Mercury removal catalyst and method of making and using same

• US 6,136,749 A
• Filed: 07/15/1998
• Issued: 10/24/2000
• Est. Priority Date: 07/28/1997
• Status: Expired due to Term

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Tao, Tinghong, Gadkaree, Kishor P.
• Primary Examiner(s): Griffin, Steven P.
• Assistant Examiner(s): DONELY, CYNTHIA M
• Application Number:
  US09/116,183
• Time in Patent Office: 832 Days
• Field of Search: 502/216, 502/182, 502/184, 502/180, 502/183, 423/215.5
• US Class Current: 502/183
• CPC Class Codes: B01D 53/8665 Removing heavy metals or compounds thereof, e.g. mercury
• CPC Class Codes: B01J 21/18 Carbon
• CPC Class Codes: B01J 23/78 with alkali- or alkaline earth metals
• CPC Class Codes: B01J 27/02 Sulfur, selenium or tellurium; Compounds thereof
• CPC Class Codes: B01J 35/00 Catalysts, in general, characterised by their form or physical properties
• CPC Class Codes: B01J 35/30 characterised by their physical properties
• CPC Class Codes: B01J 37/084 Decomposition of carbon-containing compounds into carbon
• CPC Class Codes: C01B 32/372 Coating; Grafting; Microencapsulation
• CPC Class Codes: Y10S 95/901 Activated carbon

Abstract

An activated carbon catalyst having sulfur dispersed homogeneously thereon, the sulfur being chemically bonded to the activated carbon. A method of making the catalyst involves forming an intimate mixture of a synthetic carbon precursor and a sulfur-containing material, curing the carbon precursor, carbonizing the carbon precursor, activating the carbonized carbon precursor to produce an activated carbon catalyst having sulfur chemically bonded to the activated carbon and uniformly dispersed thereon.

Claims

1. A method of making a catalyst, the method comprising:

a) forming an intimate mixture comprising a synthetic carbon precursor and a sulfur-containing material;

b) curing the carbon precursor;

c) carbonizing the carbon precursor;

d) activating the carbonized carbon precursor to produce an activated carbon catalyst having sulfur chemically bonded to said activated carbon and uniformly dispersed thereon.

2. A method of claim 1 wherein the carbon precursor is provided as a thermosetting resin.

3. A method of claim 1 wherein the sulfur is provided in the form of fine sulfur powder, wherein the average particle diameter is less than about 100 micrometers.

4. A method of claim 3 wherein the average particle diameter of the sulfur powder is less than about 10 micrometers.

5. A method of claim 1 wherein the carbon precursor and sulfur-containing material are provided in amount sufficient to result in a weight ratio of sulfur to carbon of about 0.005:

1 to 0.40;

1 in the activated carbon catalyst.

6. A method of claim 5 wherein said weight ratio is about 0.03:

1 to 0.30;

1.

7. A method of claim 1 wherein a co-catalyst precursor is included with the activated carbon.

8. A method of claim 1 wherein a co-catalyst precursor is included with the activated carbon in the intimate mixture.

9. A method of claim 1 wherein a co-catalyst precursor is included with the activated carbon by being added to the activated carbon and sulfur after the activation step.

10. A method of claim 7 wherein the co-catalyst is selected from the group consisting of metal catalyst precursor, alkali metal halide, alkaline earth metal halide, and combinations thereof.

11. A method of claim 10 wherein the co-catalyst is metal catalyst precursor wherein the weight ratio of co-catalyst metal to carbon is about 0.002:

1 to 0.5;

1.

12. A method of claim 11 wherein the weight ratio of co-catalyst metal to carbon is about 0. 05:

1 to 0.2;

1.

13. A method of claim 10 wherein the co-catalyst is selected from the group consisting of alkali metal halide, alkaline earth metal halide, and combinations thereof and the weight ratio of co-catalyst to carbon is about 0.005:

1 to 1.5;

1.

14. A method of claim 13 wherein the weight ratio of co-catalyst to carbon is about 0.05:

1 to 0.7;

1.

15. A method of claim 10 wherein the weight ratio of sulfur to carbon is about 0.005:

1 to 0.40;

1, the weight ratio of co-catalyst metal to carbon is about 0.002;

1 to 0.5;

1, and the weight ratio of alkali metal halide and/or alkaline earth metal halide to carbon is about 0.005;

1 to 0.7;

1.

16. A method of claim 15 wherein the weight ratio of sulfur to carbon is about 0.03:

1 to 0.30;

1, the weight ratio of co-catalyst metal to carbon is about 0.05;

1 to 0.2;

1, and the weight ratio of alkali metal halide and/or alkaline earth metal halide to carbon is about 0.05;

1 to 0.5;

1.

17. A method of claim 1 wherein the mixture is applied as a coating onto an inorganic substrate.

18. A method of claim 17 wherein the substrate is a honeycomb.

19. A method of claim 17 wherein the substrate is made of material selected from the group consisting of ceramic, glass, glass-ceramic, metal, and combinations thereof.

20. A method of claim 19 wherein the substrate is made of cordierite.

21. A method of claim 1 wherein the intimate mixture further comprises binder, filler material, forming aids, and vehicle, and wherein prior to the curing step, the mixture is shaped into a structure.

22. A method of claim 21 wherein the shaping is done by extrusion.

23. A method of claim 22 wherein the mixture is extruded into a honeycomb structure.