MXPA96004865A - Structures in the form of activated carbon panal which have variable adsorption capabilities and method to make myself - Google Patents

Abstract

The present invention relates to a method for making an activated carbon composite, characterized in that it comprises the steps of: a) impregnating a support material with an entangled resin to saturate the material support with the resin and form a supported resin, where the viscosity of the resin is about 50 cps at 1000 cps, said support material being selected from the group consisting of cotton, chopped wood, henequen, non-fugitive material, and combinations thereof, b) drying the supported resin; c) shaping the dry supported resin, d) curing the resin, e) carbonizing the cured resin by heating the cured resin to a temperature of about 600 ° C to 1000 ° C in an inert or reduced atmosphere; ) heat treating the resin supported from step (e) to activate the carbon and produce an active carbon adsorber compound

Description

STRUCTURES IN THE FORM OF ACTIVATED CARBON PANAL THAT HAVE VARIABLE ADSORPTION CAPACITIES AND METHOD TO MAKE THEM SAME This invention relates to activated carbon bodies with a cord-like structure configuration]. The honeycomb structures are made from the contact of an interlacing resin with material that forms 'Annals and optionally with pore forcing material and / or support fillers, training, curing, carbonization, and activation. The material that forms channels is divided into components of p > that low molecular in an inert atmosphere at high temperatures, leaving behind honeycomb structure channels. These bodies are strong and are not subject to rubbing like granulated carbon beds. The bodies have continuous flow paths to minimize pressure drop in a flow stream. The configuration of the channels, and thus the adsorption capacity can be controlled by selecting the suitable size and shape channel forming material as well as the percentage of pore-forming material and support fillers. Therefore, the bodies can be adapted to a wide variety of adsorption applications.

BACKGROUND OF THE INVENTION Activated carbon materials in the form of granules or powders are used for a variety of pollution control applications. The contaminants in liquid or gaseous streams are removed by contacting the stream with the activated carbon in granulated or powder form. The fine-pored structure of angstrom size of activated carbon allows the adsorption of impurities out of the process streams. The pores in activated carbon that impart the unique ability to adsorb contaminants even at very low concentrations (for example as low as 1 ppm) are on a scale of 5 to 20 angstrorns. Pores above 50 angstroms do not contribute significantly to adsorption at low concentrations. Although activated charcoal is used in "tubing applications for control of contamination, in the form of pellets or dust, a major disadvantage with this form of carbon is the high pressure drop associated with pellet or powder beds. Another problem is the entry of dust into the stream of flow and rubbing of the granules.One way to solve this problem is to form the dihedral carbon in the configuration of a honeycomb structure.The geometry of the structure in the form of honeycomb has the advantage of high geometric surface r * available for contact and low pressure drop * .on the bed.In the industrial TV procedures are necessary the structure geometries in honeycomb form.The resins have been used in the manufacture of carbon bodies both as binders and as carbon precursors For example, phenolic resins are struded in honeycomb structure configurations as in US Patent 4, 399, 052. The resin is cured, carbonized and activated. A major difficulty with a product as such is that during carbonization when approximately 50% by weight is lost, said bodies become distorted and in many cases break. All the above difficulties have been overcome by means of the method of covering a structure body in the form of a porous ceramic honeycomb with a thermosetting resin, and then carbonization and activation. Said products are described in the North American application S.N. ^ / ll, 3B5, filed January 29, 1993. The disadvantages associated with this procedure are the cost of first extruding and then baking a ceramic honeycomb structure and then coating, curing and activating. Second, the amount of resin and therefore the amount of carbon that can be put into the body is limited, thus limiting its capacity. The methods for making shapes by submerging rods or cylinders in the resin and then forming honeycomb structures by removing the bars after curing the resin as in US Pat., 825,460 and 1,922,412, once they are subjected to the same type of problems such as buckling and breaking while forming the cavities by means of resin extrusion. It would be very desirable to have a method in which the adsorption capacity per unit volume could be controlled so that it could be adjusted to the requirements of a specific application and at the same time exhibit properties in the body of non-friction, pressure drop reduced to a minimum, and high surface area in a given volume. The present invention provides said carbon structure and a method for doing so.

