Dry-Scrubbing Media Compositions and Methods of Production and Use

• US 20090246107A1
• Filed: 03/25/2009
• Published: 10/01/2009
• Est. Priority Date: 03/25/2008
• Status: Active Grant

• Current Assignee: Purafil, Inc. (FGI Equity LLC)
• Original Assignee: Purafil, Inc. (FGI Equity LLC)
• Inventors: England, William G.
• Granted Patent: US 8,992,867 B2
• Time in Patent Office: Days
• US Class Current: 423/230
• CPC Class Codes: B01D 2251/304 of sodium
• CPC Class Codes: B01D 2251/306 of potassium
• CPC Class Codes: B01D 2251/51 Hydrogen sulfide
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/104 Alumina
• CPC Class Codes: B01D 2253/112 Metals or metal compounds not provided for in B01D2253/104 or B01D2253/106
• CPC Class Codes: B01D 2253/1124 Metal oxides
• CPC Class Codes: B01D 2253/306 Surface area, e.g. BET-specific surface
• CPC Class Codes: B01D 2255/2047 Magnesium
• CPC Class Codes: B01D 2257/2025 Chlorine
• CPC Class Codes: B01D 2257/302 Sulfur oxides
• CPC Class Codes: B01D 2257/304 Hydrogen sulfide
• CPC Class Codes: B01D 2257/402 Dinitrogen oxide
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2259/40 Further details for adsorption processes and devices
• CPC Class Codes: B01D 53/02 by adsorption, e.g. preparative gas chromatography solid sorbent compositions B01J20/00, preparation of inorganic compounds or elements C01
• CPC Class Codes: B01D 53/52 Hydrogen sulfide
• CPC Class Codes: B01D 53/83 with moving reactants
• CPC Class Codes: B01J 20/04 comprising compounds of alkali metals, alkaline earth metals or magnesium
• CPC Class Codes: B01J 20/041 Oxides or hydroxides
• CPC Class Codes: B01J 20/08 : comprising aluminium oxide or hydroxide; comprising bauxite
• CPC Class Codes: B01J 20/20 : comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/2803 : Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products
• CPC Class Codes: B01J 20/28045 : Honeycomb or cellular structures; Solid foams or sponges
• CPC Class Codes: B01J 20/3007 : Moulding, shaping or extruding
• CPC Class Codes: B01J 20/3204 : Inorganic carriers, supports or substrates
• CPC Class Codes: B01J 20/3234 : Inorganic material layers
• CPC Class Codes: B01J 20/3236 : containing metal, other than zeolites, e.g. oxides, hydroxides, sulphides or salts
• CPC Class Codes: B01J 2220/42 : Materials comprising a mixture of inorganic materials materials coated or impregnated on a carrier B01J20/32
• CPC Class Codes: B29C 48/11 : comprising two or more partially or fully enclosed cavities, e.g. honeycomb-shaped
• CPC Class Codes: B29D 24/005 : the structure having joined ribs, e.g. honeycomb
• CPC Class Codes: B29L 2031/608 : Honeycomb structures
• CPC Class Codes: C01B 17/167 : Separation
• CPC Class Codes: Y02C 20/10 : of nitrous oxide (N2O)
• CPC Class Codes: Y02P 20/151 : Reduction of greenhouse gas [GHG] emissions, e.g. CO2
• CPC Class Codes: Y02P 70/10 : Greenhouse gas [GHG] capture, material saving, heat recovery or other energy efficient measures, e.g. motor control, characterised by manufacturing processes, e.g. for rolling metal or metal working

Abstract

Dry-scrubbing media compositions, methods of preparation and methods of use are provided. The compositions contain activated alumina and magnesium oxide. Optionally, activated carbon and other impregnates, such as hydroxides of group 1A metals, are included. The compositions exhibit improved efficiency and capacity for the removal of compounds, such as hydrogen sulfide, from an air-stream. The compositions are particularly useful for reducing or preventing the release of toxic gaseous compounds from the areas such as landfills, petroleum storage areas, refineries, drinking water systems, sewage treatment facilities, swimming pools, hospital morgues, animal rooms, and pulp and paper production sites.

Claims

1. A dry-scrubbing media composition comprising activated alumina and magnesium oxide.

2. The composition of claim 1, further comprising activated carbon.

3. The composition of claim 1, further comprising a hydroxide of a Group IA metal.

4. The composition of claim 3, wherein the hydroxide is sodium hydroxide or potassium hydroxide.

5. A dry-scrubbing media composition comprising:

(a) about 15% to about 35% by weight of activated alumina;

(b) about 20% to about 60% by weight activated carbon; and

,

(c) about 5% to about 50% by weight magnesium oxide.

6. The composition of claim 5, further comprising about 5% to about 10% by weight of sodium hydroxide or potassium hydroxide.

7. A process for making a dry-scrubbing media composition comprising:

(a) mixing activated alumina and magnesium oxide in water;

(b) forming the mixture into at least one cohesive unit; and

(c) curing the unit until the water is from about 5% to about 20% by weight of the composition.

8. The process of claim 7, wherein the step of forming the mixture into at least one cohesive unit comprises tumbling the mixture of activated alumina and magnesium oxide while spraying water on the mixture.

9. The process of claim 7, wherein the mixture in water further comprises a hydroxide of a Group IA metal;

and wherein the curing step includes curing the unit until the hydroxide is from about 5% to about 10% by weight of the composition.

10. A dry-scrubbing media composition produced by the process of claim 7.

11. A process for making a dry-scrubbing media composition comprising:

(a) forming a mixture of from about 20% to about 60% activated carbon, from about 15% to about 35% alumina, and from about 5% to about 50% magnesium oxide;

(b) combining the mixture with a mixture of from about 5% to 15% solution in water of a hydroxide of a Group IA metal to form at least one cohesive unit; and

(c) curing the unit at a temperature of from about 100 to about 225 degrees Fahrenheit until the water is about 5% to about 30% by weight of the composition.

12. An adsorbent composition produced by the process of claim 11.

13. A method for preventing or reducing release of a contaminant from an air-stream comprising administering a dry-scrubbing media composition comprising activated alumina and magnesium oxide to an air-stream, wherein the dry-scrubbing media is effective to remove the contaminant from the air stream.

14. The method of claim 13, wherein the contaminant is hydrogen sulfide.

15. The method of claim 13, wherein the dry-scrubbing media further comprises activated carbon.

16. An apparatus for removing a contaminant from an air-stream comprising a dry-scrubbing media and a reaction chamber;

wherein the dry scrubbing media comprises activated alumina and magnesium oxide.

17. The apparatus of claim 16, wherein the dry-scrubbing media further comprises activated carbon.

18. The apparatus of claim 16, wherein the contaminant comprises hydrogen sulfide.

19. The apparatus of claim 16, wherein the dry scrubbing media further comprises sodium hydroxide or potassium hydroxide.

20. The apparatus of claim 19, wherein the amount of sodium hydroxide or potassium hydroxide is about 5% to about 10% by weight.

21. A process for making a dry-scrubbing media composition comprising:

(a) forming a mixture of activated alumina and magnesium oxide; and

(b) extruding the mixture through a die to form a matrix or honeycomb structure with long open channels.

22. The process of claim 21, wherein the mixture further comprises activated carbon.

23. The process of claim 21, wherein the mixture further comprises an impregnate.