Activated carbon monolith catalyst, methods for making same, and uses thereof

Abstract

An activated carbon monolith catalyst comprising a finished self-supporting activated carbon monolith having at least one passage therethrough, and comprising a supporting matrix and substantially discontinuous activated carbon particles dispersed throughout the supporting matrix and at least one catalyst precursor on the finished self-supporting activated carbon monolith. A method for making, and a method for use, of such an activated carbon monolith catalyst in catalytic chemical reactions are also disclosed.

1 . An activated carbon monolith catalyst comprising: 
 a finished self-supporting activated carbon monolith having at least one passage therethrough and comprising a supporting matrix and substantially discontinuous activated carbon particles dispersed throughout the supporting matrix; and    at least one catalyst precursor on said finished self-supporting activated carbon monolith.    
   
   
       2 . An activated carbon monolith catalyst as in  claim 1  wherein the at least one catalyst precursor is selected from the group consisting of precious metal, base metal, or a combination thereof.  
   
   
       3 . An activated carbon monolith catalyst as in  claim 1  wherein the at least one catalyst precursor is selected from the group consisting of reduced precious metal, precious metal oxide, precious metal sulfide, precious metal with modifier, base metal, or a combination thereof.  
   
   
       4 . An activated carbon monolith catalyst as in  claim 1  wherein the at least one catalyst precursor includes a modifier selected from the group consisting of potassium, calcium, magnesium, sodium hydrated oxides, and sodium hydroxides.  
   
   
       5 . An activated carbon monolith catalyst as in  claim 1  wherein the at least one catalyst precursor is a precious metal selected from the group consisting of palladium, platinum, rhodium, ruthenium, iridium, osmium, silver, and gold.  
   
   
       6 . An activated carbon monolith catalyst as in  claim 1  wherein the at least one catalyst precursor is a base metal is selected from the group consisting of zinc, nickel, copper, manganese, iron, chromium, vanadium, and molybdenum.  
   
   
       7 . An activated carbon monolith catalyst as in  claim 1  wherein the at least one catalyst precursor is a base metal catalyst selected from the group consisting of oxides, hydrated oxides, carbonates, or sulfides.  
   
   
       8 . An activated carbon monolith catalyst as in  claim 1  wherein the at least one catalyst precursor is present on the finished self-supporting activated carbon monolith in an amount from about 0.01% to about 5.0% by weight of the activated carbon monolith catalyst.  
   
   
       9 . An activated carbon monolith catalyst as in  claim 1  wherein the finished self-supporting activated carbon monolith has an axial crushing strength from about 500 to about 1600 psi.  
   
   
       10 . A carbon monolith catalyst as in  claim 1  wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 20 to about 95% by weight of the monolith and the supporting matrix is present in the finished self-supporting activated carbon monolith in an amount from about 80 to about 5% by weight of the finished self-supporting activated carbon monolith.  
   
   
       11 . An activated carbon monolith catalyst as in  claim 1  wherein the supporting matrix is a ceramic matrix.  
   
   
       12 . An activated carbon monolith catalyst as in  claim 11  wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 20 to about 80% by weight of the monolith and the ceramic is present in the finished self-supporting activated carbon monolith in an amount from about 80 to about 20% by weight of the finished self-supporting activated carbon monolith.  
   
   
       13 . An activated carbon monolith catalyst as in  claim 11  wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 30 to about 50% by weight of the monolith and the ceramic is present in the finished self-supporting activated carbon monolith in an amount from about 70 to about 50% by weight of the finished self-supporting activated carbon monolith.  
   
   
       14 . An activated carbon monolith catalyst as in  claim 1  wherein the activated carbon particles are derived from materials selected from the group consisting of bituminous coal, lignite, peat, synthetic polymers, petroleum pitch, petroleum coke, coal tar pitch, and lignocellulosic materials.  
   
   
       15 . An activated carbon monolith catalyst as in  claim 1  wherein the activated carbon particles are derived from lignocellulosic materials selected from the group consisting of wood, wood dust, wood flour, sawdust, coconut shell, fruit pits, nut shell, and fruit stones.  
   
   
       16 . An activated carbon monolith catalyst as in  claim 1  wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 600 to about 2000 m 2  /g.  
   
   
       17 . An activated carbon monolith catalyst as in  claim 1  wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 800 to 1800 m 2  /g.  
   
   
       18 . An activated carbon monolith catalyst as in  claim 1  wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 1000 to 1600 m 2  /g.  
   
   
       19 . An activated carbon monolith catalyst as in  claim 1  wherein the activated carbon particles are characterized by having a particle size such that more than 40% by weight of the activated carbon passes through a 200-mesh screen.  
   