BRIEF DESCRIPTION OF THE INVENTION In accordance with one aspect of the invention, an activated carbon body having past flow channels is provided. Among other forms, the channels can be straight, curved or interlaced. In accordance with another aspect of the invention, a method for making an activated carbon body having past flow channels is provided. The method involves the combination and formation of material that forms channels and optional fugitive material pore forrnador and morning non-fugitive support, a ream intertwined in a raw body and healing of the resin. The temperature at which the anal-forming material begins to distort is greater than the temperature of the ream's cure. The char is carbonized and at the same time the material that forms channels is vaporized out of a carbon body that has flow channels passed in the configuration of the fugitive material. The carbon body is then activated.

BRIEF DESCRIPTION OF THE DRAWINGS rV Figure 1 shows an arrangement of elements forming channels in the form of straight solid filaments. Figure 2 shows an arrangement of elements forming channels in the form of curved solid filaments. Figure 3 shows an arrangement of elements forming channels in the form of straight hollow tubes. Figure 4 shows a structure body in shape The honeycomb formed from a mixture of res and loose solid fibers or filaments, for example, of the types shown in FIGS. 1 or 2. FIG. 5 shows the honeycomb structure of FIG. 4 after carbonization. Figure 5 shows a carbonized honeycomb structure body made by using hollow tubular filaments, for example, of the type shown in Figure 3; Figure 7 shows material forming channels in the form of a molten screen.

Figure R shows material that forms channels in the shape of a woven screen. Figure 9 shows resin in contact with a screen in the dry and still formable state. Figure 10 shows the resin and the screen of figure 9 formed afterwards in a roll.

DETAILED DESCRIPTION OF THE INVENTION The invention relates to carbon bodies or shell structures in which the adsorption capacity per unit volume can be controlled, that is, it can be done in a way that is low, intermediate or high, depending on the specific application required. The structure also eliminates problems such as friction associated with granulated beds, and the pressure drop is less than on the granulated beds. The carbon body is characterized by a honeycomb structure, ie it has channels with flow for optimum flow capacity of a working stream in the field; and pores of angstrom size (from about 5 to about 50 angstroms per adsorption). The channels u to be * straight and / or curved. The channels can essentially be parallel, and / or non-parallel, and / or interlaced. a structure exhibits high strength.

The bodies of the present invention are suitable. for use in any of a wide range of applications to which activated carbon bodies have been used in the past. Examples of such applications include residential water purification, volatile organic compound emission control, storage of natural gas for vehicles to gas dust or equipment, internal air purification, industrial respirators, cabin air filters, $ 4 automobiles, covers without ventilation, chemical separations, N0K and SO * control and exhaust valves for automobile cold start applications. Other potential applications include the use of ozone filters, mercury collection from municipal incinerators, radon adsorption, automobile gasoline tank or multiple intake emissions, drainage pump vents, oil-air separations, or any other application inThe adsorption of a component or components of a liquid stream containing multiple components is desired. The method for making the structures involves contacting a continuous fugitive material or material fopna or channels with a ream unreachable and optionally with what will be called fillers. The fillers may be non-fugitive material or support material for increasing the strength of the body, and / or non-continuous fugitive or pore-forming material that forms porosity in the wall during carbonization, the mixture is then shaped into a form by a process "V <; - that is not extrusion. The form is then dried, and the resin cured and carbonized to produce a carbon body. After the drying step, the shape can be set later if necessary. During carbonization, fugitive materials vaporize. The material that forms channels leaves behind the channels that are essentially in the same form as they were in the pre-carbonization form. The pore-forming material, if present, of the porosity in the wall. The carbonized body is then activated to produce the last body of activated carbon. The resin content determines the total amount of carbon in the body structure. The size, shape and percentage of the pore-forming material and pore-forming material determines the surface area of the available coal for the activation which, in turn, determines the adsorption capacity. The support material controls the strength and cost of the body. The adsorption capacity is controlled by the amount of carbon present in the final body structure and the percentage of this carbon available for activation. The percentage of carbon available for activation is determined by the surface area available for the activation reaction. The surface area available in turn is determined by the channel-forming material and pore form-doi. If the surface area is increased excessively, then the structure can be weakened, the support fillers improve strength and allow the surface area to be maximized. The method of the present invention allows to control the surface area available for adsorption for a given carbon weight.

