Methods of applying a sorbent coating on a substrate, a support, and/or a substrate coated with a support

• US 9,457,340 B2
• Filed: 10/04/2012
• Issued: 10/04/2016
• Est. Priority Date: 10/06/2011
• Status: Expired due to Fees

• Current Assignee: BASF Corporation (BASF SE)
• Original Assignee: BASF Corporation (BASF SE)
• Inventors: Buelow, Mark, Durilla, Michael, Kauffman, John, Tran, Pascaline Harrison
• Primary Examiner(s): Slifka, Colin W
• Application Number:
  US13/644,454
• Publication Number:
  US 20130095996A1
• Time in Patent Office: 1,461 Days
• Field of Search: None
• US Class Current: 1/1
• CPC Class Codes: B01D 2253/20 Organic adsorbents
• CPC Class Codes: B01D 2253/202 Polymeric adsorbents
• CPC Class Codes: B01D 2253/25 Coated, impregnated or composite adsorbents
• CPC Class Codes: B01D 2253/306 Surface area, e.g. BET-specific surface
• CPC Class Codes: B01D 2253/311 Porosity, e.g. pore volume
• CPC Class Codes: B01D 2253/34 Specific shapes
• 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: B01J 20/3204 Inorganic 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 20/3238 containing any type of zeolite
• CPC Class Codes: B01J 20/3251 comprising at least two different types of heteroatoms selected from nitrogen, oxygen or sulphur
• CPC Class Codes: B01J 20/3257 the functional group or the linking, spacer or anchoring group as a whole comprising at least one of the heteroatoms nitrogen, oxygen or sulfur together with at least one silicon atom, these atoms not being part of the carrier as such
• CPC Class Codes: B01J 20/327 Polymers obtained by reactions involving only carbon to carbon unsaturated bonds
• CPC Class Codes: B01J 20/3272 Polymers obtained by reactions otherwise than involving only carbon to carbon unsaturated bonds
• CPC Class Codes: Y02C 20/40 of CO2

Abstract

Methods of applying a sorbent coating on a substrate, a support, and/or a substrate coated with a support are described. One of the methods comprises: (i) optionally, preparing the substrate coated with the support by pre-treating the substrate with a slurry, wherein the slurry comprises: a. solvent, b. a binder, c. the support, and d. optional dispersant; and (ii) treating the substrate, the support, and/or the substrate coated with the support, with a sorbent.

Claims

1. A method of applying a sorbent coating on a substrate, the method comprising:

(i) preparing the substrate by pre-treating the substrate with a slurry, wherein the slurry comprises;

a. solvent,

b. a binder, and

c. a support; and

(ii) subsequently treating the substrate with a sorbent;

wherein the substrate is (a) a monolithic or honeycomb structure made of ceramic, metal, or plastic;

(b) a polyurethane foam, a polypropylene foam, a polyester foam, a metal foam, or a ceramic foam;

or (c) woven or non-woven plastic or cellulosic fibers,

wherein the support comprises alumina, silica, silica-alumina, titania, zirconia, carbon, zeolite, metal-organic framework (MOF), or combinations thereof, the support having a surface area of 150 m²/g to 250 m²/g and a pore volume of 0.7 cc/g to 1.5 cc/g,

wherein the sorbent adsorbs carbon dioxide and the sorbent is polyethylenimine (PEI);

wherein the PEI is present at a concentration of 25 wt % to 45 wt % calculated as weight of PEI divided by weight of PEI and support; and

wherein the surface area and pore volume of the support together provide the sorbent with a carbon dioxide adsorption capacity that is greater than 1.5 mmol CO₂/g coating.

2. The method of claim 1, wherein the ceramic substrate is selected from the group consisting of cordierite, alumina, cordierite-a alumina, silicon nitride, zircon mullite, spodumene, alumina-silica magnesia, zircon silicate, sillimanite, magnesium silicates, zircon, petalite, aluminosilicates, and combinations thereof.

3. The method of claim 2, wherein the ceramic substrate is cordierite, alumina, or a combination thereof.

4. The method of claim 1, wherein the metal substrate is aluminum, titanium, stainless steel, a Fe—

Cr alloy, or a Cr—

Al—

Fe alloy in the form of a sheet, mesh, foil, flakes, powder, wire, rod, or combinations thereof.

