CARBON DIOXIDE SORBENTS FOR INDOOR AIR QUALITY CONTROL

• US 20180050322A1
• Filed: 03/23/2016
• Published: 02/22/2018
• Est. Priority Date: 03/23/2015
• Status: Active Grant

• Current Assignee: BASF Corporation (BASF SE)
• Original Assignee: BASF Corporation (BASF SE)
• Inventors: Kimura, Riichiro, Buelow, Mark T., Kauffman, John, Tran, Pascaline, Wosylus, Aron
• Granted Patent: US 10,906,024 B2
• Time in Patent Office: Days
• CPC Class Codes: B01D 2253/20 Organic adsorbents
• CPC Class Codes: B01D 2253/202 Polymeric adsorbents
• CPC Class Codes: B01D 2253/25 Coated, impregnated or composite adsorbents
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2257/708 Volatile organic compounds V.O.C.'s
• CPC Class Codes: B01D 2258/06 Polluted air
• CPC Class Codes: B01D 2259/4508 for cleaning air in buildings
• CPC Class Codes: B01D 2259/4566 for use in transportation means
• CPC Class Codes: B01D 2259/4575 in aeroplanes or space ships
• 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 53/0415 Beds in cartridges
• CPC Class Codes: B01D 53/62 Carbon oxides
• CPC Class Codes: B01D 53/82 with stationary reactants
• CPC Class Codes: B01J 20/12 Naturally occurring clays or bleaching earth
• CPC Class Codes: B01J 20/28004 Sorbent size or size distribution, e.g. particle size
• CPC Class Codes: B01J 20/28011 Other properties, e.g. density, crush strength
• CPC Class Codes: B01J 20/28045 Honeycomb or cellular structures; Solid foams or sponges
• CPC Class Codes: B01J 20/28059 being less than 100 m2/g
• CPC Class Codes: B01J 20/28061 being in the range 100-500 m2/g
• CPC Class Codes: B01J 20/28069 Pore volume, e.g. total pore volume, mesopore volume, micropore volume
• CPC Class Codes: B01J 20/3078 : Thermal treatment, e.g. calcining or pyrolizing
• CPC Class Codes: B01J 20/3204 : Inorganic carriers, supports or substrates
• CPC Class Codes: B01J 20/3206 : Organic carriers, supports or substrates
• CPC Class Codes: B01J 20/3236 : containing metal, other than zeolites, e.g. oxides, hydroxides, sulphides or salts
• CPC Class Codes: B01J 20/3248 : the functional group or the linking, spacer or anchoring group as a whole comprising at least one type of heteroatom selected from a nitrogen, oxygen or sulfur, these atoms not being part of the carrier as such
• CPC Class Codes: B01J 20/3251 : comprising at least two different types of heteroatoms selected from nitrogen, oxygen or sulphur
• CPC Class Codes: B01J 20/3257 : the functional group or the linking, spacer or anchoring group as a whole comprising at least one of the heteroatoms nitrogen, oxygen or sulfur together with at least one silicon atom, these atoms not being part of the carrier as such
• 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: B01J 20/3289 : Coatings involving more than one layer of same or different nature
• CPC Class Codes: B01J 20/3433 : of sorbents or filter aids other than those covered by B01J20/3408 - B01J20/3425
• CPC Class Codes: B01J 20/3458 : in the gas phase
• CPC Class Codes: B01J 2220/62 : In a cartridge
• CPC Class Codes: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02C 20/40 : of CO2

Abstract

Disclosed in certain embodiments are carbon dioxide sorbents that include porous particles impregnated with an amine compound.

Claims

1. A sorbent comprising:

a gas-adsorbing material comprising an amine compound;

a hydroxyl-containing additive comprising at least one of glycerol, glycerin, pentaerythritol, sorbitol, sucrose, polyether, polyester, ethylene glycol, or a silicon-based compound; and

a porous support impregnated with the gas-adsorbing material.

2. The sorbent of claim 1, wherein the gas-adsorbing material comprises diethanolamine or pentaethylenehexamine, and wherein the hydroxyl-containing additive comprises glycerol, wherein the gas-adsorbing material and the hydroxyl-containing additive are mixed together forming a coating on the porous support.

4. The sorbent of claim 1, wherein the hydroxyl-containing additive comprises the silicon-based compound, wherein the silicon-based compound forms a silicon-based coating on the porous support, and wherein the gas-adsorbing material is coated onto the silicon-based coating.

5. The sorbent of claim 4, wherein silicon-based coating is present in an amount ranging from greater than 0% to 20% of a total weight of the porous support and the silicon-based coating, and wherein the amine compound is present in an amount ranging from 20% to 40% of a total weight of the sorbent.

10. The sorbent of claim 1, wherein a weight loss of the sorbent after performing an attrition test is less than 3%, and a CO₂ adsorption capacity of the sorbent is greater than 6 g/L when the sorbent is maintained at a temperature greater than 20°

C. and less than 40°

C.