THE RESIN A critical feature of the resin is that it is "non-soluble". These resins form three-dimensional structures that extend along the final body. The final body is stable to heat up and can not be made to melt or flow. Examples of resins which can be considered suitable for the practice of the present invention are the water-containing resins such as phenolics, furans, epoxies and thermoplastic polymers such as polyacrylonitrile, polyvinyl chloride, etc., although not thermosettable. , can be interlaced by means of high temperature oxidation. It is desirable that the resin with a carbon yield high in carbonization, ie, for example, be around at least 25%, and preferably at least about 40% based on the amount of ream cured. The tepnofarables res typically give these high returns. The thermosetting resins are the most preferred. Examples of thermosettable reams that can be used in the practice of the present invention are phenolics, furans, epoxies, and combinations thereof.

The preferred resins are phenolic, furan and combinations thereof due to their high carbon yield and low viscosities at room temperature. Typically, viscosities can vary from about 50 cps to about 1000 cps. Preferred viscosities are from about 100 to about 500 cps. The resins can be supplied as solids, liquids, solutions or suspensions. A resin that is especially suitable for the practice of the present invention is phenolic soleta resin. Phenolic soleta resins are solutions of phenolics in water. A higher viscosity suspension of solid phenolic powder in liquid resin can be used to increase the amount of resin in the support material (when used) and thus the final yield of carbon. A particularly suitable resin is a phenol soleine reein available from Occidental Chemical Corporation, Ni gara (^ alls, N.Y. under the product name Plyophen 43290. In accordance with OxychemR Material Safety Data Sheet No. M26359, Phyophen 43290 is a one step liquid phenolic ream containing phenol, formaldehyde and water, which has a relative density of 1.22-1.24, a boiling point > 100 ° C and pH 7.5-7.7 @ 100 rn / 1. Furan resins are available as liquids. A furan which is suitable for the practice of the present invention is provided by QO Chemical, Inc. under the name Furcarb® LP. In accordance with Material Safoty Data 1 l Sheet by 00 Chemicals, Inc., Furcarb® LP, prepares ions of phenol furfuryl reams (4% rnax) in fulle alcohol, and has a specific gravity of 1.2, and a boiling point at 170 ° C. The viscosity is 300 cps.

THE CHANNEL FORMAT MATERIAL The material forrnador of channels volatilizes and leaves For example, the material is divided into volatile low molecular weight compounds during cooking in an inert atmosphere leaving little or no residue. have a hot distortion temperature point that is higher than the cure temperature of the resin that is used so that it does not distort during the curing process.This is typical but not necessary around at least 150 ° C , which is the curing temperature for phenolic resins The channel forming material is continuous, that is, the filament or fiber type material and is of sufficient length to provide in its volatilization, low pressure fall paths or through channels. that a working current can pass continuous uninterrupted flow through the body, contrary to the porosity of the wall. in any way that provides these low pressure drop paths, such as fibers. For example, the fibers may be in the form of a plurality or arrangement of loose fibers or filaments, or in the form of a very long monofilament which is woven in a given configuration with the chosen length and diameter depending on the amount and configuration of porosity what is desired The fibers may typically vary from about one or less in diameter to half a centimeter or one centimeter or more in diameter depending on the application. The fibers can be solid or hollow being an example of the latter the commercial plastic straws. The fibers can also be deformed in a form such as woven or non-woven (cast) screens or grids, etc. Figures 1, 2, 3, 7, and 8 show some common forms of materials forming channels used in the practice of the present invention and therefore, channel configurations in the bodies of the present invention. Figures 1, 2, and 3 show fiber type materials. An arrangement of elements forming channels in the form of loose straight solid filaments is shown in Figure 1. An arrangement of elements forming channels in the loose curved solid filament form is shown in Figure 2.

