Sorbent structure applicable for carbon dioxide capture

• US 8,496,734 B2
• Filed: 02/26/2009
• Issued: 07/30/2013
• Est. Priority Date: 02/26/2009
• Status: Active Grant

• Current Assignee: Corning Incorporated
• Original Assignee: Corning Incorporated
• Inventors: Gadkaree, Kishor Purushottam, Shi, Youchun
• Primary Examiner(s): Jones, Christopher P
• Application Number:
  US12/393,239
• Publication Number:
  US 20100212495A1
• Time in Patent Office: 1,615 Days
• Field of Search: 95/78, 951/16, 951/34, 951/39, 96/27, 96/66, 502/400, 502/401, 502/416, 502/418, 502/437
• US Class Current: 95/139
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2253/342 Monoliths
• CPC Class Codes: B01D 2257/504 Carbon dioxide
• CPC Class Codes: B01D 2259/40096 by using electrical resistance heating
• CPC Class Codes: B01D 2259/402 using two 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 53/0446 Means for feeding or distributing gases
• CPC Class Codes: B01D 53/0462 Temperature swing adsorption
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/28004 Sorbent size or size distribution, e.g. particle size
• CPC Class Codes: B01J 20/2803 Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products
• CPC Class Codes: B01J 20/28045 Honeycomb or cellular structures; Solid foams or sponges
• CPC Class Codes: B01J 20/28057 Surface area, e.g. B.E.T specific surface area
• CPC Class Codes: B01J 20/3204 Inorganic carriers, supports or substrates
• 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: B01J 20/3416 of sorbents or filter aids comprising free carbon, e.g. activated carbon
• CPC Class Codes: B01J 20/3441 Regeneration or reactivation by electric current, ultrasound or irradiation, e.g. electromagnetic radiation such as X-rays, UV, light, microwaves
• CPC Class Codes: B01J 20/3483 by thermal treatment not covered by groups B01J20/3441 - B01J20/3475, e.g. by heating or cooling
• CPC Class Codes: Y02C 20/40 of CO2

Abstract

A sorbent structure comprising a continuous activated carbon body in the form of a flow-through substrate; and an additive provided on the flow-through substrate, wherein the additive is capable of enhancing the sorption of CO₂ on the sorbent structure. Methods of making the sorbent structure, its use for CO₂ capture, and methods for regenerating the structure for further use.

Claims

1. A sorbent structure comprising:

a continuous activated carbon body in the form of a flow-through substrate comprised of at least one cell defined by at least one porous wall;

wherein the carbon body comprises an electrically conducting dopant material, wherein the dopant is present within the at least one porous wall, and

wherein the temperature of said sorbent structure may be controlled by conduction of an electrical current through said electrically conducting dopant; and

an additive provided on the flow-through substrate,

wherein the additive is capable of enhancing the sorption of CO₂ on the sorbent structure.

2. A sorbent structure of claim 1, wherein the flow-through substrate is a honeycomb.

3. A sorbent structure of claim 1, wherein the flow-through substrate comprises a surface having a surface area of 100 m²/g or more.

4. A sorbent structure of claim 1, wherein the flow-through substrate comprises a total pore volume wherein at least 20% of the total pore volume is comprised of pores having a pore diameter of 5 nm or more.

5. A sorbent structure of claim 1, wherein the additive is a base.

6. A sorbent structure of claim 5, wherein the additive is an organic amine.

7. A sorbent structure of claim 5, wherein the additive is an inorganic amine.

8. A sorbent structure of claim 1, wherein the additive is organic.

9. A sorbent structure of claim 1, wherein the additive is inorganic.

10. A sorbent structure of claim 1, wherein the additive is provided as a coating on the flow-through substrate.

11. A sorbent structure of claim 1, wherein the flow-through substrate further comprises a filler.

12. A sorbent structure of claim 11, wherein the filler is coal or charcoal.

13. A method of making a sorbent structure of claim 1 comprising:

providing a continuous activated carbon body in the form of a flow-through substrate; and

applying to the flow-through substrate an additive, wherein the additive is capable of enhancing the sorption of CO₂ on the sorbent structure.

14. A method according to claim 13, wherein the continuous activated carbon body is provided by:

forming a carbon precursor into the shape of a flow-through substrate;

optionally curing the carbon precursor;

carbonizing the carbon precursor to form a continuous structure of carbon; and

activating the carbon.

15. A method according to claim 14, wherein the carbon precursor is a phenolic resin.

16. A method of removing CO₂ from a gas, the method comprising:

providing a sorbent structure of claim 1; and

contacting the sorbent structure with a gas comprising CO₂.

17. A method according to claim 16, wherein the gas is at a temperature of up to 80°

C.

18. A method of desorbing at least a portion of CO₂ from a sorbent structure, the method comprising:

providing a sorbent structure of claim 1 having CO₂ sorbed thereon; and

heating the sorbent structure to a temperature above the desorption temperature of the CO₂.

19. A method according to claim 18, which comprises heating the sorbent structure to a temperature of 50°

C. or above.

20. A method according to claim 18, which comprises heating the sorbent structure with a flow of inert gas.

21. A method according to claim 18, which comprises heating the sorbent structure by passing a current through the sorbent structure to provide resistive heating.

22. A method according to claim 18, which comprises heating the sorbent structure in a furnace or an oven.

23. A method according to claim 18, further comprising collecting the desorbed CO₂.