Method of separating gaseous mixture

• US 4,790,859 A
• Filed: 03/03/1987
• Issued: 12/13/1988
• Est. Priority Date: 10/18/1986
• Status: Expired due to Fees

• Current Assignee: Kanebo, Ltd. (HOYU Company Limited)
• Original Assignee: Kanebo, Ltd. (HOYU Company Limited)
• Inventors: Marumo, Chisato, Hayata, Eiji
• Primary Examiner(s): SPITZER, ROBERT H
• Application Number:
  US07/021,119
• Time in Patent Office: 651 Days
• Field of Search: 55/25, 55/26, 55/58, 55/62, 55/68, 55/74, 55/75, 55/387, 55/389, 55/523, 55/524, 264/29.1, 264/29.5, 502/418, 502/430, 502/432, 502/436, 502/438, 502/527
• US Class Current: 95/138
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/25 Coated, impregnated or composite adsorbents
• CPC Class Codes: B01D 2253/306 Surface area, e.g. BET-specific surface
• CPC Class Codes: B01D 2253/308 Pore size
• CPC Class Codes: B01D 2253/31 Pore size distribution
• CPC Class Codes: B01D 2253/311 Porosity, e.g. pore volume
• CPC Class Codes: B01D 2253/34 Specific shapes
• CPC Class Codes: B01D 2256/10 Nitrogen
• CPC Class Codes: B01D 2256/16 Hydrogen
• CPC Class Codes: B01D 2256/20 Carbon monoxide
• CPC Class Codes: B01D 2257/104 Oxygen
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2257/7025 Methane
• CPC Class Codes: B01D 2259/4003 with two sub-steps
• CPC Class Codes: B01D 2259/40037 with two sub-steps
• CPC Class Codes: B01D 2259/40052 Recycled product or process gas
• CPC Class Codes: B01D 2259/4006 Less than four
• CPC Class Codes: B01D 2259/40062 Four
• CPC Class Codes: B01D 2259/40064 Five
• CPC Class Codes: B01D 2259/40081 Counter-current
• CPC Class Codes: B01D 2259/401 : using a single bed
• CPC Class Codes: B01D 2259/402 : using two beds
• CPC Class Codes: B01D 2259/404 : using four beds
• 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 53/0431 : Beds with radial gas flow
• CPC Class Codes: B01D 53/047 : Pressure swing adsorption
• CPC Class Codes: B01D 53/0473 : Rapid pressure swing adsorption
• CPC Class Codes: B01J 20/20 : comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: Y02C 20/20 : of methane
• CPC Class Codes: Y02C 20/40 : of CO2
• CPC Class Codes: Y10S 95/903 : Carbon

Abstract

A method of separating at least a first gas from a gaseous mixture, in which a gaseous mixture containing a first and a second gas having different chemical compositions in an amount of at least 50% by volume based on the entire mixture is contacted with a carbonaceous porous body having a carbon content of at least 85% by weight and containing open cells in a three-dimensional network structure so that the open cells of the porous body form substantial flow passages for the gaseous mixture, thereby to adsorb at least the second gas physically on the porous body.

Claims

1. A method of separating at least a first gas from a gaseous mixture, which comprises contacting a gaseous mixture containing a first and a second gas having different chemical compositions in an amount of at least 50% by volume based on the entire mixture with a molecular sieving carbonaceous porous body, said porous body having (1) a carbon content of at least 85% by weight, (2) an apparent density of 0.1 to 0.8 g/cm³, (3) a porosity of 50 to 95%, (4) a maximum value of the pore diameter distribution at a pore diameter of not more than 10 Å

and a pore volume at a pore diameter in the range of 15 to 200 Å

of not more than 0.1 cm³ /g and containing (5) open cells in a three-dimensional network structure so that the open cells of the porous body form substantial flow passages for the gaseous mixture, thereby to adsorb at least the second gas physically on the porous body, said open cells having an average diameter of 1 to 500 micrometers.

2. The method of claim 1 wherein the first gas is nitrogen, the second gas is oxygen, and the gaseous mixture is air.

3. The method of claim 1 wherein the first gas is hydrogen and the second gas is methane.

4. The method of claim 1 wherein the first gas is hydrogen, the second gas is carbon dioxide.

5. The method of claim 1 wherein the first gas is carbon monoxide, and the second gas is methane.

6. The method of claim 1 wherein the amount of the first and second gases is at least 75% by volume of the entire gaseous mixture.

7. The method of claim 1 wherein the porous body has a carbon content of at least 90% by weight.

8. The method of claim 1 wherein the open cells of the porous body are used as substantial flow passages of the gaseous mixture by providing a container having an inlet and an outlet for the gaseous mixture at positions separated from each other, filling the porous body having a cross-section having substantially the same size and shape in contour as those of a cross-section of the container space taken at right angles to the direction extending from the inlet to the outlet, and passing the gaseous mixture from the inlet of the container.

9. The method of claim 1 wherein at least a part of the outside surface of the porous body in a direction parallel to the direction in which the gaseous mixture passes through the open cells of the porous body is sealed air-tight against the gaseous mixture.

10. The method of claim 1 wherein the porous body is cylindrical, circular or disc-like.

11. The method of claim 1 wherein the gaseous mixture is contacted with the porous body under atmospheric to elevated pressure.

12. A method of separating a first gas from a second gas, which comprises the steps of flowing a gaseous mixture containing said first and second gases, the sum of the amounts of said first and second gases being at least 50% by volume, based on the entire amount of said gaseous mixture, through a bed consisting of a carbonaceous porous body having a carbon content of at least 85% by weight, said porous body having macropores providing open, intercommunicating cells distributed in a three-dimensional network structure and defining gas flow passages through said porous body, said cells having an average pore diameter of 1 to 500 micrometers, the walls of said cells having micropores therein for adsorbing said second gas, said porous body having (1) an apparent density of from 0.1 to 0.8 g/cm², (2) a porosity of 50 to 95%, (3) a maximum value of the pore diameter distribution at a pore diameter of not more than 10 Å

and (4) a pore volume at a pore diameter in the range of 15 to 200 Å

of not more than 0.1 cm³ /g, said carbonaceous porous body having been prepared by forming a synthetic resin porous body consisting essentially of 10 to 50% by weight of polyvinyl alcohol, 10 to 40% by weight of melamine resin and the balance is essentially phenolic resin, and then carbonizing said synthetic resin porous body in a nonoxidizing atmosphere at a temperature of 500°

to 700°

C.

13. A method as claimed in claim 12 in which said gaseous mixture contains at least 90% by volume of said first and second gases, said porous body has an apparent density of 0.3 to 0.65 g/cm³ and a porosity of 60 to 82%, and said cells have an average pore diameter of 10 to 300 micrometers.

14. A method as claimed in claim 12 in which after carbonizing said synthetic resin porous body, said carbonized porous body is heat treated in an oxidizing atmosphere at a temperature of 500°

to 700°

C. so that the weight loss of said carbonized porous body is up to 15% by weight.

15. A method as claimed in claim 12 in which the pressure of said gaseous mixture is from 2 to 9 kg/cm² the temperature is from zero to 35°

C. and the flow rate of said gaseous mixture is from 1 to 50 cm/sec.