Particulate absorbent materials
First Claim
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1. A particulate absorbent material for the absorption of a chemical species from a fluid, wherein said absorbent material is fabricated by a process comprising the steps of:
- (a) providing a precursor solution comprising at least a first precursor to an absorbent compound selected from Group 1 and Group 2 metal oxides;
(b) atomizing said precursor solution to form precursor droplets comprising said first precursor;
(c) heating said precursor droplets remove liquid therefrom and form dried precursor droplets; and
(d) converting said dried precursor droplets to a particulate absorbent material comprising said absorbent compound, wherein said particulate absorbent material is adapted to absorb CO2 and has a CO2 mass absorption capacity of at least about 20 grams CO2 per 100 grams unreacted absorbent material.
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Abstract
Solid absorbent materials that are useful for absorption of chemical species from a fluid, such as a gas stream or a liquid stream. The absorbent materials are formed by spray processing and posses a well-defined chemical composition and microstructure. The absorbent materials can have a high absorption capacity for a chemical species such as H2S, CO2, NOx, and H2 and have a high recylability, such that the chemical species can be absorbed and desorbed over a large number of cycles.
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Citations
55 Claims
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1. A particulate absorbent material for the absorption of a chemical species from a fluid, wherein said absorbent material is fabricated by a process comprising the steps of:
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(a) providing a precursor solution comprising at least a first precursor to an absorbent compound selected from Group 1 and Group 2 metal oxides; (b) atomizing said precursor solution to form precursor droplets comprising said first precursor; (c) heating said precursor droplets remove liquid therefrom and form dried precursor droplets; and (d) converting said dried precursor droplets to a particulate absorbent material comprising said absorbent compound, wherein said particulate absorbent material is adapted to absorb CO2 and has a CO2 mass absorption capacity of at least about 20 grams CO2 per 100 grams unreacted absorbent material.
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2. An absorbent material as recited in claim 1, wherein said heating step and said converting step occur sequentially in a spray pyrolysis reactor.
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3. An absorbent material as recited in claim 1, wherein said heating step forms an intermediate compound capable of being post-processed to form a particulate absorbent material, and wherein said converting step comprises heating said intermediate compound to form said particulate absorbent material.
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4. A particulate absorbent material as recited in claim 1, wherein said first precursor is selected from the group consisting of a metal nitrate, a metal acetate, a metal oxalate and a metal hydroxide.
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5. A particulate absorbent material as recited in claim 1, wherein said first precursor comprises a metal oxalate.
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6. A particulate absorbent material as recited in claim 1, wherein said absorbent compound comprises a metal oxide selected from the group consisting of magnesium oxide, calcium oxide, strontium oxide and barium oxide.
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7. A particulate absorbent material as recited in claim 1, wherein said absorbent compound comprises calcium oxide.
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8. A particulate absorbent material as recited in claim 1, wherein said precursor solution comprises a metal salt of a Group 1 or a Group 2 metal selected from the group consisting of a metal oxalate salt and a metal hydroxide salt.
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9. A particulate absorbent material as recited in claim 1, wherein said heating step comprises heating said droplets in the presence of an oxygen-containing gas.
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10. A particulate absorbent material as recited in claim 1, wherein said precursor solution further comprises a morphology-enhancing agent.
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11. A particulate absorbent material as recited in claim 1, wherein said precursor solution further comprises a morphology-enhancing agent selected from the group consisting of lactic acid, glycine, alcohols, ammonium nitrate, polymers and carbohydrazide.
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12. A particulate absorbent material as recited in claim 1, wherein said precursor solution further comprises a precursor to a second compound selected from the group consisting of aluminum oxide, magnesium oxide, silicon oxide and titanium oxide.
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13. A particulate absorbent material as recited in claim 1, wherein said particulate absorbent material comprises CaO:
- MgO.
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14. A particulate absorbent material as recited in claim 1, wherein said precursor solution further comprises a precursor to magnesium oxide.
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15. A particulate absorbent material as recited in claim 1, wherein said precursor solution further comprises magnesium nitrate.
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16. A particulate absorbent material as recited in claim 1, wherein said precursor solution further comprises a precursor to alumina.
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17. A particulate absorbent material as recited in claim 1, wherein said precursor solution further comprises particulate alumina.
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18. A particulate absorbent material as recited in claim 1, wherein said precursor solution further comprises a precursor to a metal selected from the group consisting of Mg, Ni, Zn and Cu.
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19. A particulate absorbent material as recited in claim 1, wherein said heating step comprises heating said precursor droplets to a temperature of at least about 300°
- C.
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20. A particulate absorbent material as recited in claim 1, wherein said atomizing step comprises atomizing said precursor solution using a spray nozzle.
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21. A particulate absorbent material as recited in claim 1, wherein said atomizing step comprises atomizing said precursor using ultrasonic transducers.
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22. A particulate absorbent material as recited in claim 1, wherein said particulate absorbent material has an average size of from about 1 μ
- m to about 50 μ
m.
