CATALYST-FREE AND ACTIVATION-FREE ULTRA-MICROPOROUS CARBON NANOSPHERES FOR LOW PRESSURE CO2 CAPTURE AND A GREEN METHOD OF MAKING SAME
20210170321 · 2021-06-10
Assignee
Inventors
- SAEID KHODABAKHSHI (Swansea, GB)
- ENRICO ANDREOLI (Swansea, GB)
- Sajad Kiani (Swansea, GB)
- ANDREW ROSS BARRON (Swansea, GB)
Cpc classification
B01J20/28019
PERFORMING OPERATIONS; TRANSPORTING
Y02P20/151
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B01D53/02
PERFORMING OPERATIONS; TRANSPORTING
B82Y40/00
PERFORMING OPERATIONS; TRANSPORTING
C01B32/05
CHEMISTRY; METALLURGY
C01P2004/62
CHEMISTRY; METALLURGY
B01D2253/306
PERFORMING OPERATIONS; TRANSPORTING
B01J20/205
PERFORMING OPERATIONS; TRANSPORTING
Y02C20/40
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
Y02P30/00
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
B82Y30/00
PERFORMING OPERATIONS; TRANSPORTING
B01J20/28064
PERFORMING OPERATIONS; TRANSPORTING
B01D2253/304
PERFORMING OPERATIONS; TRANSPORTING
International classification
B01D53/02
PERFORMING OPERATIONS; TRANSPORTING
B01J20/20
PERFORMING OPERATIONS; TRANSPORTING
B01J20/28
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present invention relates to porous carbon spheres via one-step non-catalytic and activation-free chemical vapor deposition method possessing a large volume of ultra-micropores. The ultra-micropore structure allows for with good cyclic stability, easy regeneration, favorable selectivity, and rapid sorption kinetics resulting in high capacity of CO.sub.2 capture at atmospheric and low pressures.
Claims
1. A material for CO.sub.2 adsorption comprising: a porous carbon sphere material between 10 nm and 1 μm in diameter, with a surface area of at least 600 m.sup.2/g, and a total pore volume of at least 0.15 cm.sup.3/g, wherein 100% of pores of the porous material have diameters of less than 1 nm as measured from CO.sub.2 sorption isotherms using the density functional theory (DFT) method, wherein the porous material has an oxygen content of less than about 12 wt % as measured by X-ray photoelectron spectroscopy, and wherein the porous material has a CO.sub.2 adsorption capacity of more than about 1 mmol/g at 25° C.
2. The material of claim 1, wherein more than 50% of pores of the porous material have diameters of less than 0.5 nm as measured from CO.sub.2 sorption isotherms using the DFT method.
3. The material of claim 1, wherein the porous material has an oxygen content of less than about 5.3 wt % as measured by X-ray photoelectron spectroscopy.
4. The material of claim 1, with a surface area of at least 800 m.sup.2/g.
5. The material of claim 1, with a total pore volume of at least 0.19 cm.sup.3/g.
6. The material of claim 1, wherein the porous material has a CO.sub.2 adsorption capacity of more than about 4 mmol/g at 0° C.
7. A method of forming the porous carbon sphere material of claim 1, comprising: a. heating an aromatic poly-carboxylic acid or anhydride precursor in the first heated zone of a reactor at a temperature sufficient to volatilize the precursor; b. Flowing an inert carrier gas to transport the volatilized precursor into a second heated zone of the reactor; c. Heating the precursor vapors in the second zone of a reactor at a temperature of between about 700° C. and 900° C.
8. The method as claimed in claim 7, wherein the aromatic poly-carboxylic acid or anhydride precursor is chosen from pyromellitic acid, pyromellitic anhydride and pyromellitic dianhydride.
9. The method as claimed in claim 8, wherein the precursor is heated to a temperature of between about 400° C. and 450° C. at 1 atmosphere pressure.
10. The method as claimed in claim 8, wherein inert carrier gas is chosen from argon and nitrogen.
11. The method as claimed in claim 8, wherein the precursor vapors in the second zone of a reactor at a temperature of about 800° C.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had reference to embodiments, some of which are illustrated in the appended drawings. It is also noted, however, that the appended drawings illustrate only exemplary embodiments. And are therefore not to be considered limiting in scope, may be admit to other equally effective embodiments.