5. The method of claim 4, wherein the metal substrate is aluminum, stainless steel, Cr—

Al—

Fe alloy, or combinations thereof in the form of a sheet, mesh, or foil.

6. The method of claim 1, wherein the plastic substrate is a polymer and/or copolymer of polyolefin(s), polyester(s), polyurethane(s), polycarbonate(s), polyetheretherketone(s), polyphenylene oxide(s), polyether sulfone(s), melamine(s), polyamide(s), polyacrylates, polystyrenes, polyacrylonitriles, polyimides, polyfurfural alcohol, phenol furfuryl alcohol, melamine formaldehydes, resorcinol formaldehydes, cresol formaldehyde, phenol formaldehyde, polyvinyl alcohol dialdehyde, polycyanurates, polyacrylamides, various epoxies, agar, and agarose, or combinations thereof.

7. The method of claim 6, wherein the plastic substrate is a polymer and/or copolymer of polyolefin, polyester, polyurethane, melamine, polypropylene, or polyamide.

8. The method of claim 1, wherein the monolithic structure has channels having about 50 to about 900 cells per square inch.

9. The method of claim 8, wherein the channels are square, triangular, or sinusoidal in cross-section.

10. The method of claim 8, wherein the channels are straight, zig-zag, skewed, or herringbone in shape.

11. The method of claim 8, wherein the channels have walls that are perforated or louvered.

12. The method of claim 1, wherein the ceramic or plastic monolithic structure is made by extrusion.

13. The method of claim 1, wherein the metal or plastic monolithic structure is made by layering corrugated metal foil or corrugated plastic sheets.

14. The method of claim 1, wherein step (i) further comprises:

a. coating the substrate with the slurry;

b. removing excess solvent from the coated substrate; and

c. calcining the binder and the support onto the substrate.

15. The method of claim 14, wherein the calcining occurs at a temperature range of 200°

C. to 550°

C.

16. The method of claim 15, wherein the calcining occurs at a temperature of 425°

to 475°

C.

17. The method of claim 16, wherein the calcining occurs at a temperature of 450°

C.

18. The method of claim 1, wherein the binder in step (i) is alumina sol, aluminum oxide hydroxide, silica sol, titania sol, zirconium acetate, silicone, or combinations thereof.

19. The method of claim 18, wherein the alumina sol is milled to have a D50 particle size ranging from 1 μ

m to 10 μ

m.

20. The method of claim 19, wherein the alumina sol is milled to have a D50 particle size ranging from 3 μ

m to 6 μ

m.

21. The method of claim 1 further comprising:

(iii) after step (ii), drying the treated substrate to remove excess amounts of the sorbent and to remove excess solvent to obtain a sorbent coated substrate.

22. The method of claim 21, wherein the drying occurs at a temperature range of 30°

C. to 70°

C.

23. The method of claim 22, wherein the drying occurs at a temperature range of 40°

C. to 60°

C.

24. The method of claim 23, wherein the drying occurs at a temperature 50°

C.

25. The method of claim 1, wherein the solvent is selected from the group consisting of water, methanol, ethanol, toluene, isopropanol, 2-methoxyethyl ether, and mixtures thereof.

26. The method of claim 1, wherein the sorbent adsorbs carbon dioxide from air, from off-gases, intentionally produced carbon dioxide, or from their mixtures.

27. The method of claim 26, wherein the adsorbed carbon dioxide is stored and/or used in enhanced oil recovery, in carbonation of beverages, for food processing/cooling/freezing, as a reactant in the production of chemicals, as a feedstock for algae, or as a fire extinguishing medium.

28. The method of claim 1, wherein the sorbent purifies gases or separates gases.

29. The method of claim 1, wherein the sorbent adsorbs carbon dioxide to purify natural gas, ambient air, flue gas, or other impure gas mixtures containing carbon dioxide.

30. The method of claim 1, wherein the slurry further comprises a dispersant.

31. The method of claim 1, wherein the binder is added in an amount of up to about 10 wt % based on a total weight of the support.

32. The method of claim 1, wherein the binder is added in an amount of about 6 to about 25 wt % based on a total weight of the support.

33. The method of claim 1, wherein the sorbent is added in an amount of about 25 to about 40 wt % based on the total weight of the support.

34. The method of claim 1, wherein the support has a surface area of about 170 m²/g to 180 m²/g and a pore volume of about 0.9 cc/g to 1.2 cc/g.