- m to about 50 μ
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23. A particulate absorbent material as recited in claim 1, further comprising the step of pelletizing said particulate absorbent material.
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24. A particulate absorbent material as recited in claim 1, further comprising the step of coating said particulate absorbent material on a support structure.
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25. A particulate absorbent material as recited in claim 1, wherein said particulate absorbent material has a substantially spherical morphology.
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26. A particulate absorbent material as recited in claim 1, further comprising the step of heating said particulate absorbent material.
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27. A particulate absorbent material as recited in claim 1, wherein said particulate absorbent material has a pore volume of at least about 0.04 g/cm3.
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28. A particulate absorbent material as recited in claim 1, wherein said particulate absorbent material has a pore volume of at least about 0.15 g/cm3.
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29. A particulate absorbent material as recited in claim 1, wherein said particulate absorbent material has a surface area of at least about 15 m2/g.
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30. A particulate absorbent material as recited in claim 1, wherein said particulate absorbent material has a surface area of at least about 30 m2/g.
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31. A particulate absorbent material as recited in claim 1, wherein said absorbent compound maintains said CO2 mass absorption capacity over at least 100 cycles.
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32. A particulate absorbent material as recited in claim 1, wherein said absorbent material has a CO2 mass absorption capacity of at least about 30 grams CO2 per 100 grams of unreacted absorbent material.
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33. A particulate absorbent material as recited in claim 1, wherein said absorbent compound has a CO2 molar absorption capacity of at least about 70 mol. %.
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34. A particulate absorbent material as recited in claim 1, wherein said absorbent compound has a CO2 molar absorption capacity of at least about 90 mol. %.
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35. A particulate absorbent material as recited in claim 33, wherein said absorbent compound maintains said CO2 molar absorption capacity over at least 100 cycles.
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36. A particulate absorbent material as recited in claim 1, wherein said heating step comprises heating said droplets in a spray dryer.
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37. A particulate absorbent material adapted for the absorption of a chemical species from a fluid, wherein said particulate absorbent material comprises an intimate mixture of at least a first absorbent compound selected from Group 1 and Group 2 metal oxides and at least a first metal oxide inert additive that is different than said first absorbent compound, wherein said particulate absorbent material has a surface area of at least about 5 m2/g and wherein said particulate absorbent material comprises not greater than 50 wt. % metal oxide inert additives.
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38. A particulate absorbent material as recited in claim 37, wherein said absorbent compound is a calcium compound.
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39. A particulate absorbent material as recited in claim 37, wherein said first metal oxide inert additive is selected from the group consisting of Al2O3, MgO, SiO2 and TiO2.
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40. A particulate absorbent material as recited in claim 37, wherein said particulate absorbent material is in the form of substantially spherical particles.
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41. A particulate absorbent material as recited in claim 37, wherein said surface area is at least about 10 m2/g.
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42. A particulate absorbent material as recited in claim 37, wherein said surface area is at least about 15 m2/g.
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43. A particulate absorbent material as recited in claim 37, wherein said surface area is at least about 30 m2/g.
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44. A particulate absorbent material as recited in claim 37, wherein said particulate absorbent material has a pore volume of at least about 0.01 cm3/g.
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45. A particulate absorbent material as recited in claim 37, wherein said particulate absorbent material has a pore volume of at least about 0.04 cm3/g.
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46. A particulate absorbent material as recited in claim 37, wherein said particulate absorbent material has a pore volume of at least about 0.15 cm3/g.
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47. A particulate absorbent material as recited in claim 37, wherein said first metal oxide inert additive comprises from about 1 wt. % to 50 wt. % of said particulate absorbent material.
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48. A particulate absorbent material as recited in claim 37, where said first metal oxide inert additive comprises from about 5 wt. % to about 25 wt. % of said particulate absorbent material.
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49. A particulate absorbent material as recited in claim 37, wherein said first absorbent compound has an absorption capacity of at least about 50 mol. % for at least one selected chemical species.
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50. A particulate absorbent material as recited in claim 37, wherein said first absorbent compound has an absorption capacity of at least about 70 mol. % for at least one selected chemical species.
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51. A particulate absorbent material as recited in claim 37, wherein said first absorbent compound has an absorption capacity of at least about 90 mol. % for at least one selected chemical species.
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52. A particulate absorbent material as recited in claim 37, wherein said first absorbent compound has an absorption capacity of at least about 50 mol. % for at least one selected chemical species after at least 100 cycles.
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53. A particulate absorbent material as recited in claim 37, wherein said first absorbent compound has an absorption capacity of at least about 70 mol. % for at least one selected chemical species after at least 100 cycles.
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54. A particulate absorbent material as recited in claim 37, wherein said first absorbent compound has an absorption capacity of at least about 90 mol. % for at least one selected chemical species after at least 100 cycles.
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55. A particulate absorbent material as recited in claim 37, wherein said particulate absorbent material is pelletized.
Specification