Activated Porous Fibers and Products Including Same

• US 20190309455A1
• Filed: 04/04/2019
• Published: 10/10/2019
• Est. Priority Date: 04/04/2018
• Status: Active Grant

• Current Assignee: Unifrax, LLC
• Original Assignee: Unifrax I LLC (ASP Unifrax Holdings, Inc.)
• Inventors: Cross, Jonathan, Kelsall, Adam, Zoitos, Bruce, Cannan, Chad
• Granted Patent: US 11,987,914 B2
• Time in Patent Office: Days
• CPC Class Codes: B01D 2255/102 Platinum group metals
• CPC Class Codes: B01D 2255/90 Physical characteristics of catalysts
• CPC Class Codes: B01D 2257/2025 Chlorine
• CPC Class Codes: B01D 2257/302 Sulfur oxides
• CPC Class Codes: B01D 2257/404 Nitrogen oxides other than dinitrogen oxide
• CPC Class Codes: B01D 2257/502 Carbon monoxide
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2257/602 Mercury or mercury compounds
• CPC Class Codes: B01D 2257/702 Hydrocarbons
• CPC Class Codes: B01D 2257/708 Volatile organic compounds V.O.C.'s
• CPC Class Codes: B01D 53/86 Catalytic processes
• CPC Class Codes: B01J 23/40 of the platinum group metals
• CPC Class Codes: B01J 23/42 Platinum
• CPC Class Codes: B01J 35/40 characterised by dimensions, e.g. grain size in a colloidal state B01J35/23; crystallite size B01J35/77
• CPC Class Codes: B01J 35/56 Foraminous structures having flow-through passages or channels, e.g. grids or three-dimensional monoliths
• CPC Class Codes: B01J 35/58 Fabrics or filaments
• CPC Class Codes: B01J 37/0201 Impregnation
• CPC Class Codes: D04H 1/4209 Inorganic fibres
• CPC Class Codes: D04H 1/52 by applying or inserting filamentary binding elements
• CPC Class Codes: D04H 1/728 by electro-spinning electro-spinning methods and apparatus D01D5/0007
• CPC Class Codes: D04H 1/732 : by fluid current, e.g. air-lay
• CPC Class Codes: F01N 3/035 : with catalytic reactors , e.g. catalysed diesel particulate filters
• CPC Class Codes: F01N 3/10 : by thermal or catalytic conversion of noxious components of exhaust by using other chemical processes, chemical aspects of catalytic conversion, e.g. using specified catalysts, B01D53/34
• CPC Class Codes: F01N 3/101 : Three-way catalysts
• CPC Class Codes: F01N 3/2835 : fibrous
• CPC Class Codes: Y02C 20/40 : of CO2

Abstract

A composition including inorganic fibers having a surface area of at least 5 m²/g and an active agent incorporated into the inorganic fibers and/or applied onto at least a portion of the inorganic fibers. Products including the composition may include fiber aggregates, composite materials, filter elements, catalytic elements, exhaust gas treatment devices and other exhaust system components, and papers.

Claims

1. A composition comprising:

inorganic fibers having a surface area of at least 5 m²/g; and

an active agent incorporated into the inorganic fibers and/or applied onto at least a portion of the inorganic fibers.

2. The composition according to claim 1, wherein the active agent is a transitional metal-containing catalyst.

3. The composition according to claim 2, wherein the active agent is present in an amount, based on a total weight of the composition, of greater than 0 to 10 percent by weight.

4. The composition according to claim 2, wherein the active agent is present in an amount, based on a total weight of the composition, of 0.5 to 5 percent by weight.

5. The composition according to claim 2, wherein the active agent is present in an amount, based on a total weight of the composition, of 1 to 3 percent by weight.

6. The composition according to claim 2, wherein the active agent comprises a platinum group metal-containing catalyst.

7. The composition according to claim 2, further comprising at least one secondary agent selected from a carbon dioxide capturing agent, a nitrogen oxide capturing agent, or a sorbent for lead or cadmium;

wherein the secondary agent is incorporated into the inorganic fibers or applied onto at least a portion of the inorganic fibers.