An arrangement of elements forming channels in the form of loose straight hollow tubes is shown in Figure 3. Figures 7 and 3 show preformed shapes. Figure 7 shows a molten screen (70) in which after carbonization the openings (72) between the screen area (74) will be the carbon while the area (74) will form the channels. Figure 8 shows a woven screen (80) in the "" ue after carbonization the openings (82) between the screen area (84) will be the carbon while the area (84) will form the channels. The flow channels of the body turn the shape of the fugitive material into the precarbonated body, the fugitive material is preferably not wettable by the resin liquid, solution or suspeneion so that the channels of clean and defined form are formed in the vaporization. J * Therefore, the nature, quantity, size, and form of the continuous fugitive material are chosen depending on the desired degree and configuration of the desired channels in the final body.The above factors also determine the surface area of the available coal. Thermoplastic materials are some materials that are especially suitable as fugitive materials Examples of thermoplastics are polymers that during atmospheric carbonification inert are divided into low molecular compounds and disappear without leaving residue. Examples of these materials are polyester, polypropylene. A thermoplastic polymer as such is a polypropylene which is provided in the form of a monofilament by Glassmaster Inc., Lexington, S.C. A suitable continuous fugitive material is propylene which may be in the form of fibers or screens.

The fibers are provided by Glasemaster, Lexington, S.C. Screens of different mesh sizes are provided by Tet o, Tnc. Briarcliff Manor, N. Y. Any size, shape, or chemical combination of channel forrcing materials and filler materials can be used. According to one embodiment, a body is produced having a honeycomb structure that is formed of a fiber arrangement or a p > channel of material forming material.