14. The sorbent of claim 4, wherein the silicon-based coating was formed by treating the porous support with one or more of tetraethylorthosilicate, colloidal silica, or sodium silicate.

16. The sorbent of claim 1, wherein a CO₂ adsorption capacity of the sorbent remains greater than 60% of an initial CO₂ adsorption capacity when the sorbent maintained at a temperature from 40°

C. to 60°

C. for up to 100 hours.

17. The sorbent of claim 1, wherein the amine compound comprises molecular species each comprising at least two amine moieties.

19. The sorbent of claim 1, wherein the amine compound comprises one or more of diethanolamine, triethylenepentamine, tetraethylenepentamine, pentaethylenehexamine, triethylenetetramine, bis(2-hydroxypropyl)amine, N,N′

-bis(2-hydroxyethyl)ethylenediamine, monoethanolamine, diisopropanolamine, alkylamines, methylamine, linear polyethyleneimine, branched polyethyleneimine, dimethylamine, diethylamine, methyldiethanolamine, methylethanolamine, or polyethylene polyamines.

22. The sorbent of claim 1, wherein a CO₂ adsorption capacity of the sorbent is greater than 8 g/L when the sorbent is maintained at a temperature greater than 20°

C. and less than 40°

C.

27. The sorbent of claim 1, wherein the porous support comprises one or more of bentonite, attapulgite, kaolinite, montmorillonite, ball clay, fuller'"'"'s earth, hectorite, palygorskite, saponite, sepiolite, halloysite, silica, calcium sulfate, zeolite, synthetic zeolite, alumina, fumed silica, activated charcoal, or metal organic framework.

29. The sorbent of claim 1, wherein the porous support comprises clay having silica coated thereon, wherein a surface area of the porous support is greater than 50 m²/g prior to impregnation with the gas-adsorbing material, and wherein an average pore volume of the sorbent is greater than 0.2 cc/g and less than 0.8 cc/g.

42. The sorbent of claim 1, wherein the sorbent is in a form of granules, a powder, a porous ceramic honeycomb, a metallic honeycomb, or a polymeric foam having the sorbent washcoated thereon.

88. A system comprising:

one or more filtration units arranged to contact a flow of air received into the system; and

the sorbent of claim 1 disposed within the one or more filtration units,

wherein the system is selected from a group consisting of a CO₂ scrubbing system, an automobile ventilation system, an aircraft environmental control system, and an air control system for removing carbon dioxide from atmospheric air.

3. (canceled)

6-9. -9. (canceled)

11-13. -13. (canceled)

15. (canceled)

18. (canceled)

20. (canceled)

21. (canceled)

23-26. -26. (canceled)

28. (canceled)

30-41. -41. (canceled)

43-54. -54. (canceled)

55. A method for producing a sorbent, the method comprising:

forming a silicon-based coating on a porous support to form a coated support; and

impregnating the coated support with a gas-adsorbing material, the gas-adsorbing material comprising an amine.

56. The method of claim 55, wherein forming the silicon-based coating on the porous support comprises treating the porous support with one or more of tetraethylorthosilicate, colloidal silica, or sodium silicate.

57. The method of claim 55, further comprising:

calcining the coated support prior to forming the silicon-based coating or after forming the silicon-based coating, wherein the calcining comprises calcining at a temperature ranging from 400°

C. and 600°

C.

62. The method of claim 55, wherein the amine compound comprises one or more of diethanolamine, triethylenepentamine, tetraethylenepentamine, pentaethylenehexamine, triethylenetetramine, bis(2-hydroxypropyl)amine, N,N′

-bis(2-hydroxyethyl)ethylenediamine, monoethanolamine, diisopropanolamine, alkylamines, methylamine, linear polyethyleneimine, branched polyethyleneimine, dimethylamine, diethylamine, methyldiethanolamine, methylethanolamine, or polyethylene polyamines.

70. The method of claim 55, wherein the porous support comprises one or more of bentonite, attapulgite, kaolinite, montmorillonite, ball clay, fuller'"'"'s earth, hectorite, palygorskite, saponite, sepiolite, halloysite, silica, calcium sulfate, zeolite, synthetic zeolite, alumina, fumed silica, activated charcoal, or metal organic framework.

58-61. -61. (canceled)

63-69. -69. (canceled)

71-87. -87. (canceled)

89-95. -95. (canceled)

96. A sorbent comprising:

a support comprising a clay having a silicon-based coating formed thereon, wherein the silicon-based coating is present in an amount from greater than 0% to 20% by weight based on a total weight of the support; and

a gas-adsorbing material comprising diethanolamine or pentaethylenehexamine, wherein the gas-adsorbing material is impregnated onto the support in an amount ranging from 20% to 40% of a total weight of the sorbent.