   
       20 . An activated carbon monolith catalyst as in  claim 1  wherein the activated carbon particles are characterized by having a particle size such that more than 65% by weight of the activated carbon passes through a 200-mesh screen.  
   
   
       21 . An activated carbon monolith catalyst as in  claim 11  wherein the finished self-supporting activated carbon monolith is made according to a process comprising extruding an extrudable mixture comprising the activated carbon particles, a ceramic forming material, flux material and water, drying the extruded monolith, and firing the dried monolith at a temperature and for a time period sufficient to fuse the ceramic forming material together and form the ceramic matrix.  
   
   
       22 . An activated carbon monolith catalyst as in  claim 21  wherein the flux material is a feldspathic mineral.  
   
   
       23 . An activated carbon monolith catalyst as in  claim 22  wherein the feldspathic mineral is nepheline syenite.  
   
   
       24 . An activated carbon monolith catalyst as in  claim 21  wherein the flux material further comprises sodium silicate.  
   
   
       25 . An activated carbon monolith catalyst as in  claim 21  wherein the ceramic forming material is selected from the group consisting of ball clay, plastic kaolins, smectite clay minerals, bentonite, and combinations thereof.  
   
   
       26 . An activated carbon monolith catalyst as in  claim 21  wherein the ceramic forming material further comprises a shrinkage reducing filler material.  
   
   
       27 . An activated carbon monolith catalyst as in  claim 26  wherein the shrinkage reducing filler material is calcined kaolin clay.  
   
   
       28 . An activated carbon monolith catalyst as in  claim 1  wherein the finished self-supporting activated carbon monolith has a plurality of passages therethrough for receiving a flow of fluid and an open frontal area greater than 50% and up to 85%.  
   
   
       29 . An activated carbon monolith catalyst as in  claim 1  wherein the finished self-supporting activated carbon monolith is honeycomb shaped.  
   
   
       30 . An activated carbon monolith catalyst as in  claim 1  wherein the finished self-supporting activated carbon monolith is porous and the at least one catalyst precursor is at least partially disposed in pores of the finished self-supporting activated carbon monolith.  
   
   
       31 . A method for making an activated carbon monolith catalyst comprising: 
 providing a finished self-supporting activated carbon monolith having at least one passage therethrough and comprising a supporting matrix and substantially discontinuous activated carbon particles dispersed throughout the supporting matrix; and    applying at least one catalyst precursor to said finished activated carbon monolith.    
   
   
       32 . A method as in  claim 31  wherein the step of applying catalyst precursor comprises applying a catalyst precursor selected from the group consisting of precious metal, base metal, or a combination thereof.  
   
   
       33 . A method as in  claim 31  wherein the step of applying catalyst precursor comprises applying a catalyst precursor selected from the group consisting of reduced precious metal, precious metal oxide, precious metal sulfide, precious metal with modifier, base metal, or a combination thereof.  
   
   
       34 . A method as in  claim 31  wherein the step of applying catalyst precursor comprises applying a precious metal catalyst precursor and a modifier selected from the group consisting of potassium, calcium, magnesium, sodium hydrated oxides, and sodium hydroxides.  
   
   
       35 . A method as in  claim 31  wherein the step of applying catalyst precursor comprises applying a precious metal catalyst precursor selected from the group consisting of palladium, platinum, rhodium, ruthenium, iridium, osmium, silver, and gold.  
   
   
       36 . A method as in  claim 31  wherein the step of applying catalyst precursor comprises applying a base metal catalyst precursor selected from the group consisting of zinc, nickel, copper, manganese, iron, chromium, vanadium, and molybdenum.  
   
   
       37 . A method as in  claim 31  wherein the step of applying catalyst precursor comprises applying a base metal catalyst precursor selected from the group consisting of oxides, hydrated oxides, carbonates, or sulfides.  
   
   
       38 . A method as in  claim 31  wherein the step of applying catalyst precursor comprises applying catalyst precursor to the finished self-supporting activated carbon monolith in an amount from about 0.01% to about 5.0% by weight of the activated carbon monolith catalyst.  
   
   
       39 . A method as in  claim 31  wherein the step of applying catalyst precursor includes applying the catalyst precursor in solution to the finished self-supporting activated carbon monolith and drying the finished self-supporting activated carbon monolith.  
   
   
       40 . A method as in  claim 31  wherein the step of applying catalyst precursor includes dipping the finished self-supporting activated carbon monolith in a solution of the catalyst precursor and drying the finished self-supporting activated carbon monolith.  
   
   
       41 . A method as in  claim 31  wherein the step of applying catalyst precursor includes dissolving the catalyst precursor in a liquid bath, placing the finished self-supporting activated carbon monolith in the liquid bath, removing the finished self-supporting activated carbon monolith from the liquid bath and drying the finished self-supporting activated carbon monolith.  
   