FILLERS ADDITIVES Traditionally, the filler material may be in contact with the carcass and channel forcing material. The filler material can be pore-forming or support material or combinations of the two types. The pore-forming material is essentially the same in terms of chemical composition as the channel-forming material, but the relative sizes and shapes of the two t LPOS vary. The material that will form channels of flow past in a body of given size is the term forming channel for that body. The material that is not its long length in size to form channels in a body of given size, which will form porosity, is called pore-forming material. As for the materials forming channels, the pore-forming material preferably is not wettable so that the p > forms of clean and defined form are formed in the 'vaporization. A material that is especially suitable for use as the pore-forming material in the practice of the present invention is fine-powder polymer fibers such as polyester bodies provided by International Filler Corp., North Tona Anda, NY under the designation 31UPF. . The body is formed by spraying continuous fibers of the terrnoplastic material to a very small size so that the material is dusty. The fiber lengths in flake materials are typically less than about 150 microns. Regarding the material form of channels, the nature, quantity, size and shape of the pore forcing material are chosen depending on the desired size and quantity of desired porosity in the final body. The above factor also determines the surface area of available carbon for adsorption. With the non-fugitive term or support it is understood that the material is not reactive volatile, and remains essentially unchanged during the steps of a procedure and intact as a part of the body of the final product, unlike fugitive or combustion materials. The non-fugitive material serves as a support for the coal and contributes to the strength of the body. Some support materials are cordierite, for example, cordierite powder, clays, glass powders, aluminosilicate, sand, and combinations thereof. Some preferred support materials are cordierite, clays, glass powders, aluminum oxide and combinations thereof. Especially preferred is cordierite powder because of its cost or when a casting process is used. The support material may be in the form of a piara mat especially facilitating the forming and providing a tight tissue or strong support for the resin and subsequent for the carbon. The mat is preferably made of fibers * Ortas but in some cases long fibers can be used to make a given configuration in the final body product. Also for forming mats, it is preferred that the fibers be between 1-50 and most preferred of about 2-10 nanometers in diameter. The mats are of a low overall density (high vacuum volume). The void volume may vary from about 50% to about 98%. The preferred void volume is around i7C.-Q5%. It is preferred that the support ester is capable of absorbing at least approximately three times its weight and is preferred at least about five times its weight in contact with it. A preferred support mat is made of aluminoeilicate fibers, especially in the form of short fibers, such as the fiber Fiberfax 970 provided by Carborundun Co. , Niagara Falls, N.Y. The ream is connected to the materials that form channels and to any filler that is being - ^ «ilized and the material is formed in a raw body. In accordance with the present invention, the crude body means the body formed before any curing of the resin. The contact can be made by means of any technique designed to join the materials and form them in the desired shape, such as, for example, immersing the solid components such as screens and fibers in the resin in a static and continuous process. The conventional techniques The moldings are very suitable for the purposes of the following invention. The raw body is heated to dry-and cure-the resin. The drying is done to remove the liquid phases, for example solvents, etc., from them. The drying advances the resin to a state that is not viscous but still flexible, commonly called the "B state". In this state, I heard partial entanglement in the resin happens. The drying conditions of temperature and time are chosen depending on the combination and amount of resins and support material, although typical drying temperatures are on the scale of about 80PC-1109c. * -the drying conditions can be adjusted as necessary to achieve the "B" status. For example, in the case of phenolic soleta resin, water, the solvent is removed by drying at about 80 ° C-85 ° C, and then at about 100 ° C-11 ° C for a total time of up to about three hours. For example for a thick sheet of 2-3 rnm or mat of alunmoeilicate fiber "impregnated with ream, the drying time is around 1.5-2 hours at approximately 80QC-85OC and after around- for 20-30 minutes At approximately 100 C-110 C to obtain the flexible state that is not viscous, in this case, if the fugitive and non-fugitive screens or mats are used or made, they can also be formed as desired, for example, the screens can then be cut, sharpened, and the pieces cut with the additional shape of the dried body or can be rolled, etc. Some techniques suitable for contact, form and drying are described below, although it should be understood that the invention is not limited to them 1) .- One technique is to form a wet mixture of all the conposites: res, material forrnador of channels in 1? Form of loose fibers and optionally the fillers .- material forrnador of pores and / or support, the mixture desμuo * . can be formed by introducing the components in a mold 2) Another technique is to use fibers that form channels in the form of a screen, for example, polyester terryplastic, polypropylene, etc., and optionally e? nate? *? to the pore former in the form of very small loose fibers, for example, polyester flake, etc. In this case, the resin is mixed with the pore-forming material if it is used, and the mixture is then poured into a mold in which the screen has been placed. Figure 9 shows a dried body (90) having a screen (92) such as the type shown inFigures 7 or 8 in contact with the resin (94) that has been dried in step B. The dried resin and screen can be formed further. Figure 10 shows the additional formation of this body dried on a roll. 3) The resin can be mixed with a support material for example, cordierite powder, and this mixture poured into a mold in which it has been placed in a structure of channel-forming material such as a screen. 4) The support material can preforrnarce and then be connected with the resin. The channel forrnador material can be adjusted in the preformed material. For example, the resin may be in contact with a support material, for example, an alosilicate, and dried, after the channel-forming fibers are adjusted on the resin sol-mat. 5) The channel-forming material can be preformed and then in contact with the resin. The support material can be adjusted in the preformed material. 6) The material forms jor of channels in the form of an ionic, for example, made of a polypropylene polymer or polypropylene, can be removed through a resin bath, for example, a phenolic restroom to coat the monofilament with the resin. Optionally, the pore-forming filler material and / or support material and / or solid ream can be included in the resin bath. At this time, the resulting coated monofilament can optionally be passed through a die with a sili- cone hole to remove excess resin in the rnonofilament. In any case, the coated onofilarnetto is then entangled in a drum with a long or round cross section. In this way the monofilament layers can accumulate in the drum by means of continuous entanglement. After the thickness of the rnonofilament is accumulated to the desired level in the drum, the interlacing operation is discontinued and the layers are removed from the drum and can then be formed by means of pressure in the formed green body. The raw body is dried and the ream cured. Alternatively, the drying can be carried out in the drum, the drying form can then be formed if desired. In some cases, the support material, if used, may at first be impregnated with a catalyst which is known to accelerate the cure reaction, and then mixed with the ream. 01 pour into the mold, the resin becomes stiff and a cured body can be formed. An example of this process is the case of furan resin cured with such catalysts as ZnCl 2, PT A (paratoluene sulfonic acid), citric acid, or other catalyst. If the formation was done when molding, the mold with the raw body is heated to dry the raw body and take care of the resin. After the body has been formed in the desired shape the resin is then finally cured in the form It is heated by heating under specific temperature and time conditions required for the specific resin. That can be found in the literature of the manufacturers. For example, for phenolic sole 43290 of Occidental Chemical Co. the body is heated in air at about 140QC-155OC.

