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WO1999062616A1 - Structure carbonee - Google Patents

Structure carbonee Download PDF

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Publication number
WO1999062616A1
WO1999062616A1 PCT/GB1999/001749 GB9901749W WO9962616A1 WO 1999062616 A1 WO1999062616 A1 WO 1999062616A1 GB 9901749 W GB9901749 W GB 9901749W WO 9962616 A1 WO9962616 A1 WO 9962616A1
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WO
WIPO (PCT)
Prior art keywords
carbon
resin
fibres
carbon structure
substrate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/GB1999/001749
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English (en)
Inventor
Stephen Robert Tennison
Benjamin David Leigh
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
MATERIALS AND SEPARATIONS TECHNOLOGY INTERNATIONAL Ltd
Original Assignee
MATERIALS AND SEPARATIONS TECHNOLOGY INTERNATIONAL Ltd
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Filing date
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Priority to AU45176/99A priority Critical patent/AU4517699A/en
Publication of WO1999062616A1 publication Critical patent/WO1999062616A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2055—Carbonaceous material
    • B01D39/2065—Carbonaceous material the material being fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2055—Carbonaceous material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D39/00—Filtering material for liquid or gaseous fluids
    • B01D39/14—Other self-supporting filtering material ; Other filtering material
    • B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
    • B01D39/2068—Other inorganic materials, e.g. ceramics
    • B01D39/2082—Other inorganic materials, e.g. ceramics the material being filamentary or fibrous
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
    • B01J20/10—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate
    • B01J20/103—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising silica or silicate comprising silica
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/02—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material
    • B01J20/20—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof comprising inorganic material comprising free carbon; comprising carbon obtained by carbonising processes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
    • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
    • B01J20/28033—Membrane, sheet, cloth, pad, lamellar or mat
    • B01J20/28038—Membranes or mats made from fibers or filaments
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
    • B01J20/28014—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their form
    • B01J20/28042—Shaped bodies; Monolithic structures
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
    • B01J20/28054—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J20/28057—Surface area, e.g. B.E.T specific surface area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
    • B01J20/28054—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J20/28069—Pore volume, e.g. total pore volume, mesopore volume, micropore volume
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/28—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties
    • B01J20/28054—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof characterised by their form or physical properties characterised by their surface properties or porosity
    • B01J20/28078—Pore diameter
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/3007—Moulding, shaping or extruding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/3078—Thermal treatment, e.g. calcining or pyrolizing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/32—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating
    • B01J20/3202—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating characterised by the carrier, support or substrate used for impregnation or coating
    • B01J20/3204—Inorganic carriers, supports or substrates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/32—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating
    • B01J20/3231—Impregnating or coating ; Solid sorbent compositions obtained from processes involving impregnating or coating characterised by the coating or impregnating layer
    • B01J20/3234—Inorganic material layers
    • B01J20/324—Inorganic material layers containing free carbon, e.g. activated carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/34—Regenerating or reactivating
    • B01J20/3416—Regenerating or reactivating of sorbents or filter aids comprising free carbon, e.g. activated carbon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J20/00—Solid sorbent compositions or filter aid compositions; Sorbents for chromatography; Processes for preparing, regenerating or reactivating thereof
    • B01J20/30—Processes for preparing, regenerating, or reactivating
    • B01J20/34—Regenerating or reactivating
    • B01J20/3441—Regeneration or reactivation by electric current, ultrasound or irradiation, e.g. electromagnetic radiation such as X-rays, UV, light, microwaves
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/02—Types of fibres, filaments or particles, self-supporting or supported materials
    • B01D2239/0241—Types of fibres, filaments or particles, self-supporting or supported materials comprising electrically conductive fibres or particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0471—Surface coating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/04—Additives and treatments of the filtering material
    • B01D2239/0471—Surface coating material
    • B01D2239/0492—Surface coating material on fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/06—Filter cloth, e.g. knitted, woven non-woven; self-supported material
    • B01D2239/0604—Arrangement of the fibres in the filtering material
    • B01D2239/0613—Woven
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01D—SEPARATION
    • B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
    • B01D2239/12—Special parameters characterising the filtering material
    • B01D2239/1216—Pore size
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J2220/00—Aspects relating to sorbent materials
    • B01J2220/40—Aspects relating to the composition of sorbent or filter aid materials
    • B01J2220/48—Sorbents characterised by the starting material used for their preparation
    • B01J2220/4812—Sorbents characterised by the starting material used for their preparation the starting material being of organic character

