# US 11,298,675 B2 · 3D printed zeolite monoliths for CO2 removal

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- Number: US 11,298,675 B2
- Document ID: US11298675B2
- Status: Granted
- Kind: B2
- Application number: 16/136,957
- Filed: 2018-09-20
- Published: 2019-03-21
- Granted: 2022-04-12
- Earliest claimed: 2017-09-20
- Assignees: The Curators of the University of Missouri
- Applicants: The Curators of the University of Missouri
- Inventors: Fateme Rezaei; Harshul V. Thakkar
- Web page: https://patentgrep.com/patent/US11298675B2

## CPC

- B01J 20/165: {Natural alumino-silicates, e.g. zeolites}
- B01D 53/02: by adsorption, e.g. preparative gas chromatography {(solid sorbent compositions B01J20/00, preparation of inorganic compounds or elements C01)}
- B01J 20/12: Naturally occurring clays or bleaching earth
- B01J 20/18: Synthetic zeolitic molecular sieves
- B01J 20/2803: {Sorbents comprising a binder, e.g. for forming aggregated, agglomerated or granulated products}
- B01J 20/28042: {Shaped bodies; Monolithic structures}
- B01J 20/28071: {being less than 0.5 ml/g}
- B33Y 70/10: Composites of different types of material, e.g. mixtures of ceramics and polymers or mixtures of metals and biomaterials
- B01D 2253/108: Zeolites
- B01D 2253/11: Clays
- B01D 2253/342: Monoliths
- B01D 2257/504: Carbon dioxide
- B01D 2258/06: Polluted air
- B01J 2220/82: Shaped bodies, e.g. monoliths, plugs, tubes, continuous beds
- B33Y 80/00: Products made by additive manufacturing
- Y02C 20/40: of CO2
- B01J: CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01D: SEPARATION (separating solids from solids by wet methods B03B, B03D; by pneumatic jigs or tables B03B; by other dry methods B07; magnetic or electrostatic separation of solid materials from solid materials or fluids, separation by high-voltage electric fields B03C; centrifuges, vortex apparatus B04; presses per se for squeezing-out liquid from liquid-containing material B30B9/02; treatment of water C02F, e.g. softening by ion-exchange C02F1/42; {arrangements of air intake cleaners in gas turbine plants F02C7/05} ; arrangements or mounting of filters in air-conditioning, air-humidification or ventilation F24F13/28)
- B33Y: ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
- Y02C: CAPTURE, STORAGE, SEQUESTRATION OR DISPOSAL OF GREENHOUSE GASES [GHG]

## Abstract

Carbon dioxide (CO2) capture materials comprising one or more 3D-printed zeolite monoliths for the capture and or removal of CO2 from air or gases in enclosed compartments, including gases or mixtures of gases having less than about 5% CO2. Methods for preparing 3D-printed zeolite monoliths useful as CO2 capture materials and filters, as well as methods of removing CO2 from a gas or mixture of gases in an enclosed compartment using 3D-printed zeolite monoliths are provided.

## Claims

### Claim 1

A method of preparing a 3D-printed zeolite monolith, the method comprising:
mixing zeolite powder, bentonite clay, a plasticizing organic binder, and an organic co-binder using a high-performance dispersing instrument at 2500 rpm to obtain a powder mixture;
adding a sufficient amount of distilled water to the powder mixture and mixing using the high-performance dispersing instrument at 2500 rpm to form an aqueous paste; and
depositing the aqueous paste layer-by-layer, using a 3D-printing apparatus, onto a substrate to produce a 3D-printed zeolite monolith.

### Claim 2 (depends on 1)

The method according to claim 1, wherein the zeolite powder is selected from the group consisting of a 13X zeolite powder and a 5A zeolite powder.

### Claim 3 (depends on 1)

The method according to claim 1, wherein the plasticizing organic binder is methyl cellulose.

### Claim 4 (depends on 1)

The method according to claim 1, wherein the organic co-binder is polyvinyl alcohol.

### Claim 5 (depends on 1)

The method according to claim 1, wherein a combined amount of plasticizing organic binder and organic co-binder comprises from about 3 weight percent to about 5 weight percent of the 3D-printed zeolite monolith.

### Claim 6 (depends on 1)

The method according to claim 1, wherein the 3D-printed zeolite monolith comprises from about 80 weight percent to about 90 weight percent zeolite powder.

### Claim 7 (depends on 5)

The method according to claim 5, wherein the 3D-printed zeolite monolith comprises from about 7 weight percent to about 15 weight percent bentonite clay.

### Claim 8 (depends on 7)

The method according to claim 7, wherein the 3D-printed zeolite monolith comprises from about 2.0 weight percent to about 3.5 weight percent plasticizing organic binder.

### Claim 9 (depends on 8)

The method according to claim 8, wherein the 3D-printed zeolite monolith comprises from about 1.0 weight percent to about 1.5 weight percent organic co-binder.

### Claim 10 (depends on 1)

The method according to claim 1, further comprising:
calcining the 3D-printed zeolite monolith so as to substantially remove the plasticizing organic binder and the organic co-binder to generate a zeolite monolith comprising microporosity, mesoporosity, and microporosity.