Method to reduce fuel vapor emissions

• US 5,288,307 A
• Filed: 08/28/1992
• Issued: 02/22/1994
• Est. Priority Date: 08/28/1992
• Status: Expired due to Fees

• Current Assignee: The Dow Chemical Company (Dow, Inc.)
• Original Assignee: The Dow Chemical Company (Dow, Inc.)
• Inventors: Demopolis, Tom N., Goltz, H. Robert
• Primary Examiner(s): SPITZER, ROBERT H
• Application Number:
  US07/937,799
• Time in Patent Office: 543 Days
• Field of Search: 55/68, 55/74, 55/387
• US Class Current: 95/143
• CPC Class Codes: B01J 20/26 Synthetic macromolecular compounds
• CPC Class Codes: C08F 8/24 Haloalkylation
• CPC Class Codes: F02M 25/0854 Details of the absorption canister
• CPC Class Codes: Y10S 95/90 Solid sorbent

Abstract

Hydrocarbon emissions from fuel reservoirs, particularly those associated with motor vehicles, are abated by contacting a vented hydrocarbon fuel vapor stream from the reservoirs with a polymeric adsorbent derived from a macroporous or macroreticular copolymer of at least one monovinylidene aromatic monomer and a crosslinking monomer. The macroporous copolymers are converted into suitable adsorbents by post-polymerization crosslinking in a swollen state in the presence of a Friedel-Crafts catalyst. The resulting adsorbent has improved hydrocarbon adsorption capacity relative to conventional activated carbon adsorbents.

Claims

1. A method for reducing hydrocarbon fuel vapor emissions from fuel reservoirs which comprises:

contacting a vented hydrocarbon fuel vapor stream from a fuel reservoir with a polymeric adsorbent to retain at least a portion of the hydrocarbon fuel vapors emitted from reservoir, the polymeric adsorbent comprising a macroporous or macroreticular copolymer of at least one monovinylidene aromatic monomer and a crosslinking monomer which has been post-crosslinked in a swollen state in the presence of a Friedel-Crafts catalyst.

2. The method of claim 1 wherein the at least one monovinylidene aromatic monomer is selected from styrene, vinylbenzyl chloride, vinyltoluene, ethylstyrene, or t-butylstyrene.

3. The method of claim 1 wherein the crosslinking monomer is selected from divinylbenzene, trivinylbenzene, or ethylene glycol dimethacrylate.

4. The method of claim 1 wherein the macroporous or macroreticular copolymer comprises from about 99.25 to about 95 weight percent of the at least one monovinylidene aromatic monomer and from about 0.75 to about 5 weight percent of the crosslinking monomer, based on monomer weight.

5. The method of claim 1 wherein the macroporous or macroreticular copolymer further comprises less than about 30 weight percent of a non-aromatic monovinylidene monomer based on monomer weight.

6. The method of claim 5 wherein the nonaromatic monovinylidene monomer is methyl methacrylate, methyl acrylate, or methyl ethyl acrylate.

7. The method of claim 1 wherein the macroporous or macroreticular copolymer is post-crosslinked by steps which comprise:

contacting the macroporous or macroreticular copolymer with a haloalkylating agent under conditions sufficient to substitute the copolymer with haloalkyl moieties;

removing any excess haloalkylating agent from the copolymer;

swelling the copolymer with a swelling agent;

maintaining the swollen copolymer at a temperature and in the presence of a Friedel-Crafts catalyst such that individual haloalkyl moieties on a copolymer chain react with an aromatic ring of an adjacent copolymer chain to form a bridging moiety; and

removing the swelling agent from the copolymer.

8. The method of claim 7 wherein the haloalkyl moieties are chloromethyl groups.

9. The method of claim 7 wherein the bridging moiety is a --CH₂ -- moiety.

10. The method of claim 7 wherein the swelling solvent is dichloroethane.

11. The method of claim 1 wherein the polymeric adsorbent has a total porosity of from about 0.5 to about 1.5 cc/g.

12. The method of claim 11 wherein from about 0.04 to about 0.5 cc/g of the total porosity is composed of macropores having a diameter of at least about 100 Å

.

13. The method of claim 1 wherein the polymeric adsorbent has a specific surface area of at least about 1200 m² /g.

14. The method of claim 1 wherein the polymeric adsorbent has a butane working capacity of at least about 14 g/100 cc.

15. A method for reducing hydrocarbon fuel vapor emissions from fuel reservoirs which comprises:

contacting a vented hydrocarbon fuel vapor stream from a fuel reservoir with a polymeric adsorbent to retain at least a portion of the hydrocarbon fuel vapors emitted from the fuel reservoir, the adsorbent comprising a macroporous or macroreticular copolymer of at least one monovinylidene aromatic monomer and a crosslinking monomer which is post-crosslinked in a swollen state in the presence of a Friedel-Crafts catalyst, the macroporous or macroreticular copolymer comprising a cellular polymeric structure wherein a macroporous void phase is dispersed within a continuous copolymer phase, the void phase comprising a plurality of cellular void spaces which are at least partially enclosed by walls of the continuous copolymer phase.

16. The method of claim 15 wherein the macroporous or macroreticular copolymer comprises from about 1 to about 4 weight percent crosslinking monomer based on monomer weight.

17. The method of claim 15 wherein the cellular void spaces have diameters of from about 100 to about 2000 Å

.

18. The method of claim 15 wherein the at least one monovinylidene aromatic monomer is selected from styrene, vinylbenzyl chloride, vinyltoluene, ethylstyrene, or t-butylstyrene.

19. The method of claim 15 wherein the crosslinking monomer is selected from divinylbenzene, trivinylbenzene, or ethylene glycol dimethacrylate.

20. The method of claim 15 wherein the at least one monovinylidene aromatic monomer is styrene and the crosslinking monomer is divinylbenzene.

21. The method of claim 15 wherein the macroporous or macroreticular copolymer further comprises less than about 30 weight percent of a non-aromatic monovinylidene monomer based on total monomer weight.

22. The method of claim 21 wherein the nonaromatic monovinylidene monomer is selected from methyl methacrylate, methyl acrylate, or methyl ethyl acrylate.

23. The method of claim 15 wherein the macroporous or macroreticular copolymer is post-crosslinked by steps which comprise:

contacting the macroporous or macroreticular copolymer with a haloalkylating agent under conditions sufficient to substitute the copolymer with haloalkyl moieties;

removing any excess haloalkylating agent from the copolymer;

swelling the copolymer with a swelling agent;

maintaining the swollen copolymer at a temperature and in the presence of a Friedel-Crafts catalyst such that individual haloalkyl moieties on a copolymer chain react with an aromatic ring of an adjacent copolymer chain to form a bridging moiety; and

thereafter removing the swelling agent from the copolymer.

24. The method of claim 23 wherein the haloalkyl moieties are chloromethyl groups.

25. The method of claim 23 wherein the bridging moiety is a --CH₂ -- moiety.

26. The method of claim 23 wherein the swelling solvent is dichloroethane.

27. The method of claim 15 wherein the polymeric adsorbent has a total porosity of from about 0.5 to about 1.5 cc/g.

28. The method of claim 27 wherein from about 0.04 to about 0.5 cc/g of the total porosity is composed of macropores having a diameter of at least about 100 Å

.

29. The method of claim 15 wherein the polymeric adsorbent has a specific surface area of at least about 1200 m² /g.

30. The method of claim 15 wherein the polymeric adsorbent has a butane working capacity of at least about 14 g/100 cc.