The final temperature is carried out slowly, so that the body is not distorted. For example, the body at the beginning is heated to approximately 90QC-100 C, then around '- < 20QC-130QC and maintained at that temperature for approximately 1-2 hours. Then it is heated around 140 < ? c-l55QC and maintained for approximately 30 minutes-- 2 hours for final healing. The rigid form obtained by the ream during the formation described above, which is carried out at low temperatures, is not distorted during curing. Figure 4 shows a honeycomb structure body (40) formed of a mixture of resin (42) and loose solid filament fibers (44), for example, of the types "shown in Figures 2". The resulting cured resin formed body is then carbonized and activated to convert the ream into activated carbon.Carbonization also results in the removal of fugitive materials to form the respective formae of the channels and the porosity of the wall. carried out by heating the body in an inert or reduced atmosphere such as nitrogen or '* rgono or formant gas. The formant gas is a mixture of nitrogen and hydrogen. Typical mixtures by volume are 92: 8 or 94: 5 N2: H2, although any mixture can be used. The carbonization temperatures are about 600QC-1000QC or more typically around 700QC-1000QC for a length of time generally around 1-20 hours. While the body is on the temperature scale of approximately 300QC-600QC, the fugitive materials are . During the carbonization, low molecular weight compounds are separated and carbon atoms form graphite structures, for example, for phenol soleta resin 43290 from Occidental Chemical Co. and furcarb resin from 00 Chemicals, carbonization. It is carried out on heating at a speed of about 150 ° C / hr at N ° 0. The temperature is maintained at about 900 ° C for about fj-10 hours to complete the carbonization, the temperature is then reduced to 25 ° C. C at a cooling rate of about 50 ° C / hr In carbonization, the body contains three-dimensional oriented graphitic platelets with amorphous carbon between the platelets Figure 5 shows the honeycomb structure in the figure 4 after carbonization (50) The channel forcing material has been extinguished to leave flow channels past (52) in the coal structure (54) Figure 6 shows a body structure in the form na 'r * f carbonized honeycomb (60) made by using hollow tubular filaments, for example of the type shown in Figure 3. The tubular filaments have been extinguished to leave channels (62). The carbon in the body after it is activated by partially oxidizing in a suitable oxidant such as CO2, vapor, air, or a combination thereof, etc .; The activation can be carried out at temperatures between about 700 ° C-iao ° C. . ' < The activation conditions depend on the type and amount of resin, gas flow velocity, etc. For example, for Furcab and phenolic soleta resins, the activation conditions are approximately 900 ° C for approximately 1 hour in CO2 at a flow rate of around 14.2 1 / hr (approximately 14,158 LH (liters per hour). ). The partial oxidation during the activation causes the amorphous carbon to be removed and the molecular size porosity formation between the graphitic platelets. This porosity and graphitic platelets odd-bear the adsorption characteristics < to the resulting activated carbon body. According to another embodiment, the resin-containing mats having pore-forming material can be divided into granules or various sizes suitable for the application. At any time of the procedure after healing, the mats are divided. For example, it can be performed either after curing and before carbonization, or after carbonization and after activation or after activation. The granules are then subjected to the rest of the steps through activation to form a mixed carbon body. Said granules have a high surface area due to the pores formed in the combustion of the pore-forming material. The activated carbon body of the present invention is a continuous carbon structure and is therefore high in strength. To further illustrate the invention, the following non-limiting examples are presented. All parts, portions, and percentages are on a weight basis unless otherwise specified.

