Solid materials and method for CO 2 removal from gas stream

• US 8,118,914 B2
• Filed: 08/07/2009
• Issued: 02/21/2012
• Est. Priority Date: 09/05/2008
• Status: Expired due to Fees

• Current Assignee: General Electric Technology GmbH (GE Aerospace)
• Original Assignee: Alstom Technology Ltd. (Alstom SA)
• Inventors: Liu, Zheng, Ferguson, Alan W., Handagama, Nareshkumar B.
• Primary Examiner(s): Lawrence, Jr., Frank
• Application Number:
  US12/537,666
• Publication Number:
  US 20100154636A1
• Time in Patent Office: 928 Days
• Field of Search: 951/39, 959/00, 961/53, 961/54, 502/150, 502/400, 502/439, 423/220, 423228-230
• US Class Current: 95/139
• CPC Class Codes: B01D 2253/112 Metals or metal compounds not provided for in B01D2253/104 or B01D2253/106
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• 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 53/62 Carbon oxides
• CPC Class Codes: B01J 20/02 comprising inorganic material
• CPC Class Codes: B01J 20/041 Oxides or hydroxides
• CPC Class Codes: B01J 20/046 containing halogens, e.g. halides
• CPC Class Codes: B01J 20/06 comprising oxides or hydroxides of metals not provided for in group B01J20/04
• CPC Class Codes: B01J 20/08 comprising aluminium oxide or hydroxide; comprising bauxite
• CPC Class Codes: B01J 20/103 comprising silica
• CPC Class Codes: B01J 20/12 Naturally occurring clays or bleaching earth
• CPC Class Codes: B01J 20/186 Chemical treatments in view of modifying the properties of the sieve, e.g. increasing the stability or the activity, also decreasing the activity
• CPC Class Codes: B01J 20/22 comprising organic material
• CPC Class Codes: B01J 20/223 containing metals, e.g. organo-metallic compounds, coordination complexes
• CPC Class Codes: B01J 20/261 obtained by reactions only involving carbon to carbon unsaturated bonds macromolecular compounds obtained by reactions only involving carbon-to-carbon unsaturated bonds per se C08F
• CPC Class Codes: B01J 20/264 derived from different types of monomers, e.g. linear or branched copolymers, block copolymers, graft copolymers
• CPC Class Codes: B01J 20/2803 Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products
• CPC Class Codes: B01J 20/28042 Shaped bodies; Monolithic structures
• CPC Class Codes: B01J 20/28057 Surface area, e.g. B.E.T specific surface area
• CPC Class Codes: B01J 20/3078 Thermal treatment, e.g. calcining or pyrolizing
• CPC Class Codes: B01J 20/3204 : Inorganic carriers, supports or substrates
• CPC Class Codes: B01J 20/3206 : Organic carriers, supports or substrates
• CPC Class Codes: B01J 20/3236 : containing metal, other than zeolites, e.g. oxides, hydroxides, sulphides or salts
• CPC Class Codes: B01J 20/3248 : the functional group or the linking, spacer or anchoring group as a whole comprising at least one type of heteroatom selected from a nitrogen, oxygen or sulfur, these atoms not being part of the carrier as such
• CPC Class Codes: Y02A 50/20 : Air quality improvement or preservation, e.g. vehicle emission control or emission reduction by using catalytic converters
• CPC Class Codes: Y02C 20/40 : of CO2

Abstract

A system (10) for removing carbon dioxide from a process gas generated during the combustion of a fuel comprises at least one absorption vessel (12, 14) through which the process gas may be forwarded. The absorption vessel (12, 14) is provided with a sorbent material (50) which is operative for reversibly collecting carbon dioxide from the process gas being forwarded through the sorbent material (50). The sorbent material (50) comprises at least one amine, at least one carbon dioxide activating catalyst, and at least one porous material supporting the at least one catalyst and the at least one amine.

Claims

1. A system for removing carbon dioxide from a process gas generated during the combustion of a fuel, said system comprising at least one absorption vessel through which the process gas may be forwarded, said absorption vessel being provided with a sorbent material which is operative for reversibly collecting carbon dioxide from the process gas being forwarded through the sorbent material, said sorbent material comprising at least one amine, at least one carbon dioxide activating catalyst, and at least one porous material supporting the at least one catalyst and the at least one amine.