8. The composition according to claim 7, wherein the carbon dioxide capturing agent is at least one selected from the group consisting of barium carbonate, barium oxide, and barium hydroxide;

wherein the nitrogen oxide capturing agent is at least one selected from the group consisting of cerium, lanthanum, and barium; and

wherein the sorbent for lead or cadmium is an alumino-silicate compound.

9. The composition according to claim 1, wherein the inorganic fibers have a median fiber diameter of 0.5 to 10 μ

m.

10. The composition according to claim 1, wherein the inorganic fibers have a median fiber diameter of 4 to 10 μ

m and less than 0.1 percent by weight of the inorganic fibers have a diameter of less than 3 μ

m.

11. The composition according to claim 1, wherein the inorganic fibers have a melting point of 1500°

C. or greater.

12. A method of treating a gas comprising:

causing the gas to contact an activated fiber composition comprising inorganic fibers having a surface area of at least 5 m²/g and an active agent incorporated into the inorganic fibers and/or applied onto at least a portion of the inorganic fibers;

wherein the gas comprises at least one selected from the group consisting of carbon monoxide, carbon dioxide, nitrogen oxides, sulfur oxides, hydrogen chloride, hydrogen fluoride, arsenic, boron, lead, mercury, unburned hydrocarbons and volatile organic compounds.

13. The method according to claim 12, wherein the active agent is a transition metal-containing catalyst.

14. The method according to claim 13, wherein the active agent is present in an amount, based on a total weight of the composition, of 0.5 to 5 percent by weight.

15. The method according to claim 13, wherein the active agent comprises a platinum group metal-containing catalyst.

16. The method according to claim 13, further comprising at least one secondary agent selected from a carbon dioxide capturing agent, a nitrogen oxide capturing agent, or a sorbent for lead or cadmium;

wherein the secondary agent is incorporated into the inorganic fibers or applied onto at least a portion of the inorganic fibers.

17. The method according to claim 16, wherein the carbon dioxide capturing agent is at least one selected from the group consisting of barium carbonate, barium oxide, and barium hydroxide;

wherein the nitrogen oxide capturing agent is at least one selected from the group consisting of cerium, lanthanum, and barium; and

wherein the sorbent for lead or cadmium is an alumino-silicate compound.

18. The method according to claim 12, wherein the inorganic fibers have a median fiber diameter of 4 to 10 μ

m and less than 0.1 percent by weight of the inorganic fibers have a diameter of less than 3 μ

m.

19. The method according to claim 13, wherein the inorganic fibers have a melting point of 1500°

C. or greater.

20. An emission control device comprising:

an activated fiber composition comprising inorganic fibers having a surface area of at least 5 m²/g and an active agent incorporated into the inorganic fibers and/or applied onto at least a portion of the inorganic fibers; and

a permeable support, wherein the activated fiber composition is enclosed within the permeable support and the permeable support allows fluid communication therethrough.

21. The device according to claim 20, wherein the active agent is a transition metal-containing catalyst.

22. The device according to claim 21, wherein the active agent is present in an amount, based on a total weight of the composition, of 0.5 to 5 percent by weight.

23. The device according to claim 21, wherein the active agent comprises a platinum group metal-containing catalyst.

24. The device according to claim 21, further comprising at least one secondary agent selected from a carbon dioxide capturing agent, a nitrogen oxide capturing agent, or a sorbent for lead or cadmium;

wherein the secondary agent is incorporated into the inorganic fibers or applied onto at least a portion of the inorganic fibers.

25. The device according to claim 24, wherein the carbon dioxide capturing agent is at least one selected from the group consisting of barium carbonate, barium oxide, and barium hydroxide;

wherein the nitrogen oxide capturing agent is at least one selected from the group consisting of cerium, lanthanum, and barium; and

wherein the sorbent for lead or cadmium is an alumino-silicate compound.

26. The device according to claim 20, wherein the inorganic fibers have a median fiber diameter of 4 to 10 μ

m and less than 0.1 percent by weight of the inorganic fibers have a diameter of less than 3 μ

m.

27. The device according to claim 21, wherein the inorganic fibers have a melting point of 1500°

C. or greater.

28. The device according to claim 21, wherein the permeable support is a mesh.

29. The device according to claim 28, wherein the permeable support is a metallic mesh or a polymeric mesh.