Chemistry of inorganic compounds – Modifying or removing component of normally gaseous mixture
Reexamination Certificate
1999-03-31
2002-01-15
Griffin, Steven P. (Department: 1754)
Chemistry of inorganic compounds
Modifying or removing component of normally gaseous mixture
C210S660000, C502S400000, C502S406000, C502S408000, C502S414000, C502S324000, C502S331000, C502S336000, C502S338000, C502S342000, C502S345000, C502S346000, C502S349000, C502S350000, C502S351000, C502S353000, C502S354000, C502S355000
Reexamination Certificate
active
06338830
ABSTRACT:
BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates generally to an adsorbent and/or catalyst particle that has improved adsorbent properties and/or improved or newly existing catalytic properties by the use of the particle in combination with a particular binder to produce a particle/binder system. The binder can either cross-link to the particle, cross-link to itself and envelope the particle or both.
2. Background Art
Oxides of metals and certain non-metals are known to be useful for removing constituents from a gas or liquid stream by adsorbent mechanisms. For example, the use of activated alumina is considered to be an economical method for treating water for the removal of a variety of pollutants, gasses, and some liquids. Its highly porous structure allows for preferential adsorptive capacity for moisture and contaminants contained in gasses and some liquids. It is useful as a desiccant for gasses and vapors in the petroleum industry, and has also been used as a catalyst or catalyst-carrier in chromatography and in water purification. Removal of contaminants such as phosphates by activated alumina are known in the art. See, for example, Yee, W., “Selective Removal of Mixed Phosphates by Activated Alumina,”
J.Amer. Waterworks Assoc.
, Vol. 58, pp. 239-247 (1966).
U.S. Pat. No. 5,366,948 to Absil et al. discloses the preparation of a fluid cracking catalyst. The catalyst was prepared by the addition of phosphoric acid to a zeolite slurry. A second slurry was prepared by mixing colloidal silica with a source of alumina which is acid soluble. This slurry was mixed with a clay, then the zeolite slurry was added. The final slurry was spray dried at an outlet temperature of 350-360° F. and a pH of 2.8, then calcined in air at approximately 1000° F. The cracking catalyst was used to produce high octane gasoline, and increased lower olefins, especially propylene and butylene.
U.S. Pat. No. 5,422,323 to Banerjee et al. discloses the preparation of a pumpable refractory insulator composition. The composition consists of the combination of a wet component of colloidal silica (40%) in water, and a dry component consisting of standard refractory material. Examples of refractory material include clay, kaolinite, mullite, alumina and alumina silicates. The resulting insulating composition was cast into shape, dried and baked to form an insulating layer.
Japanese Patent No. 63264125 to Fumikazu et al. discloses the preparation of dry dehumidifying materials. Moisture is removed from room air or gas as it passes through a dehumidifying rotor of zeolite (70% by weight) and an inorganic binder (2-30% by weight). The inorganic binder includes colloidal silica, colloidal alumina, silicates, aluminates and bentonite. Wet air was passed through the dehumidifying rotor, and the amount of dried air was assessed.
Japanese Patent No. 60141680 to Kanbe et al. discloses the preparation of a refractory lining repair material. The material was prepared by adding a solution of phosphoric acid with ultra fine silica powder to a mixture of refractory clay and refractory aggregates composed of grog, alumina, silica, zircon and pyrophyllite. The refractory material has improved bonding strength and minute structure, and are useful for molten metal vessels such as ladles, tundishes, and electric furnaces.
Adsorbent particles of the prior art have not achieved the ability to remove particular contaminants from a liquid or gas stream, such as, for example, a waste stream or drinking water, to acceptably low levels. Additionally, the adsorbent particles of the prior art have not been able to bind tightly to particular contaminants so that the adsorbent particle/contaminant composition can be safely disposed of in a landfill. Thus, there has been a need in the art for adsorbents that have improved ability to adsorb particular materials, particularly contaminants from a gas or liquid stream, to thereby purify the stream. There has been a need in the art for the adsorbent particles to tightly bind to the adsorbed contaminant. Also, there has been a need in the art for catalysts that have the ability or that have an improved ability to catalyze the reaction of contaminants into non-contaminant by-products.
Typically in the art, binders block active sites on the adsorbent and catalyst particles, thereby reducing the efficiency of such particles. Therefore, there is a need in the art for a binder system that binds adsorbent and/or catalytic particles together without reducing the performance of the particles.
Applicants have discovered that by using a special binder for adsorbent and/or catalytic particles, improved or new adsorbent and/or catalytic properties can be achieved.
None of the above-cited documents discloses the compositions or processes such as those described and claimed herein.
SUMMARY OF THE INVENTION
In accordance with the purpose(s) of this invention, as embodied and broadly described herein, this invention, in one aspect, relates to a method for producing an adsorbent and/or catalyst and binder system comprising
i) mixing components comprising
a) a binder comprising a colloidal metal oxide or colloidal metalloid oxide,
b) an oxide adsorbent and/or catalyst particle, and
c) an acid,
ii) removing a sufficient amount of water from the mixture to cross-link components a and b to form an adsorbent and/or catalyst and binder system.
In another aspect, the invention provides for an adsorbent and/or catalyst system made by the processes of the invention.
In one aspect, the invention provides an adsorbent and/or catalyst and binder system comprising a binder that has been cross-linked with at least one type of oxide adsorbent and/or catalyst particle.
In yet another aspect, the invention provides a method for reducing or eliminating the amount of a contaminant from a liquid or gas stream comprising contacting the adsorbent and/or catalyst binder system with the contaminant in the stream for a sufficient time to reduce or eliminate the amount of contaminant from the stream.
In yet another aspect, the invention provides a method for catalyzing the degradation of an organic compound comprising contacting the organic compound with the adsorbent and/or catalyst system for a sufficient time to catalyze the degradation of an organic compound.
In yet another aspect, the invention provides a method for reducing or eliminating the amount of a contaminant from a gas stream by catalysis comprising contacting the adsorbent and/or catalyst binder system with a gas stream containing a contaminant comprising an oxide of nitrogen, an oxide of sulfur, carbon monoxide, hydrogen sulfide, or mixtures thereof for a sufficient time to reduce or eliminate the contaminant amount.
In yet another aspect, the invention provides a method for producing an adsorbent and/or catalyst and binder system comprising
i) mixing components comprising
a) a binder comprising a colloidal metal oxide or colloidal metalloid oxide,
b) a first adsorbent and/or catalyst particle that does not cross-link with the binder, and
c) an acid,
ii) removing a sufficient amount of water from the mixture to cross-link component a to itself, thereby entrapping and holding component b within the cross-linked binder, to form an adsorbent and/or catalyst and binder system.
In another aspect the invention relates to a composition for binding adsorbent and/or catalytic particles to produce an agglomerated particle comprising (a) a colloidal metal oxide or colloidal metalloid oxide and (b) an acid.
In another aspect the invention relates to a kit for binding adsorbent and/or catalytic particles to produce an agglomerated particle comprising (a) a colloidal metal oxide or colloidal metalloid oxide and (b) an acid.
In yet another aspect, the invention provides a method for binding adsorbent and/or catalytic particles, comprising the steps of:
(a) mixing colloidal alumina or colloidal silica with the particles and an acid;
(b) agitating the mixture to homogeneity; and
(c) heating the mixture for a sufficient time to cause cross-linking of the alum
Kepner Bryan E.
Moskovitz Mark L.
Apyron Technologies, Inc.
Griffin Steven P.
Ildebrando Christina
Needle & Rosenberg P.C.
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