
a three-dimensional structure comprising an electrically conductive ceramic material, wherein the conductive ceramic material has an open cell structure with a plurality of intra-material pores; a sorbent additive primarily present in the intra-material pores of the conductive ceramic material for adsorption of a gas; and at least two electrodes in electrical communication with the conductive ceramic material.

2 . The product as recited in claim 1 , wherein the three-dimensional structure is characterized as exhibiting sufficient joule heating upon application of an electrical current thereto to drive adsorbed gas from the sorbent additive.

3 . The product as recited in claim 1 , comprising a plurality of inter-material pores, wherein an average diameter of the inter-material pores is in a range of about 100 microns to about 1 millimeter.

4 . The product as recited in claim 1 , wherein an average diameter of the intra-material pores is in a range of greater than 0 nanometers to less than 10 microns.

5 . The product as recited in claim 1 , wherein the conductive ceramic material has at least one physical property selected from the group of physical properties consisting of: a thermal conductivity of the ceramic material is in a range of greater than 1 to about 100 W/mK, an electrical conductivity of the ceramic material is in a range of greater than 1 to about 1000 reciprocal ohm per centimeter, and a surface area of the three-dimensional structure is in a range of greater than 1 to about 500 m 2 /g.

6 . The product as recited in claim 1 , wherein the sorbent additive is present in a range of greater than 20 weight percent to less than 70 weight percent of a combined weight of the sorbent additive and ceramic material.

7 . The product as recited in claim 1 , the sorbent additive is selected from the group consisting of: an organic molecule, an oligomer, a polymer, an aromatic polymer, a non-aromatic polymer, and a co-polymer.

8 . The product as recited in claim 1 , wherein the sorbent additive is selected from the group consisting of: an amine-containing sorbent additive, a hydroxyl-containing sorbent additive, a carbonate-containing sorbent additive, a phosphate containing sorbent additive, and a combination thereof.

9 . The product as recited in claim 8 , the sorbent additive being the amine-containing sorbent additive comprising: a structure selected from the group consisting of: a branched structure, a linear structure, and a dendritic structure; and a molecular weight in a range of 10 2 to 10 5 daltons.

10 . The product as recited in claim 9 , wherein the amine-containing sorbent additive is selected from the group consisting of: poly(alkylamine), poly(ethylenimine), poly(propylenimine), poly(vinylamine), poly(allylamine), and a combination thereof.

11 . The product as recited in claim 1 , wherein the conductive ceramic material includes at least one material selected from the group consisting of: a metal carbide, a metalloid carbide, a metal boride, a metalloid boride, a metal oxide, a metalloid oxide, a metal nitride, a metalloid nitride, a metal silicide, and a combination thereof.

12 . The product as recited in claim 1 , wherein the three-dimensional structure has a pre-defined geometric arrangement of features comprising:
a plurality of filaments comprising the conductive ceramic material having the intra-material pores, and, a plurality of inter-material pores defined between adjacent filaments, wherein the inter-material pores form continuous channels from one side of the structure to the other side of the structure.

13 . A method of forming a product for separating gases, the method comprising:
forming a three-dimensional ceramic support, wherein the three-dimensional ceramic support comprises an electrically conductive ceramic material configured for joule heating, heating the three-dimensional ceramic support at a temperature for an effective duration of time to result in the conductive ceramic material having a plurality of intra-material pores; and incorporating a sorbent additive into the intra-material pores of the conductive ceramic material.

14 . The method as recited in claim 13 , wherein the electrically conductive ceramic material has a porosity in a range of 25% to 70%.

15 . The method as recited in claim 13 , wherein forming the three-dimensional ceramic support includes using at least in part an additive manufacturing technique, wherein the forming the three-dimensional ceramic support comprises, printing a three-dimensional structure using one or more inks, wherein at least one of the one or more inks comprises a ceramic powder; and
drying the printed structure, wherein the heating creates a partially sintered ceramic material.

16 . The method as recited in claim 15 , wherein the additive manufacturing includes a technique selected from the group consisting of: an extrusion-based technique, a powder bed-based technique, a material jetting technique, a sheet lamination technique, an electrostatic deposition technique, a laser fusion technique, use of a mold, and use of a template.

17 . The method as recited in claim 13 , wherein incorporating the sorbent additive includes:
immersing the ceramic support in a mixture of the sorbent additive suspended in a solvent; and drying the ceramic support to remove the solvent by evaporation.

18 . The method as recited in claim 13 , wherein the sorbent additive is an amine-containing sorbent additive selected from the group consisting of: poly(alkylamine), poly(ethylenimine), poly(propylenimine), poly(vinylamine), poly(allylamine), and a combination thereof.

19 . A method of using a porous sorbent ceramic product having a sorbent additive for separating gases, the method comprising:
contacting a gas stream comprising a mixture of more than one gas with the porous sorbent ceramic product for causing sorption of a first of the gases by the sorbent additive; and applying an electrical current to the porous sorbent ceramic product for causing joule heating of the porous sorbent ceramic product to a pre-defined temperature for desorbing the first gas from the sorbent additive.

20 . The method as recited in claim 19 , wherein the sorbent additive is selected from the group consisting of: an amine-containing sorbent additive, a hydroxyl-containing sorbent additive, a carbonate-containing sorbent additive, a phosphate-containing sorbent additive, and a combination thereof.

Assignees

• L Livermore Nat Security Llc

Inventors

• Ellebracht Nathan C
• Baker Sarah E
• Duoss Eric B
• Pang Simon Hoching
• Stolaroff Joshuah K

Classifications

• B01J20/28023

  Fibres or filaments (fibres or filaments in the form of membranes B01J20/28038; B01J20/28007 takes precedence) · CPC title

• B01J20/3204

  Inorganic carriers, supports or substrates · CPC title

• B01J20/28011 Primary

  Other properties, e.g. density, crush strength · CPC title

• B01J20/0251

  Compounds of Si, Ge, Sn, Pb (B01J20/10 takes precedence) · CPC title

• B01J20/3293

  Coatings on a core, the core being particle or fiber shaped, e.g. encapsulated particles, coated fibers · CPC title