2. A system according to claim 1, wherein the at least one carbon dioxide activating catalyst comprises a catalyst selected from the group of catalysts comprising organo-metallic complex catalysts, inorganic metal complex catalysts, metal oxides, and metal halides.

3. A system according to claim 2, wherein the at least one carbon dioxide activating catalyst comprises a catalyst selected from the group of catalysts comprising organic transition metal complex catalysts, and inorganic transition metal complex catalysts.

4. A system according to claim 1, wherein the at least one amine comprises a secondary amine.

5. A system according to claim 1, wherein the at least one amine comprises an amine having at least one hydroxyl group.

6. A system according to claim 1, wherein the at least one amine comprises a secondary amine having at least two hydroxyl groups.

7. A system according to claim 1, wherein the at least one porous material supporting the at least one carbon dioxide activating catalyst and the at least one amine has a specific BET area of at least 50 m²/g.

8. A system according to claim 7, wherein the at least one porous material has a specific BET area of 100-1000 m²/g.

9. A system according to claim 1, wherein the at least one carbon dioxide activating catalyst also works as a porous material supporting said at least one amine.

10. A system according to claim 1, wherein the porous material supporting the at least one carbon dioxide activating catalyst and the at least one amine is provided as a sorbent layer on a substrate.

11. A system according to claim 10, wherein the substrate forms at least a part of at least one channel which is operative for receiving at least a portion of the flow of the process gas.

12. A system according to claim 11, wherein the substrate forms a monolithic unit.

13. A system according to claim 12, wherein the monolithic unit is a flow-through monolithic unit.

14. A system according to claim 12, wherein the monolithic unit is a wall-flow monolithic unit.

15. A system according to claim 11, wherein the substrate is a structured packing comprising at least one turbulence promoting device.

16. A method of forming a sorbent material adapted for reversible absorption of carbon dioxide in an absorption vessel through which a process gas generated during the combustion of a fuel may be forwarded, said method comprising forming said sorbent material by immobilizing at least one amine, and at least one carbon dioxide activating catalyst, on at least one porous material.

17. A method according to claim 16, wherein the at least one amine and the at least one carbon dioxide activating catalyst are co-immobilized on the porous material.

18. A method according to claim 16, wherein the porous material comprising the at least one amine and the at least one carbon dioxide activating catalyst immobilized thereon is coated on a substrate to form a sorbent layer thereon.

19. A method according to claim 16, wherein the porous material is coated on a substrate before immobilizing the at least one amine and the at least one carbon dioxide activating catalyst thereon.

20. A method according to claim 16, further comprising:

A) forming a slurry of the porous material, a solvent, and a binder,

B) applying said slurry to a substrate, followed by drying, and then calcining at a temperature of 200-1000°

C.,

C) impregnating the at least one amine and the at least one carbon dioxide activating catalyst onto the porous material, and

D) drying said substrate to obtain said sorbent material.

21. A method according to claim 16, comprising the steps of

A) wet impregnating the at least one carbon dioxide activating catalyst on the porous material,

B) drying the porous material,

C) forming a slurry of said porous material, a solvent, and a binder,

D) applying said slurry to a substrate,

E) drying said substrate followed by calcining the substrate at a temperature of 200-1000°

C. to immobilize the porous material thereon,

F) wet impregnating the at least one amine on the porous material immobilized onto the substrate, and

G) drying the substrate to obtain said sorbent material.

22. A method of forming a sorbent material adapted for reversible absorption of carbon dioxide in an absorption vessel through which a process gas generated during the combustion of a fuel may be forwarded, said method comprising forming said sorbent material by immobilizing at least one amine on at least one porous material comprising a carbon dioxide activating catalyst.

23. A method of removing carbon dioxide from a process gas generated during the combustion of a fuel, said method comprising:

bringing the process gas into contact with a sorbent material which is operative for reversibly collecting carbon dioxide from the process gas, and

wherein said sorbent material comprises at least one amine, at least one carbon dioxide activating catalyst, and at least one porous material supporting the at least one catalyst and the at least one amine, such that carbon dioxide is absorbed by said at least one amine under the influence of said at least one carbon dioxide activating catalyst.