POROUS STABILIZED BEDS, METHODS OF MANUFACTURE THEREOF AND ARTICLES COMPRISING THE SAME

• US 20140291570A1
• Filed: 07/06/2012
• Published: 10/02/2014
• Est. Priority Date: 07/08/2011
• Status: Active Grant

• Current Assignee: University of Florida Research Foundation, Incorporated (State University System of Florida)
• Original Assignee: University of Florida Research Foundation, Incorporated (State University System of Florida)
• Inventors: Klausner, James F., Mei, Renwei, Momen, Ayyoub Mehdizadeh, Allen, Kyle
• Granted Patent: US 9,966,171 B2
• Time in Patent Office: Days
• US Class Current: 252/62.56
• CPC Class Codes: B01J 23/745 Iron
• CPC Class Codes: B01J 37/0009 Use of binding agents; Moulding; Pressing; Powdering; Granulating; Addition of materials ameliorating the mechanical properties of the product catalyst
• CPC Class Codes: B01J 37/0221 of particles
• CPC Class Codes: C01B 32/50 Carbon dioxide
• CPC Class Codes: C04B 35/01 based on oxide ceramics
• CPC Class Codes: C04B 35/515 based on non-oxide ceramics
• CPC Class Codes: C04B 38/0038 by superficial sintering or bonding of particulate matter
• CPC Class Codes: C04B 38/0096 Pores with coated inner walls
• CPC Class Codes: H01F 1/01 of inorganic materials H01F1/44 takes precedence
• CPC Class Codes: H01F 1/342 Oxides H01F1/36 and H01F1/38 take precedence
• CPC Class Codes: H01F 41/00 Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties

Abstract

Disclosed herein is a method comprising disposing a first particle in a reactor; the first particle being a magnetic particle or a particle that can be influenced by a magnetic field, an electric field or a combination of an electrical field and a magnetic field; fluidizing the first particle in the reactor; applying a uniform magnetic field, a uniform electrical field or a combination of a uniform magnetic field and a uniform electrical field to the reactor; elevating the temperature of the reactor; and fusing the first particles to form a monolithic solid.

Claims

1. A method comprising:

disposing a first particle in a reactor;

the first particle being a magnetic particle or a particle that can be influenced by a magnetic field, an electric field or a combination of an electrical field and a magnetic field;

fluidizing the first particle in the reactor;

applying a uniform magnetic field, a uniform electrical field or a combination of a uniform magnetic field and a uniform electrical field to the reactor;

elevating the temperature of the reactor; and

fusing the first particles to form a monolithic solid.

2. The method of claim 1, further comprising disposing a second particle in the reactor;

wherein the second particle is not a magnetic particle and is not influence by the magnetic field, the electrical field or the combination of the electrical field and the magnetic field.

3. The method of claim 2, wherein the elevating the temperature of the reactor promotes a fusing of the first particles and the second particles to form the monolithic solid.

4. The method of claim 1, wherein the fluidizing is conducted using steam.

5. The method of claim 1, wherein the first particle comprises iron, cobalt, nickel or a combination comprising at least one of iron, cobalt or nickel.

6. The method of claim 1, wherein the first particles are in the form of aligned chains after the fusing.

7. The method of claim 2, wherein the second particle comprises a metal, an inorganic oxide, an inorganic carbide, an inorganic oxycarbide, an inorganic nitride, an inorganic oxynitride, a polymer or a combination thereof.

8. The method of claim 1, wherein the elevating the temperature comprises raising the temperature to about 300 to about 2,000°

C.

9. The method of claim 1, wherein the fluidizing is conducted using a flow rate of 0.01 to about 5 standard liters per minute.

10. The method of claim 1, further comprising disposing the monolithic solid in a reactive atmosphere and growing nanorods, nanotubes, whiskers, or nanoparticles in a pore of the monolithic solid.

11. The method of claim 2, wherein the first particle is disposed on the second particle to form a composite particle.

12. The method of claim 11, where the first particle is disposed on the second particle via a chemical vapor deposition process.

13. The method of claim 2, wherein the second particle comprises silica.

14. The method of claim 2, wherein the second particle is an inorganic oxide and is selected from the group consisting of silica, alumina, zirconia, titania, ceria, iron oxide, and a combination comprising at least one of the foregoing inorganic oxides.

18. The article of claim 14, wherein the article is used to facilitate chemical reactions that generate hydrogen.

15. An article comprising:

a monolithic solid comprising;

a plurality of metal particles fused together in the form of aligned chains;

the monolithic solid being porous.

16. The article of claim 15, wherein the article is used in a fluidized bed reactor as a solid monolith.

17. The article of claim 16, wherein the article is used to facilitate chemical reactions.

19. A method comprising:

disposing a first particle in a reactor;

the first particle being a magnetic particle or a particle that can be influenced by a magnetic field, an electric field or a combination of an electrical field and a magnetic field;

fluidizing the first particle in the reactor;

applying a uniform magnetic field, a uniform electrical field or a combination of a uniform magnetic field and a uniform electrical field to the reactor;

disposing a plurality of reactants into the reactor;

elevating the temperature of the reactor to react the reactants in the reactor; and

fusing the first particles to form a monolithic solid.

20. The method of claim 19, further comprising disposing a second particle in the reactor;

wherein the second particle is not a magnetic particle and is not influence by the magnetic field, the electrical field or the combination of the electrical field and the magnetic field.

21. The method of claim 20, wherein the elevating the temperature of the reactor promotes a fusing of the first particles and the second particles to form the monolithic solid.

22. The method of claim 19, wherein the fluidizing is conducted using steam.

23. The method of claim 19, wherein the first particle comprises iron, cobalt, nickel or a combination comprising at least one of iron, cobalt or nickel.

24. The method of claim 20, wherein the second particle comprises silica.

25. The method of claim 20, wherein the second particle is an inorganic oxide and is selected from the group consisting of silica, alumina, zirconia, titania, ceria, iron oxide, and a combination comprising at least one of the foregoing inorganic oxides.

26. The method of claim 20, wherein the second particle comprises carbon.

27. The method of claim 26, where the carbon is converted to carbon dioxide.