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[0031] Various components of the same type may be distinguished by following the reference label by a letter that distinguishes among the similar components and/or features.
DETAILED DESCRIPTION
[0032] As a comparison, to show the merits of the present pathway to carbon spheres, Table 1 lists some reported activation methods for the synthesis of porous carbon materials with a comparison between the capacities (mmol/g) of maximum CO.sub.2 uptake on various carbon spheres at 1 bar.
TABLE-US-00001 TABLE 1 Method and type of Uptake Uptake Selectivity activation temp. (mmol/g) CO.sub.2:N.sub.2 Reference Pyrolysis HNO.sub.3 30° C. 2.57 .sup. 4.81 Sun et al. activation Stöber synthesis 0° C. 2.63 9.4 Li et al. Pyrolysis-potassium 0° C. 6.6 — Ludwinowicz oxalate monohydrate et al. activation Condensation reactions 25° C. 2.47 41 Mohanty et al. Stöber synthesis 23° C. 4 — Marszewska et al. Pyrolysis- 25° C. 3.65 — Chen et al. KOH activation Pyrolysis- 25° C. 4.61 25 Ren et al. KOH activation Pyrolysis- 25° C. 4.3 — Zhang et al. KOH activation CVD, activation-free 25° C. 2.85 30 Present invention CVD, activation-free 0° C. 4.0 23 Present invention
[0033] Furthermore Table 2 lists CVD methods for carbon spheres production. As can be seen, the CVD method mainly feeds on hydrocarbon gases and liquids such as acetylene and ethylene and demands a metal or silica-based catalyst, while we used a solid feedstock instead without catalyst. However, both catalyst price or catalyst removal are the main drawbacks of these available approaches. The carbon spheres prepared by our catalyst-free strategy, however, requires a usual pyrolysis temperature to deliver sphere size of approximately 200 nm which is still smaller than those published in previous literature.
TABLE-US-00002 TABLE 2 Deposition Sphere Temperature size Carbon (° C.)/time Porosity average feedstock Catalyst (min) type (nm) Reference Ethylene NiFe-LDHs 900/60 Non-porous 740 Carrasco et al Acetylene Fe-KIT-6 800 Meso- 750 Karthikeyan et al. porous Ethylene Kaolin supported 750-900 Not 400 and Miao et al. transition metal measured 2000 Ethylene Mesoporous 800 Meso- 260 Chen et al. silica template porous Ethylene Mesoporous 800 Meso- 400 Kukułka et al. silica template porous Polypropylene Mesoporous 900 Non-porous 1000 Tripathi et al. silica template Styrene, Toluene, None 900-1200 Non-porous 300-700 Jin et al. Benzene, Hexane, Cyclohexane and Ethene Pyromellitic None 700-900 Micro- 200 Present acid porous invention
[0034] The present invention contemplates new and improved systems and methods that resolve the above-referenced difficulties and others.
[0035]
[0036]
[0037] As can be seen from
[0038] The EDS mapping analysis of the carbon spheres represents a carbon content of 96.35 atomic % and an oxygen content of 3.64%. These results are also close to those recorded by elemental analysis, with a C and O content of 96.43% and 3.57%, respectively. The crystallinity of the carbon spheres prepared at 800° C. was studied by SAED showing no crystalline structure. In addition, the X-ray diffraction spectrum also showed an amorphous nature for the carbon spheres prepared at 800° C. (
[0039] The surface composition of sample carbon spheres prepared at 800° C. was analyzed using XPS (
[0040] Although the sphere formation from pyromellitic acid is not affected by changing temperature from 700° C. to 900° C., the textural properties can be slightly influenced. To find out the effect of carbonization temperature on the CO.sub.2 capture capacity, N.sub.2 and CO.sub.2 adsorption measurements were performed (
[0041] As can be seen from the Table 3, the pore volume and pore size slightly change as a function of carbonization temperature. Table 3 also lists C, 0, H content of carbon spheres measured by elemental analysis.
