Self-supporting structures having active materials
AssigneeExxonMobil Technology and Engineering Company
InventorsJohn F. Brody, Bradley Wooler, Francesco J. Altera, Paul J. Tindall, Yi Du
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Abstract
A method and system for manufacturing and using a self-supporting structure in processing unit for adsorption or catalytic processes. The self-supporting structure has greater than 50% by weight of the active material in the self-supporting structure to provide an open-celled structure providing access to the active material. The self-supporting structures, which may be disposed in a processing unit, may be used in swing adsorption processes and other processes to enhance the recovery of hydrocarbons.
Claims18
A method for removing contaminants from a feed stream, the method comprising:
- a) performing one or more adsorption steps using a process unit comprised of a plurality of adsorbent bed units, wherein each of the one or more adsorption steps comprises:
- passing a gaseous feed stream through at least one of the plurality of adsorbent bed units comprising a self-supporting structure disposed in an interior region of a housing of the adsorbent bed unit to remove one or more contaminants from the gaseous feed stream, wherein the self-supporting structure has greater than 50% by weight of an active material in the self-supporting structure, wherein the self-supporting structure is an open-celled structure configured to provide one or more defined channels for fluid flow paths through the self-supporting structure, wherein the self-supporting structure comprises a plurality of pores formed in the active material by removal of a plurality of polyethylene spheres;
- b) performing one or more regeneration steps, wherein each of the one or more regeneration steps comprise conducting away at least a portion of the one or more contaminants from the at least one of the plurality of adsorbent bed units in a contaminant output stream;
- and
- c) repeating the steps a) to b) for at least one additional cycle.
A method for removing contaminants from a feed stream, the method comprising:
- a) performing one or more adsorption steps using a process unit comprised of a plurality of adsorbent bed units, wherein each of the one or more adsorption steps comprises:
- passing a gaseous feed stream through at least one of the plurality of adsorbent bed units comprising a self-supporting structure disposed in an interior region of a housing of the adsorbent bed unit to remove one or more contaminants from the gaseous feed stream, wherein the self-supporting structure has greater than 50% by weight of an active material in the self-supporting structure, wherein the self-supporting structure is an open-celled structure configured to provide one or more defined channels for fluid flow paths through the self-supporting structure;
- b) performing one or more regeneration steps, wherein each of the one or more regeneration steps comprise conducting away at least a portion of the one or more contaminants from the at least one of the plurality of adsorbent bed units in a contaminant output stream;
- c) repeating the steps a) to b) for at least one additional cycle;
- and
- wherein the self-supporting structure further comprises a silica binder material, the self-supporting structure being formed by:
- creating a template for the self-supporting structure;
- disposing a mixture within the template, wherein the mixture has greater than 50% by weight of the active material in the self-supporting structure and the silica binder material;
- curing the template and the mixture to form the self-supporting structure, the self-supporting structure maintaining a solid form;
- and
- removing the template from the self-supporting structure, wherein the one or more defined channels are based on the template.
Dependencies are inferred from the claim text.