SUBSTRATES FOR CARBON DIOXIDE CAPTURE AND METHODS FOR MAKING SAME

• US 20130207034A1
• Filed: 02/07/2013
• Published: 08/15/2013
• Est. Priority Date: 02/09/2012
• Status: Abandoned Application

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Addiego, William Peter
• Application Number:
  US13/761,908
• Publication Number:
  US 20130207034A1
• Time in Patent Office: Days
• US Class Current: 252/184
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/104 Alumina
• CPC Class Codes: B01D 2253/106 Silica or silicates
• CPC Class Codes: B01D 2253/108 Zeolites
• CPC Class Codes: B01D 2253/25 Coated, impregnated or composite adsorbents
• CPC Class Codes: B01D 2253/3425 Honeycomb shape
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2258/0283 Flue gases
• CPC Class Codes: B01D 53/04 with stationary adsorbents B01D53/025 takes precedence
• CPC Class Codes: B01D 53/62 Carbon oxides
• CPC Class Codes: B01D 53/82 with stationary reactants
• CPC Class Codes: B01J 20/261 obtained by reactions only involving carbon to carbon unsaturated bonds macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds per se C08F
• CPC Class Codes: B01J 20/262 obtained otherwise than by reactions only involving carbon to carbon unsaturated bonds, e.g. obtained by polycondensation macromolecular compounds obtained otherwise than by reactions only involving unsaturated carbon-to-carbon bonds per se C08G
• 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 20/28054 characterised by their surface properties or porosity
• CPC Class Codes: B01J 20/28061 being in the range 100-500 m2/g
• CPC Class Codes: B01J 20/28064 being in the range 500-1000 m2/g
• CPC Class Codes: B01J 20/3007 Moulding, shaping or extruding
• CPC Class Codes: B01J 20/305 Addition of material, later completely removed, e.g. as result of heat treatment, leaching or washing, e.g. for forming pores
• CPC Class Codes: B01J 20/327 : Polymers obtained by reactions involving only carbon to carbon unsaturated bonds
• CPC Class Codes: B01J 20/3272 : Polymers obtained by reactions otherwise than involving only carbon to carbon unsaturated bonds
• CPC Class Codes: Y02C 20/40 : of CO2

Abstract

An absorbent structure for CO₂ capture includes a honeycomb substrate having a plurality of partition walls extending in an axial direction from an inlet end to an outlet end thereby forming a plurality of flow channels. The honeycomb substrate comprises a powder component and a binder that are solidified. The absorbent structure also includes a functional mer group dispersed throughout the powder component of the partition walls of the honeycomb substrate. The functional mer group is positioned in and on the partition walls such that, when a gas stream containing CO₂ flows in the flow channels from the inlet end to the outlet end, the functional mer group absorbs the CO₂ by forming a coordinated bond that forms carbonate, bicarbonate, carbamates, or another coordinated or ionic compound with the CO₂.

Claims

1. An absorbent structure for CO₂ capture comprising:

a honeycomb substrate having a plurality of partition walls extending in an axial direction from an inlet end to an outlet end thereby forming a plurality of flow channels, wherein the honeycomb substrate comprises a powder component and a binder that are solidified; and

a functional mer group dispersed throughout the powder component of the partition walls of the honeycomb substrate, wherein the functional mer group is positioned in and on the partition walls such that, when a gas stream containing CO₂ flows in the flow channels from the inlet end to the outlet end, the functional mer group absorbs the CO₂ by forming a coordinated bond that forms carbonate, bicarbonate, carbamates, or another coordinated or ionic compound with the CO₂.

2. The absorbent structure for CO₂ capture of claim 1, wherein the powder component comprises an inorganic oxide.

3. The absorbent structure for CO₂ capture of claim 1, wherein the powder component is selected from the group consisting of non-refractory alumina, an inorganic molecular silicate, a non-crystalline amorphous silica, a double-layered hydroxide, zeolite and combinations thereof.

4. The absorbent structure for CO₂ capture of claim 3, wherein:

the zeolite is selected from the group consisting of faujasites, X-type, A-type, β

-type, and MFI-type;

the non-refractory aluminia is selected from the group consisting of alumina tri-hydroxides, boehmite, γ

-alumina, ρ

-alumina, and transition or activated alumina; and

the non-crystalline amorphous silica is selected from the group consisting of precipitated silica, silica gel, and mesoporous silica.

5. The absorbent structure for CO₂ capture of claim 1, wherein the powder component is activated carbon.

6. The absorbent structure for CO₂ capture of claim 1, wherein an average surface area of the powder component is greater than 50 m²/g.

7. The absorbent structure for CO₂ capture of claim 6, wherein an average surface area of the powder component is from about 150 m²/g to about 1000 m²/g.

8. The absorbent structure for CO₂ capture of claim 1, wherein the honeycomb substrate has a porosity from about 20% to about 90%.

9. The absorbent structure for CO₂ capture of claim 1, wherein the functional mer group comprises an amine.

10. The absorbent structure for CO₂ capture of claim 9, wherein the amine is selected from a group consisting of polyethyleneimine, polyamidoamine, and polyvinylamine.

11. The absorbent structure for CO₂ capture of claim 1, wherein the honeycomb substrate is unsintered.

12. A method of forming an absorbent structure for CO₂ capture comprising:

dry blending a powder component and a binder into a mixture;

adding a solution of a functional mer group and a solvent to the mixture to form a precursor, wherein the functional mer group absorbs CO₂ by forming a coordinated bond that forms carbonate, bicarbonate, carbamates, or other coordinated or ionic compound with CO₂;

mulling the precursor;

extruding the precursor to form a consolidated monolith having a plurality of partition walls extending in an axial direction from an inlet end to an outlet end thereby forming a plurality of flow channels; and

removing the solvent from the consolidated monolith to form a honeycomb substrate.

13. The method of claim 12, wherein the mixture further comprises a polymerizing agent and/or a cross-linking agent, and the polymerizing agent polymerizes the functional mer group and/or the cross-linking agent cross-links the functional mer group when thermally activated at an elevated temperature.

14. The method of claim 12 further comprising activating the functional mer group by introducing a polymerization agent and/or a cross-linking agent to the honeycomb substrate.

15. The method of claim 12, wherein the solvent is removed from the consolidated monolith by heating the consolidated monolith to evaporate the solvent.

16. The method of claim 12, wherein when processing the consolidated monolith into the honeycomb substrate, a processing temperature is maintained below a decomposition temperature of the functional mer group.

17. The method of claim 12, wherein the solvent is an alcohol solution.

18. The method of claim 12, wherein the solvent comprises water.

19. The method of claim 12, further comprising homogenizing the precursor prior to extruding.

20. A method of forming an absorbent structure for CO₂ capture comprising:

forming a slurry comprising a powder component, a functional mer group, and a first solvent;

removing the first solvent from the slurry to form individual grains of the powder component impregnated with the functional mer group, wherein the functional mer group absorbs CO₂ by forming a coordinated bond that forms carbonate, bicarbonate, carbamates, or other coordinated or ionic compound with CO₂;

blending a precursor comprising the impregnated individual grains of the powder component, a binder, and a second solvent;

extruding the precursor to form a consolidated monolith having a plurality of partition walls extending in an axial direction from an inlet end to an outlet end thereby forming a plurality of flow channels; and

removing the second solvent from the consolidated monolith to form a honeycomb substrate.