TABLE-US-00003 TABLE 3 Synthesis S.sub.BET Total pore Atomic content (%) temperature (m.sup.2 .Math. g.sup.−1) volume (cm.sup.3 .Math. g.sup.−1) C H O 900° C. 635.3 0.156 94.80 1.94 3.26 800° C. 804.3 0.192 92.6 1.82 5.58 700° C. 639.7 0.168 85.79 2.41 11.8
[0042] Thermogravimetric analysis (TGA) at the temperature ranging from 23° C. to 900° C. under airflow was used to check the thermal stability of carbon spheres. The TG profile for the synthesized carbon spheres shows a similar oxidation behavior to those previously reported in the literature with a negligible weight loss before 450° C. A slight mass loss during the initial stage can be attributed to the absorbed water and a single step degradation of spheres is obvious between 450-580° C. (
[0043] Wettability of the carbon spheres prepared at 800° C. was also evaluated via water contact angles measurement (
[0044] By a volumetric gas adsorption instrument, the performance of the prepared carbon spheres for CO.sub.2 capture was assessed at different pressures ranging from 0.1 to 10 bar while keeping at four constant temperature of 0° C., 25° C., 35° C., and 45° C. As can be seen from
[0045] A typical flue gas stream emanated from coal-fired power plants comprises approximately 15% of CO.sub.2 and 75% of N.sub.2; while the rest includes O.sub.2, H.sub.2O, sulfur oxides (SO.sub.x), and nitrogen oxides (NO.sub.x). Therefore, a candidate CO.sub.2 capture adsorbent must also exhibit high selectivity for CO.sub.2 over N.sub.2 to ensure the technical feasibility of the presented approach for an adsorption-based CO.sub.2 capture unit which is critical to CCUS economics.
[0046] As a comparison of low-pressure CO.sub.2 adsorption between carbon spheres prepared at 800° C. (2.0 mmol/g at 0° C. and 1.1 mmol/g at 25° C.) are higher than the value reported for holey graphene frameworks (0.91 mmol/g at 0° C. and 0.53 mmol/g at 25° C.), and metal-organic frameworks (0.75 mmol/g at 0° C. and 0.4 mmol/g at 20° C.), KOH activated carbon derived from waste wool (1.3 mmol/g at 0° C. and 0.8 mmol/g at 20° C.). As a comparison, the carbon spheres prepared at 800° C. exhibits a CO.sub.2 uptake of 2.85 mmol/g at 1 bar and 25° C., making it at least as good as the best materials that are prepared with activation by acidic or caustic activators. The adsorption capacity of carbon spheres prepared at 800° C. of the present invention is more than non-KOH activated carbon.
[0047] In an adsorption-based capture unit, estimation of isosteric heat of adsorption (Qst) plays also as a key factor through which the local changes in the temperature of both adsorbent inside an adsorption column during the sorption process can be controlled. Overall gas separation yield can be effected as the local adsorption equilibria and kinetics are function of the heat of adsorption. Here, the CO.sub.2 Qst of the carbon spheres of the present invention was calculated by adsorption isotherms measured at 25, 35, and 45° C. and determined as between 27.5-29.5 kJ/mol with the CO.sub.2 amount adsorbed varying from 0.1 to 5.5 mmol/g (
[0048] By taking into account that as-synthesized carbon spheres of the present invention benefit from a high level of hydrophobicity, herein, the effect of humidity on the CO.sub.2 uptake performance of carbon spheres prepared at 800° C. was also evaluated through a TGA-CO.sub.2 sorption test under humidified conditions (
Examples
[0049] STEM and HRTEM images of the spheres were performed using a JEOL 2100F Transmission Electron Microscope. SEM images of the spheres were obtained with JEOL 7800F FEG SEM (JEOL, Akishima, Tokyo, Japan). The Raman data of the prepared spheres were recorded at room temperature on a Renishaw inVia Raman Microscope (Renishaw plc, Miskin, Pontyclun, UK) with excitation wavelength of 457, 514, and 633 nm. The elemental analyzer (Vario EL cubewas, Germany) was used to determine the amount of carbon, hydrogen and oxygen. The samples were characterized by FT-IR model a Thermo Scientific Nicolet iS10 FT-IR Spectrometer. Thermogravimetric analysis (TGA) was carried out on 10-mg samples using a TA Instruments SDT Q600 at a heating rate of 5 C/min from room temperature to 900° C. in air. N.sub.2 adsorption/desorption isotherms were obtained using a Quadrosorb SI (Quantachrome Instruments, Boynton Beach, Fla., USA). Specific surface area was calculated based on the Brunauer-Emmett-Teller (BET) method, and pore size distribution was determined using the density functional theory (DFT) method. XPS was performed using a Kratos Axis Supra (Kratos Analytical, Japan) utilizing a monochromatic Al—K.sub.α X-ray source (K.sub.