Flow-through sorbent comprising a metal sulfide

Abstract

A flow-through sorbent comprising at least 30 wt % of a metal sulfide, and a binder. The sorbent may be used, for example, for the removal of a contaminant, such as mercury, from a fluid stream.

1 . A method of making a flow-through sorbent comprising at least 30 wt % metal sulfide and a binder, which comprises:
 providing a mixture comprising
 a metal sulfide, or a combination of 1) a metal oxide or metal sulfide with 2) an additional sulfur source, and 
 an inorganic binder; 
   forming the mixture into the shape of a flow-through structure; and   drying and optionally firing the shaped structure.   
     
     
         2 . The method according to  claim 1 , wherein the mixture comprises elemental sulfur as the additional sulfur source. 
     
     
         3 . The method according to  claim 1 , which comprises forming the mixture into the shape of a flow-through structure by extrusion. 
     
     
         4 . The method according to  claim 1 , wherein the mixture further comprises an organic binder. 
     
     
         5 . The method according to  claim 1 , wherein the flow-through sorbent comprises a monolith. 
     
     
         6 . The method according to  claim 5 , wherein the flow-through sorbent monolith comprises an inlet end, an outlet end, and a multiplicity of cells extending from the inlet end to the outlet end, the cells being defined by intersecting porous cell walls, wherein the inlet end and the outlet end are not plugged. 
     
     
         7 . A method of making a flow-through sorbent according to  claim 1 , which comprises:
 providing a mixture comprising
 a metal sulfide, optionally an additional sulfur source, and 
 a curable organic binder; 
   forming the mixture into the shape of a flow-through structure; and   drying and optionally curing the shaped structure.   
     
     
         8 . The method according to  claim 7 , wherein the mixture comprises elemental sulfur as the additional sulfur source. 
     
     
         9 . The method according to  claim 7 , which comprises forming the mixture into the shape of a flow-through structure by extrusion. 
     
     
         10 . The method according to  claim 7 , wherein the flow-through sorbent comprises a monolith. 
     
     
         11 . The method according to  claim 10 , wherein the flow-through sorbent monolith comprises an inlet end, an outlet end, and a multiplicity of cells extending from the inlet end to the outlet end, the cells being defined by intersecting porous cell walls, wherein the inlet end and the outlet end are not plugged. 
     
     
         12 . A method of making a honeycomb flow-through sorbent comprising an inlet end, an outlet end, and a multiplicity of cells extending from the inlet end to the outlet end, the cells being defined by intersecting porous cell walls, wherein the inlet end and the outlet end are not plugged, wherein the honeycomb flow through sorbent comprises a composition comprising at least 30 wt % of a metal sulfide;
 elemental sulfur; and a binder matrix comprising an organic binder, wherein the metal sulfide and the elemental sulfur are dispersed within the binder matrix; wherein the method comprises   providing a mixture comprising:
 a metal sulfide; 
 an elemental sulfur source, and 
 an inorganic binder; 
   forming the mixture into the shape of a flow-through structure; and   drying and optionally firing the shaped structure.   
     
     
         13 . The method according to  claim 12 , which comprises forming the mixture into the shape of a flow-through structure by extrusion.