Catalyst – solid sorbent – or support therefor: product or process – Solid sorbent – Free carbon containing
Reexamination Certificate
1999-01-14
2001-02-13
Dunn, Tom (Department: 1754)
Catalyst, solid sorbent, or support therefor: product or process
Solid sorbent
Free carbon containing
C502S423000
Reexamination Certificate
active
06187713
ABSTRACT:
This invention relates to activated carbon with improved adsorption properties. The activated carbon is derived from synthetic carbon precursors and the improved adsorption is due to the inclusion of an additive or modifier for the precursor to enhance the adsorption properties of the carbon precursor.
BACKGROUND OF THE INVENTION
Activated carbon is utilized in many industrial applications for process stream purifications as well as pollution control.
Activated carbon can take the form of a shaped body, or a coating on a substrate, or as granules.
One method of making activated carbon is to carbonize a carbon precursor such as a synthetic resin, followed by activation.
Activated carbon coated inorganic honeycombs have been discussed in U.S. Pat. No. 5,451,444. The cordierite honeycombs are coated with a synthetic polymeric precursor to carbon. The polymer infiltrates the porous honeycomb and forms an interpenetrating network structure.
Thermosetting synthetic resins are preferred because of low cost and water solubility. The activated carbon coated honeycombs obtained by carbonizing and activating the carbon coat on the cordierite honeycombs have high adsorption capacity, high strengths, and ability to perform at high temperatures.
The present invention provides an activated carbon product with improved adsorption properties.
SUMMARY OF THE INVENTION
In accordance with one aspect of the invention, there is provided a method of making an activated carbon body which involves providing an inorganic substrate, a thermosetting resin, and an adsorption enhancing additive which can be sulfur and/or oil which is non-miscible with and non-reactive with the carbon precursor, contacting the inorganic substrate with the carbon precursor and the adsorption enhancing additive to coat the substrate therewith, curing and carbonizing the carbon precursor, and activating the carbon, to produce a coating of activated carbon on the substrate and form the activated carbon body.
In accordance with another aspect of the invention, there is provided a method for making an activated carbon body which involves forming a mixture of thermosetting resin, adsorption enhancing additive, which can be sulfur, phosphoric acid, and/or the oil, temporary organic binder, optional forming aid, and fillers, shaping the mixture into a body, followed by curing, carbonizing, and activating to produce a shaped body of activated carbon.
In accordance with another aspect of the invention, there is provided activated carbon bodies made by the above-described methods. When sulfur is utilized, there is formed a carbon-sulfur bond that is characterized by a peak at 165.9 eV when analyzed by Electron Spectroscopy for Chemical Analysis.
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Corning Incorporated
Dunn Tom
Gheorghiu Anca C.
Hendrickson Stuart L.
Herzfeld L. Rita
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