α=1486.58 eV), 15 mA emission current, magnetic hybrid lens, and slot aperture. Region scans were performed using a pass energy of 40 eV and step size of 0.1 eV. Peak fitting of the narrow region specra was performed using a Shirley type background, and the synthetic peaks were of a mixed Gaussian-Lorentzian type. Carbon sp.sup.2 was used for charge reference assumed to have a binding energy of 284 eV. All the adsorbents were degassed at 160° C. under vacuum for 2 h prior to adsorption study. CO.sub.2 adsorption performance of carbon spheres were measured volumetrically in an Isorb apparatus (Germany) at four different temperatures (0, 25, 35 and 45° C.) and pressures from 0.1 to 10 bar. Degasification temperature was internally controlled by covering the cell, containing the sample, with a thermojacket, while the adsorption temperature was adjusted by a jacketed beaker connected to a circulating bath containing water and ethylene glycol. For each experiment, about 200 mg of carbon spheres was used for the adsorption studies. Ultra-pure CO.sub.2 (99.9%) and N.sub.2 (oxygen free) as gas sources were used throughout the experiments. N.sub.2 adsorption experiments at 25° C. and different pressures were also recorded through the same procedure for CO.sub.2. The laboratory-scale set-up employed to conduct CO.sub.2-adsorption experiments is illustrated in
[0050] Example 1. Pyromellitic acid (96%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic acid were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 700° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon, and the pure carbon spheres were collected from the quartz tube and used without any further process.
[0051] Example 2. Pyromellitic acid (96%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic acid were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 800° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon, and the pure carbon spheres were collected from the quartz tube and used without any further process.
[0052] Example 3. Pyromellitic acid (96%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic acid were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 900° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon, and the pure carbon spheres were collected from the quartz tube and used without any further process.
[0053] Example 4. Pyromellitic acid (96%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic acid were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 850° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon, and the pure carbon spheres were collected from the quartz tube and used without any further process.
[0054] Example 5. Pyromellitic acid (96%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of mellitic acid were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 650° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon. The impure carbon spheres were formed via this procedure.
[0055] Example 6. Pyromellitic dianhydride (97%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic dianhydride were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 700° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon, and the pure carbon spheres were collected from the quartz tube and used without any further process.
[0056] Example 7. Pyromellitic dianhydride (97%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic dianhydride were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 800° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon, and the pure carbon spheres were collected from the quartz tube and used without any further process.
[0057] Example 8. Pyromellitic dianhydride (97%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic dianhydride were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 900° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon, and the pure carbon spheres were collected from the quartz tube and used without any further process.
[0058] Example 8. Pyromellitic dianhydride (97%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic dianhydride were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 650° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon. The impure carbon spheres were formed via this procedure.
[0059] Example 10. Pyromellitic acid (97%) and urea 99.0%) were purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of pyromellitic acid and 1 of urea were mixed and placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 800° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon. The carbon spheres were not formed via this procedure.
[0060] Example 11. Trimesic acid (95%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of trimesic acid were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 800° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon. The carbon spheres were not formed via this procedure.
[0061] Example 12. Terephthalic acid (98%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of terephthalic acid were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 800° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon. The carbon spheres were not formed via this procedure.
[0062] Example 13. Mellitic acid (99%) was purchased from Sigma-Aldrich and used without further purification. In a typical procedure, 1 g of mellitic acid were placed in a ceramic boat and inserted into the zone 1 of a tubular furnace under argon (200 mL/min) and at atmospheric pressure. The temperature of zone 2 was raised to 800° C. with a heating rate of 1° C./s. When the desired temperature was reached, the temperature of zone 1 was also increased to 450° C. and left for 30 min. Then, the furnace was cooled down to room temperature under argon. The carbon spheres were not formed via this procedure.