Acid-impregnated activated carbon and methods of forming and using the same

• US 9,114,358 B2
• Filed: 02/03/2012
• Issued: 08/25/2015
• Est. Priority Date: 08/23/2006
• Status: Active Grant

• Current Assignee: Sulvaris Inc.
• Original Assignee: Sulvaris Inc.
• Inventors: Johnson, Richard L., Kuzub, R. Eugene, Tak, Jin Kwon
• Primary Examiner(s): HENDRICKSON, STUART L
• Application Number:
  US13/365,877
• Publication Number:
  US 20120137744A1
• Time in Patent Office: 1,299 Days
• Field of Search: 502/417
• US Class Current: 1/1
• CPC Class Codes: B01D 2251/50 Inorganic acids
• CPC Class Codes: B01D 53/58 Ammonia
• CPC Class Codes: B01D 53/8634 Ammonia
• CPC Class Codes: B01J 20/20 comprising free carbon; comprising carbon obtained by carbonising processes
• CPC Class Codes: B01J 20/28016 Particle form
• CPC Class Codes: B01J 20/28057 Surface area, e.g. B.E.T specific surface area
• CPC Class Codes: B01J 20/3007 Moulding, shaping or extruding
• CPC Class Codes: B01J 20/3021 Milling, crushing or grinding
• CPC Class Codes: B01J 20/3028 Granulating, agglomerating or aggregating
• CPC Class Codes: B01J 20/3085 Chemical treatments not covered by groups B01J20/3007 - B01J20/3078
• CPC Class Codes: B01J 2220/4812 the starting material being of organic character
• CPC Class Codes: B01J 2220/4875 the starting material being a waste, residue or of undefined composition
• CPC Class Codes: C01B 32/342 characterised by non-gaseous activating agents
• CPC Class Codes: C05C 3/00 Fertilisers containing other salts of ammonia or ammonia itself, e.g. gas liquor
• CPC Class Codes: C05D 9/00 Other inorganic fertilisers
• CPC Class Codes: C05G 5/40 Fertilisers incorporated into a matrix
• 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: Y02E 50/30 Fuel from waste, e.g. synthetic alcohol or diesel

Abstract

An acid-impregnated activated carbon matrix is formed from a carbonaceous material by the addition of a mineral acid, and may be used to chemisorb ammonia from a gas stream. The ammonia reacts with the acid to form a fertilizer salt. The spent matrix may be used as a fertilizer, or the fertilizer salt may be elutriated from the matrix.

Claims

1. A method of chemisorbing ammonia from a gas stream comprising the steps of:

(a) reacting liquid acid with a carbonaceous biomass material under ambient conditions to convert the biomass to a porous carbon matrix impregnated with the liquid acid, and without a heat treatment, washing or neutralization step;

(b) flowing an ammonia-containing gas over or through the porous carbon matrix impregnated with a mineral acid in a reactor, such that the ammonia reacts with the mineral acid, to produce ammonium salt.

2. The method of claim 1 wherein the liquid acid comprises sulphuric acid, phosphoric acid, nitric acid or hydrochloric acid.

3. The method of claim 2 wherein the liquid acid comprises concentrated sulphuric acid.

4. The method of claim 1 wherein the porous carbon matrix impregnated with the mineral acid is disturbed during gas flow.

5. The method of claim 1 comprising the further step of pelletizing or granulating the porous carbon matrix impregnated with the mineral acid prior to chemisorption.

6. The method of claim 5 wherein the porous carbon matrix pellets or granules are disturbed during gas flow.

7. A method of producing a fertilizer product comprising the steps of:

(a) reacting liquid acid with a carbonaceous biomass material under ambient conditions to convert the biomass to a porous carbon matrix impregnated with the liquid acid, and without a heat treatment, washing or neutralization step;

(b) flowing an ammonia-containing gas over or through the porous carbon matrix impregnated with a mineral acid in a reactor, such that the ammonia reacts with the mineral acid, to produce an ammonium salt fertilizer.

8. The method of claim 7 further comprising the step of screening, pelletizing or granulating the porous carbon matrix to a desired particle size range.

9. The method of claim 7, further comprising the step of elutriating the ammonium salt fertilizer from the porous carbon matrix.

10. The method of claim 7 wherein the liquid acid comprises sulphuric acid, phosphoric acid, nitric acid or hydrochloric acid.

11. The method of claim 10 wherein the mineral acid comprises concentrated sulphuric acid.