EXAMPLE 1 The polypropylene fibers continue to be intimately grown in liquid phenolic soleta and the resulting mixture was then dried and cured at about 80 ° C for about?! =. 2 hours, about 100 ° C for about 1 hour, and about 150 ° C for approximately 30 minutes. The compact solid was then charred at about 900 ° C for about 6 hours in nitrogen.At the end of the carbonization, the compact was a honeycomb structure with continuous paths instead of polypropylene fibers.

The carbon was then activated at about 900 ° C for about 1 hour in carbon dioxide. The diameter of 1.54 cn by 2.54 cm long of the honeycomb structure tube a butane adsorption capacity of approx. 800mg EXAMPLE 2 A mixture of phenolic soleta resin 43290 from Occidental Chemical Co., a solid phenolic powder from the isma No. 7716, and polyester flake (31UPF Fine Powder polymer fiber from International Filler Corp), in the weight ratio of 77.4%, 15.5%, and 7.2% respectively, was made and observed in a mold containing continuous polypropylene fibers. The mold was then heated to about 80 ° C and dried and then slowly heated to about 125 ° C and maintained for about 1 hour and then heated in nitrogen to about 900 ° C maintained at that temperature for approximately 6 hours . During heating and carbonization the polypropylene and polyester fibers disintegrated and disappeared leaving holes behind. A structure of honeycomb structure with straight parallel channels was formed. The walls of the honeycomb structure were also porous allowing the maximum surface area to be increased. This honeycomb structure was activated in carbon dioxide at approximately 900 ° C. This honeycomb structure of the same size as that of example 1 had a butane adsorption capacity of about 345 rn.

EXAMPLE 3 A blend of about 13.8% Fiberfrax aluminosilicate fiber from Carborundum Corp., approximately 14% polopoly 31UPF from International Filier Corp., around 20-4% 7716, and approximately 51.8% phenolic resin 43290 9 Occidental Chemical was poured into a mold containing polypropylene fiber of about 1 mm in diameter. The ream was cured at about 150 ° C as in Example 2, and charred and activated as before to obtain a carbon honeycomb structure of the same size as that of Example 1. The butane adsorption capacity of this body was approximately 525 mg.

EXAMPLE 4 A blend of about 6.2% policopo, approximately 13.8% res to solid phenolic 7716 and about 69% liquid phenolic reein 43290 from Occidental Chemical, and about 11% fiber fiber from Carborundum was mixed and poured into a mold containing alternating screens of mesh 25 and propylene of mesh 200 of Te or Inc. The "" ours were carbonized and activated as described above to obtain a structure in the form of honeycomb of the same size as in the previous examples. The butane adsorption capacity was around 552 rng.

EXAMPLE 5 The Fiberfrax mat 970 from Carborundum Co. was < , jmerg? in resin and then allowed to dry at about 80 ° C for about 2 hours at about 100 ° C for about 1 hour. The polypropylene monofilaments with in Example 3 were then pressed into a flexible, soft mat and a preform was made by placing several mats together and pressing and heating to cure. The preform was carbonized and activated to obtain a honeycomb structure of the same size as in the previous examples with adsorption capacity of approximately 029 g of butane.