   
       42 . A method as in  claim 31  wherein the supporting matrix is a ceramic matrix.  
   
   
       43 . A method as in  claim 42  wherein the activated carbon monolith catalyst is made according to a process comprising extruding an extrudable mixture comprising the activated carbon particles, ceramic forming material, flux material and water, drying the extruded monolith, and firing the dried monolith at a temperature and for a time period sufficient to fuse the ceramic forming material together and form the ceramic matrix.  
   
   
       44 . A method as in  claim 43  wherein the flux material is a feldspathic mineral flux material.  
   
   
       45 . A method as in  claim 43  wherein the finished self-supporting activated carbon monolith has an axial crushing strength from about 500 to about 1600 psi.  
   
   
       46 . A method as in  claim 31  wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 20 to about 95% by weight of the monolith and the supporting matrix is present in the finished self-supporting activated carbon monolith in an amount from about 80 to about 5% by weight of the finished self-supporting activated carbon monolith.  
   
   
       47 . A method as in  claim 42  wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 20 to about 80% by weight of the finished self-supporting activated carbon monolith and the ceramic is present in the finished self-supporting activated carbon monolith in an amount from about 80 to about 20% by weight of the finished self-supporting activated carbon monolith.  
   
   
       48 . A method as in  claim 42  wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 30 to about 50% by weight of the finished self-supporting activated carbon monolith and the ceramic is present in the finished self-supporting activated carbon monolith in an amount from about 70 to about 50% by weight of the finished self-supporting activated carbon monolith.  
   
   
       49 . A method as in  claim 31  wherein the activated carbon particles are derived from materials selected from the group consisting of bituminous coal, lignite, peat, synthetic polymers, petroleum pitch, petroleum coke, coal tar pitch, and lignocellulosic materials.  
   
   
       50 . A method as in  claim 31  wherein the activated carbon particles are derived from lignocellulosic materials selected from the group consisting of wood, wood dust, wood flour, sawdust, coconut shell, fruit pits, nut shell, and fruit stones.  
   
   
       51 . A method as in  claim 31  wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 600 to about 2000 m 2 /g.  
   
   
       52 . A method as in  claim 31  wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 800 to 1800 m 2 /g.  
   
   
       53 . A method as in  claim 31  wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 1000 to 1600 m 2/ g.  
   
   
       54 . A method as in  claim 31  wherein the activated carbon particles are characterized by having a particle size such that more than 40% by weight of the activated carbon passes through a 200 mesh screen.  
   
   
       55 . A method as in  claim 31  wherein the activated carbon particles are characterized by having a particle size such that more than 65% by weight of the activated carbon passes through a 200 mesh screen.  
   
   
       56 . A method as in  claim 44  wherein the feldspathic mineral is nepheline 35 syenite.  
   
   
       57 . A method as in  claim 43  wherein the flux material further comprises sodium silicate.  
   
   
       58 . A method as in  claim 43  wherein the ceramic forming material is selected from the group consisting of ball clay, plastic kaolins, smectite clay minerals, bentonite, and combinations thereof.  
   
   
       59 . A method as in  claim 43  wherein the ceramic forming material further comprises a shrinkage reducing filler material.  
   
   
       60 . A method as in  claim 59  wherein the shrinkage reducing filler material is calcined kaolin clay.  
   
   
       61 . A method as in  claim 31  wherein the finished self-supporting activated carbon monolith has a plurality of passages therethrough for receiving a flow of fluid and an open frontal area greater than 50% and up to 85%.  
   
   
       62 . A method as in  claim 31  wherein said finished self-supporting activated carbon monolith is honeycomb shaped.  
   
   
       63 . A method for catalytic chemical reaction comprising contacting at least one reactant with an activated carbon monolith catalyst comprising (a) a finished self-supporting activated carbon monolith having at least one passage therethrough and comprising a supporting matrix and substantially discontinuous activated carbon particles dispersed throughout the supporting matrix, and (b) at least one catalyst precursor on said finished self-supporting activated carbon monolith.  
   
   
       64 . A method as in  claim 63 , wherein the at least one catalyst precursor is selected from the group consisting of precious metal, base metal, or a combination thereof.  
   
   
       65 . A method as in  claim 63 , wherein the at least one catalyst precursor is selected from the group consisting of reduced precious metal, precious metal oxide, precious metal sulfide, precious metal with modifier, base metal, or a combination thereof.  
   
   
       66 . A method as in  claim 63 , wherein the at least one catalyst precursor includes a modifier selected from the group consisting of potassium, calcium, magnesium, sodium hydrated oxides, and sodium hydroxides.  
   