Definitions

  • the present invention relates to a composite structure made from silica and carbon which structure is particularly useful in filtration, separation and adsorption processes.
  • Carbon in various forms is widely used in separating and filtration processes, for example in removing solids from liquids and from gases, separating liquids from gases, water purification, exhaust gas clean up etc. Carbon is also used as an adsorbent for the adsorption of gases and liquids. Hitherto the carbon has been used as a bed of particulate carbon or as finely divided carbon, for example in the form of charcoal, carbon black etc.
  • the carbon particles can be packed in a bed or bound together with a binder or can be in the form of an activated carbon cloths which has very good adsorption properties but is limited by cost and the fact that is only available as flexible thin sheets.
  • Solid carbon structures have been made using carbon fibre as in carbon/carbon composites, but these structures do not have any voids in them and are not suitable for separation and filtration processes.
  • Carbon because of its chemical and biological inertness, good high temperature properties (particularly in non-oxidising atmospheres) is particularly useful as a filter element or in a separator.
  • carbon because of the difficulty of obtaining strong integral carbon structures with the right pore structure, carbon is normally used as an adsorbent in the form of a bed of particles and cannot be used in many applications. There can also be difficulties in the removal of separated material from carbon beds and in the regeneration of the carbon beds.
  • US Patent 5834114 discloses a method of forming a carbon material for the adsorption of contaminants comprising coating a mineral fibre substrate with a resin, cross-linking the resin, heating the coated fibre substrate to carbonise the resin and exposing the coated fibre substrate to an etchant to activate the resin.
  • the only fibres disclosed are glass fibres.
  • a carbon structure which comprises a porous silica substrate having carbon bound to at least the surface of the substrate.
  • the structure has the advantage of being rigid.
  • the porous silica substrate can be in the form of fibres which are formed into a mat, woven together etc. to form a substrate.
  • the substrate can be in the form of random interlocking fibres which can be self binding to form a mat or batt of the fibres.
  • Suitable silica fibres are made by HITCO Technologies Inc. and are sold under the registered trade mark "Refrasil".
  • the material is sold in the form of mats, bulk fibre, o cloth, tape, cordage and yarn.
  • the fibre is refractory and stable up to 980 C and this enables the resin coated fibre to be heated to this temperature and in the activation stage this can improve the performance and pore characteristics of the carbon o structure formed.
  • the carbon is preferably in the form of a porous coherent integral layer and is bound directly to the silica substrate without the need for binders etc.
  • the thickness of the carbon layer can be varied according to the need and is preferably up to approximately 10% of the supporting fibre diameter - in the case of the Refrasil fibres this is around 10 microns.
  • the carbon can interpenetrate the fibres and, in the case of mats, the carbon can be in the bulk of the material, i.e. it is not confined to just the outermost surface of the substrate so that a solid three dimensional carbon structure is formed around the silica fibres.
  • porous is meant that the carbon has voids or pores, e.g. it can be a macroporous carbon structure suitable for filtration and separation.
  • the invention provides carbon structures with macropores which are the pores between the coated fibres in the range from 1 to 1000 microns, preferably in the range of 5 to 100 microns.
  • pore sizes in the range of up to 2 nm (micropores) and from 2 to 30 nm (mesopores) are used.
  • the invention can provide carbon layers on the silica fibres which have pores of these sizes in the carbon layer, which make them useful for adsorption.
  • the structure is monolithic, i.e. it is in a single piece, not granular and not composed of particles bound together by a binder etc; it is in the form of a coherent solid structure.
  • the invention also provides a method of forming a carbon structure which method comprises contacting a substrate of silica fibres with an uncured resin, curing the resin and carbonising the cured resin.
  • the resin coats the fibres and, when it is cured it holds or locks the fibres in place.
  • Resins which can be used include phenolic resins which are well known materials and copolymers of phenolic resins with other polymers.