EXAMPLE 6 A mixture of approximately 11% fine base cordierite powder having an average particle size of about 10 millimeters in diameter, about 6% polyole, about 13.6% resin 7716 and about 69.4% Western resin 43290 Chemical was poured into a mold containing a 25 mesh polypropylene screen from Tetko Inc. The mold was heated for curing, carbonization and resin activation as in the previous examples. The body that has the same size as in the previous exernpioe had a butane adsorption capacity of approximately 565. The examples show that carbon structures with parallel flow paths can be made with controlled adsorption properties. Depending on the requirements for the product and economic considerations, the carbon structures produced can be made to have different adsorption capacities. It should be understood that while the present invention has been described in detail with respect to certain illustrative and specific embodiments thereof, it should not be considered limiting to such, but can be used in other ways without departing from the spirit of the invention and the scope of the invention. the attached claims.

Claims (21)

NOVELTY OF THE INVENTION CLAIMS

1. - A method for making an activated carbon body having past flow channels, said method comprising: a) providing an interlacing resin; b) provide a continuous fugitive material where the temperature at which said continuous fugitive material begins to distort is greater than the cure temperature of the resin; c) combining and forming the continuous fugitive material and the resin in a crude body, and curing the resin; d) carbonizing the resin and at the same time vaporizing the continuous fugitive material to form a carbon body having flow channels passed in the configuration of the fugitive material; and e) heating the carbon body to activate the carbon and producing said carbon body > + htiva o.

2. A method according to claim 1, further characterized in that the resin is a thermosetting resin.

3. A method (according to claim 2, further characterized in that the resin is selected from the group comprising phenolic, furan, epoxy, and combinations thereof.)

4. A method according to claim 1. 3, further characterized in that the resin is selected from the group comprising phenol resins, furan and combinations thereof.

5. A method according to claim 3, further characterized in that the resin is phenolic sole.

6. A method according to claim 1, further characterized in that the continuous fugitive material is selected from the group comprising poi ester, polypropylene, and combinations thereof.

7. A method according to claim 1. 1, further characterized in that the continuous fugitive material is in a form selected from the group comprising straight solid fibers, straight hollow fibers, fibers curved ovals, curved hollow fibers, screens, and combinations of the most.

8. A method according to claim 1, further characterized in that before the curing step, the The filler waste is in contact with the resin and the continuous fugitive material, said filler material being selected from the group comprising non-fugitive support material, fugitive pore-forming material which is not continuous, and combinations of the same.

9. A method according to claim 8, character- ized in addition because the filler material is material (Je sopor-t or 10.- A method (Je conformity with the claim 9, further characterized in that the support material is selected from the group comprising cordierite, clays, glass powders, alkylsilicate and combinations thereof. 11. A method according to claim 10, further characterized in that the support material is in the form of an aluminosilicate mat. 12. A method according to claim 8, further characterized in that the filler material is pore-forming material. 13.- A method in accordance with the claim 12, further characterized in that the pore-forming material is selected from the group comprising polyester flake, polypropylene powder, and combinations thereof. 14.- A method according to the claim 8, further characterized in that the filler material- is "support material and pore-forming material." 15. A method in accordance with the claim. 14, further characterized in that the support material is selected from the group comprising cordierite, clays, glass powders, aluininosilica + o, and combinations thereof, and the pore-forming material is selected from the group that comprises poly ester flake, polypropylene powder, and combinations thereof .. 16.- A method (Jo complying with the claim 15, also characterized because the support material is in the form of a mat of aluminum. 17.- A m all in accordance with the claim i, further characterized in that the shape is made by molding the ream and fugitive material in a mold. 18. A body of activated carbon produced by the method according to claim 1. 19. A body of activated carbon produced by the method according to claim 7. 20. An activated carbon body having a continuous carbon structure, and having porosity in the shape of channels curved through where the fluid passes in and out of the body through the curved channels. 21. A body of activated carbon that has a continuous carbon structure and has porosity in the form of interlaced channels where liquid flows into and out of the body through the interlaced channels.