   
       67 . A method as in  claim 63 , wherein the at least one catalyst precursor is a precious metal selected from the group consisting of palladium, platinum, rhodium, ruthenium, iridium, osmium, silver, and gold.  
   
   
       68 . A method as in  claim 63 , wherein the at least one catalyst precursor is a base metal is selected from the group consisting of zinc, nickel, copper, manganese, iron, chromium, vanadium, and molybdenum.  
   
   
       69 . A method as in  claim 63 , wherein the at least one catalyst precursor is a base metal catalyst selected from the group consisting of oxides, hydrated oxides, carbonates, or sulfides.  
   
   
       70 . A method as in  claim 63 , wherein the at least one catalyst precursor is present on the finished self-supporting activated carbon monolith in an amount from about 0.01% to about 5.0% by weight of the activated carbon monolith catalyst.  
   
   
       71 . A method as in  claim 63 , wherein the finished self-supporting activated carbon monolith has an axial crushing strength from about 500 to about 1600 psi.  
   
   
       72 . A method as in  claim 63  wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 20 to about 95% by weight of the monolith and the supporting matrix is present in the finished self-supporting activated carbon monolith in an amount from about 8o to about 5% by weight of the finished self-supporting activated carbon monolith.  
   
   
       73 . A method as in  claim 63  wherein the supporting matrix is a ceramic matrix.  
   
   
       74 . A method as in  claim 73 , wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 20 to about 80% by weight of the finished self-supporting activated carbon monolith and the ceramic is present in the monolith in an amount from about 80 to about 20% by weight of the finished self-supporting activated carbon monolith.  
   
   
       75 . A method as in  claim 73 , wherein the activated carbon particles are present in the finished self-supporting activated carbon monolith in an amount from about 30 to about 50% by weight of the finished self-supporting activated carbon monolith and the ceramic is present in the monolith in an amount from about 70 to about 50% by weight of the finished self-supporting activated carbon monolith.  
   
   
       76 . A method as in  claim 63 , wherein the activated carbon particles are derived from materials selected from the group consisting of bituminous coal, lignite, peat, synthetic polymers, petroleum pitch, petroleum coke, coal tar pitch, and lignocellulosic materials.  
   
   
       77 . A method as in  claim 63 , wherein the activated carbon particles are derived from lignocellulosic materials selected from the group consisting of wood, wood dust, wood flour, sawdust, coconut shell, fruit pits, nut shell, and fruit stones.  
   
   
       78 . A method as in  claim 63 , wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 600 to about 2000 m 2  /g.  
   
   
       79 . A method as in  claim 63 , wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 800 to 1800 m 2 /g  
   
   
       80 . A method as in  claim 63 , wherein the activated carbon particles are characterized by a nitrogen B.E.T. surface area from about 1000 to 1600 m 2 /g  
   
   
       81 . A method as in  claim 63 , wherein the activated carbon particles are characterized by having a particle size such that more than 40% by weight of the activated carbon passes through a 200 mesh screen.  
   
   
       82 . A method as in  claim 63 , wherein the activated carbon particles are characterized by having a particle size such that more than 65% by weight of the activated carbon passes through a 200 mesh screen.  
   
   
       83 . A method as in  claim 73 , wherein the finished self-supporting activated carbon monolith is made according to a process comprising extruding an extrudable mixture comprising the activated carbon particles, ceramic forming material, flux material and water, drying the extruded monolith, and firing the dried monolith at a temperature and for a time period sufficient to fuse the ceramic forming material together and form the ceramic matrix.  
   
   
       84 . A method as in  claim 83 , wherein the flux material is a feldspathic mineral.  
   
   
       85 . A method as in  claim 84 , wherein the feldspathic mineral is nepheline syenite.  
   
   
       86 . A method as in  claim 83 , wherein the flux material further comprises sodium silicate.  
   
   
       87 . A method as in  claim 83 , wherein the ceramic forming material is selected from the group consisting of ball clay, plastic kaolins, smectite clay minerals, bentonite, and combinations thereof.  
   
   
       88 . A method as in  claim 83 , wherein the ceramic forming material further comprises a shrinkage reducing filler material.  
   
   
       89 . A method as in  claim 83 , wherein the shrinkage reducing filler material is calcined kaolin clay.  
   
   
       90 . A method as in  claim 63 , wherein the finished self-supporting activated carbon monolith further has a plurality of passages therethrough for receiving a flow of fluid and an open frontal area greater than 50% and up to 85%.  
   
   
       91 . A method as in  claim 63 , wherein the finished self-supporting activated carbon monolith is honeycomb shaped.  
   
   
       92 . A method as in  claim 63 , wherein the chemical reaction comprises organic chemical synthesis.