  • Phenolic resins are made by the condensation of a phenol and an aldehyde, e.g. formaldehyde. The condensation is initially carried out to produce a partially condensed product. The condensation may be carried out so as to produce a resin which is fully curable on further heating (Resol). Alternatively, the condensation may be carried out so as to produce a Novolak resin which is only curable when an additional cross-linking agent is mixed with it, e.g. hexamethylene tetramine (known as "hexamine” or "hex"). It is preferred to use Resole resin in the process of the present invention.
  • EP 0 254 551 gives details of methods of forming porous carbons and the methods and the process steps disclosed for the carbonisation of phenolic resins in this patent can be used in the carbonisation steps in the present invention and its contents are included herein by reference.
  • Mixed resin systems can also be used such as a phenolic resin as described above mixed with an epoxy resin.
  • silica fibre forms superior carbon structures compared with glass fibres, the reason for this is not properly understood but is thought to be due to the nature of the bond that is formed between the silica fibre and the resin on carbonisation and is specific for silica fibres.
  • the silica substrate is contacted with the resin forming components e.g. a resole and cured to produce a cured resin according to the known methods.
  • the cured resin is then carbonised to form the carbon structure.
  • the resin forming components can be coated onto the fibres using conventional means.
  • the preferred method comprises dissolving the components in a solvent, coating the silica fibres with the solution and evaporating the solvent off to leave the fibres coated with the resin forming components.
  • Solvents which can be used include alcohols, ketones and proprietary solvents which are commercially available. Solutions of phenolic resin forming components are commercially available and are commonly referred to as resols. The nature and type of solvent will depend on the actual components chosen.
  • the thickness of the resin coating formed on the fibres is affected by the thickness of the fibres, the nature of the resin formed, the concentration of the resin component in the solution, etc. If thicker layers of the resin are required several layers can be sequentially formed by repeated applications and curing to obtain the desired thickness.
  • the thickness of the carbon layer formed will depend on the thickness of the resin layer.
  • layers of resin of 5 to 20 microns can be formed on silica fibres of 9 microns thickness. This will give a carbon layer thickness on the fibres, after carbonisation of up to about 10 microns. This can be varied as described above.
  • the macropore structure of the final product is influenced by a range of factors such as the thickness, nature and spacing of the silica fibres in the substrate; the closer they are in the starting material the smaller the pore size, thus a woven starting material will give a carbon structure with a different pore size to a needle felt or mat.
  • the silica fibre substrate coated with the resin forming components can be compressed to reduce the pore size and the amount, nature and concentration of resin forming components in solution will also influence the pore size in the final material and will enable a material to be made for specific applications.
  • the carbonisation steps take place preferably by heating above 600 C for the requisite time, e.g. 11 to 48 hours and takes place under an inert atmosphere or vacuum to prevent oxidation of the carbon.
  • the porous carbon can optionally be activated to modify the pore volume and surface area.
  • Activation can take place in either steam or carbon dioxide o at elevated temperatures above approximately 750 C.
  • the activation process is carried out for a time that varies with the temperature and the activation gas composition and should produce carbon with the requisite properties.
  • Activation can also be carried out in air at temperatures above approximately 300C. This process is highly exothermic and therefore difficult to control and is not normally used in large scale processing. It can however be used advantageously to produce larger micropores than can be produced using steam or carbon dioxide.
  • the shaped carbon materials can be produced by coating a shaped silica substrate with the resin.
  • the silica fibre precursor such as a woven tube
  • the precursor can be produced by forming a resin coated silica fibre or cloth known as prepreg around a substrate.
  • the silica fibres coated with the resin forming components can be shaped into any desired shape and, on curing, this shape is retained so that after carbonisation a carbon product of the desired shape is formed.
  • the coated silica substrate is formed into the tubular shape and on carbonisation a carbon structure of this shape is formed.
  • the carbon structures of the present invention have good structural integrity and rigidity and have no tendency to flake or come away from the silica substrate even under thermal shock and at a temperatures above that which glass fibre based structures can be used. This enables articles to be made from the carbon compositions of the present invention and to form stable three dimensional structures.
  • the carbon structure is porous which enables it to be used in a wide range of filtration and separation processes.
  • the structures have good high temperature properties being o o stable up to temperatures of around 400 C and up to 900 C and higher in non- oxidising atmospheres.
  • the carbon structures of the present invention can also be used in the removal of particles from organic liquids such as the separation of particles from hydrocarbon fuels, etc.
  • the controlled macro pore size and the ability to form stable three dimensional structures of the carbon compositions of the present invention enables them to be used as absolute filters whilst their structural rigidity enables filtered substances to be more readily removed, e.g. by back flushing, etc. to regenerate the filter.
  • the high porosity, good mechanical properties and solvent resistance of the carbon structures of the present invention also make them suitable for use as supports for polymeric membranes.
  • the carbon structures are electrically conductive which makes them especially useful where static build up is to be avoided, for example when hydrocarbon liquids such as gasoline and aircraft fuel are to be filtered.
  • the electrical conductivity can also allow the materials to be directly heated by passing an electric current through the structure which can be used to accelerate the desorption of adsorbed materials when the materials are used in adsorbent applications.
  • the controlled micro and meso pore structure of the carbon compositions of the present invention enables them to be used as adsorbents to adsorb vapours and components from liquid streams.
  • the high open macro porosity and the ability to form them into large flat structures makes them particularly suitable for applications where very low pressure drops are required such as in adsorption systems for use in air conditioning and air purification systems in printed circuit manufacturing facilities, vehicle cabin air purification and in the purification of, for instance, water for process use and drinking.
  • the materials of the present invention can also be used to combine filtration and adsorption properties into a single element for the purification of both liquid and gaseous streams.
  • the structures can also be used as catalyst support in place of some carbon supports.
  • composition was then placed in a furnace under a gas flow of 8L/min of carbon
  • the structure o was then oxidised in carbon dioxide at 850 C After holding at temperature for 30 minutes and cooling back to room temperature, the product was examined and was found to be a solid three dimensional carbon composition which showed no flaking or spalling and was rigid and stable.
  • the carbon content of the carbonised material was determined by placing a small sample of the composite structure in a furnace at
  • composite media with a surface area of above 800m per gram can be obtained,
  • the material formed is strong and temperature resistance and contains no polymeric material. Filtration tests were carried out on sample 16 and all particles of above 25 microns were rejected in a standard filtration test using an ISO Coarse A.T.D.12103-1 A4 filtration standard.
  • Example 1 The process of Example 1 was repeated and compared with a glass fibre based structure made by the same process using a Dow Corning S2 glass fibre using different temperatures for activation.
  • the adsorption kinetics Rate min/cc/g C are derived from the time taken to reach the first data point in the nitrogen adsorption isotherms at a P/Po of 0.0009. It can be seen that the silica based samples, give significantly higher carbon surface areas than the glass (S2) media demonstrating the benefits of the silica materials.
  • This data encompasses three different silica materials, 3 different resin dilutions (75/25, 50/50 and 50/18), two different resins (Blagden and Hitco) and preparations that include between 1 and 5 resin coats and oxidation for between 2 and 6 hours at 900°C.
  • This data demonstrates that media surface areas of up to 800m2/g are attainable provided that the resin and carbon loadings are optimised with respect to the degree of activation (samples 28 and 29).

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Analytical Chemistry (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Materials Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Health & Medical Sciences (AREA)
  • Electromagnetism (AREA)
  • General Health & Medical Sciences (AREA)
  • Toxicology (AREA)
  • Thermal Sciences (AREA)
  • Carbon And Carbon Compounds (AREA)
  • Filtering Materials (AREA)

Abstract

L'invention se rapporte à une structure carbonée, poreuse, monolithique, stable, utile dans le cadre de processus de filtration et de séparation, qu'il est possible de former en enduisant un substrat constitué de fibres de silice avec une résine, en polymérisant la résine et en carbonisant la résine polymérisée, cette dernière étant de préférence activée par chauffage au dioxyde de carbone ou à la vapeur.
PCT/GB1999/001749 1998-06-02 1999-06-02 Structure carbonee Ceased WO1999062616A1 (fr)

Priority Applications (1)

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AU45176/99A AU4517699A (en) 1998-06-02 1999-06-02 Carbon structure

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GB9811840A GB9811840D0 (en) 1998-06-02 1998-06-02 Carbon structure
GB9811840.9 1998-06-02

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Cited By (4)

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Publication number Priority date Publication date Assignee Title
WO2001028768A1 (fr) * 1999-10-15 2001-04-26 Hitco Carbon Composites, Inc. Composites a matrice carbone/fibres de silice pour applications semi-structurelles
WO2003008068A1 (fr) * 2001-07-16 2003-01-30 Carbon Technologies Nv Filtre
WO2004105439A1 (fr) * 2003-05-21 2004-12-02 Mast Carbon International Ltd Element chauffant pour fluides comprenant un monolithe poreux electroconducteur
CN115679700A (zh) * 2021-07-27 2023-02-03 财团法人工业技术研究院 含浸液与活性碳布及其形成方法

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US4500328A (en) * 1983-02-22 1985-02-19 Gilbert W. Brassell Bonded carbon or ceramic fiber composite filter vent for radioactive waste
JPS63209719A (ja) * 1987-02-25 1988-08-31 Nippon Muki Kk 溶湯濾過用フイルタ
JPH07116433A (ja) * 1993-10-21 1995-05-09 Mitsui Eng & Shipbuild Co Ltd フィルタ
EP0745416A2 (fr) * 1995-06-02 1996-12-04 Corning Incorporated Dispositif pour l'élimination des contaminants de courants fluides
US5834114A (en) * 1995-05-31 1998-11-10 The Board Of Trustees Of The University Of Illinois Coated absorbent fibers

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Publication number Priority date Publication date Assignee Title
US4500328A (en) * 1983-02-22 1985-02-19 Gilbert W. Brassell Bonded carbon or ceramic fiber composite filter vent for radioactive waste
JPS63209719A (ja) * 1987-02-25 1988-08-31 Nippon Muki Kk 溶湯濾過用フイルタ
JPH07116433A (ja) * 1993-10-21 1995-05-09 Mitsui Eng & Shipbuild Co Ltd フィルタ
US5834114A (en) * 1995-05-31 1998-11-10 The Board Of Trustees Of The University Of Illinois Coated absorbent fibers
EP0745416A2 (fr) * 1995-06-02 1996-12-04 Corning Incorporated Dispositif pour l'élimination des contaminants de courants fluides

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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2001028768A1 (fr) * 1999-10-15 2001-04-26 Hitco Carbon Composites, Inc. Composites a matrice carbone/fibres de silice pour applications semi-structurelles
WO2003008068A1 (fr) * 2001-07-16 2003-01-30 Carbon Technologies Nv Filtre
US7160366B2 (en) 2001-07-16 2007-01-09 Mast Carbon International Ltd. Filter element
WO2004105439A1 (fr) * 2003-05-21 2004-12-02 Mast Carbon International Ltd Element chauffant pour fluides comprenant un monolithe poreux electroconducteur
US7317871B2 (en) 2003-05-21 2008-01-08 Mast Carbon International, Ltd. Heater for fluids comprising an electrically conductive porous monolith
CN115679700A (zh) * 2021-07-27 2023-02-03 财团法人工业技术研究院 含浸液与活性碳布及其形成方法
CN115679700B (zh) * 2021-07-27 2024-08-02 财团法人工业技术研究院 含浸液与活性碳布及其形成方法

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AU4517699A (en) 1999-12-20

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