Adsorbent product, method for producing adsorbent product, method for recovering component and use

Abstract

The application relates to an adsorbent product and a method for producing an adsorbent product. The adsorbent product comprises a polymer matrix and an adsorbent agent, in which the powdered adsorbent agent is mixed to the polymer matrix to form a mixture and the adsorbent product with a three-dimensional shape is formed by shaping from the mixture. Further, the application relates to a method for recovering a predetermined component from a stream using the adsorbent product and a use of the adsorbent product.

Description

FIELD The application relates to an adsorbent product as defined in claim 1, a method for producing an adsorbent product as defined in claim 9 and a method for recovering a predetermined component from a stream as defined in claim 15. Further, the application relates to a use of the adsorbent product. BACKGROUND It is known to use different adsorbents, such as solution or powder, in different processes for removing different components from streams. The solution and powdery adsorbents are challenging to use and treat in the processes. Further, usually the adsorbents are disposable . Further, membranes are used to recover different components from streams or to purify streams. However, the membranes clog up easily, and the membranes are difficult to maintain. OBJECTIVE An objective is to alleviate the disadvantages mentioned above. In particular, the objective is to disclose a novel type of adsorbent. The objective is to disclose an adsorbent with large surface area. Further, the objective is to disclose a novel type of 3D-printed adsorbent. Further, the objective is to achieve an effective process for removing and recovering desired components from streams and / or purifying streams. SUMMARY The adsorbent product, the method for producing the adsorbent product, the method for recovering a component from a stream and the use are characterized by what are presented in the claims. The adsorbent product is formed from a polymer matrix and an adsorbent agent, in which the adsorbent agent is mixed to the polymer matrix to form a mixture, and the adsorbent product is formed from the mixture. In the method for producing the adsorbent product, an adsorbent agent is mixed to a polymer matrix to form a mixture and the adsorbent product is formed by shaping from the mixture. In the method for recovering a predetermined component from a stream, the adsorbent product is formed, and the adsorbent product is arranged to recover a predetermined component from the stream. DETAILED DESCRIPTION The adsorbent product comprises a polymer matrix and an adsorbent agent, in which the powdered adsorbent agent is mixed to the polymer matrix to form a mixture, and the adsorbent product with a three-dimensional shape is formed by shaping from the mixture. The method for producing the adsorbent product comprises mixing a powdered adsorbent agent to a polymer matrix to form a mixture; and forming the adsorbent product with a three-dimensional shape by shaping from the mixture. In this context, the polymer matrix means any polymer material, polymer composition, carrier material, supporting material or any combination thereof. The polymer matrix can comprise one or more components. The polymer matrix can be formed from any polymer, resin and / or plastic. In one embodiment, the polymer, resin and / or plastic is selected from chemically resistant substance, e.g. heat-resistant, pH-resistant or the like substance. In one embodiment, the polymer matrix is formed from thermosetting polymer (s) or resin (s) . In one embodiment, the polymer matrix is formed from thermoplastic (s) or resin(s). In one embodiment, the polymer matrix comprises polyethylene, polypropylene, engineering plastic, speciality plastic or any combination thereof. In one embodiment, the polymer matrix is formed from recycled polymers, resins and / or plastics. In one embodiment, the polymer matrix consists of resin (s). Preferably, the polymer matrix is formed such that the adsorbent agent can be bound easily to the said matrix. Preferably, the polymer matrix is selected such that the polymer matrix is not used as an adsorbent material. In one embodiment, the polymer matrix is in solid form, e.g. in particle form or in powdered form. In one embodiment, the polymer matrix is in liquid form. In this context, the adsorbent agent means any adsorbent agent, material or molecules, which can be bound to the polymer matrix. In one embodiment, the adsorbent agent consists of molecules. Preferably, the adsorbent agent is the powdered material. The adsorbent agent may comprise one or more components. Any adsorbent agent may be used. In one embodiment, the adsorbent agent is a metal adsorbent agent. In one embodiment, the molecule of the adsorbent agent comprises a functional end or a chemical group or radical, which can be bound by the polymer matrix. In one embodiment, the adsorbent agent is a hydrophilic agent. In one embodiment, the adsorbent agent is a hydrophobic agent. In one embodiment, the adsorbent agent is at least partly a hydrophobic agent and partly a hydrophilic agent. In this context, the adsorbent product means any adsorbent product, which comprises the adsorbent agent and polymer matrix and which has a three-dimensional shape. The adsorbent product may be formed of two or more components, comprising at least the polymer matrix and adsorbent agent. In one embodiment, the adsorbent product consists of the polymer matrix and adsorbent agent. The adsorbent product is formed by shaping. The adsorbent product may have any size and shape. Preferably, the adsorbent product is in the form of a fixed or a solid structure. The adsorbent product has the three-dimensional structure with predetermined dimensions, e.g. length, width, depth and / or diameter, and with predetermined shape. Preferably, the adsorbent product is a non-membrane structure. The adsorbent product is not a membrane or film structure. In one embodiment, the adsorbent product is a monolith. In one embodiment, the adsorbent product has a solid structure comprising thin structural parts. In one embodiment, the adsorbent product comprises thin-walled structural parts. In one embodiment, the adsorbent product is a thinwalled non-membrane solid structure. Preferably, the adsorbent product comprises several adsorbent surfaces for adsorbing the desired components. In one embodiment, the adsorbent product is shaped such that a surface area of the adsorbent product is maximised with relation to a volume of the product. In one embodiment, the adsorbent product comprises regularly shaped portions. In one embodiment, the adsorbent product is in the form of regularly shaped portions. In one embodiment, the adsorbent product comprises a comb shape or a lattice shape. In one embodiment, the adsorbent product has a lattice structure. In one embodiment, the adsorbent product comprises a closed structure and a shaped structure with several adsorbent surfaces, e.g. a comb or lattice structure. In one embodiment, the adsorbent product has a functional shape, e.g. for increasing flow and / or turbulence. In one embodiment, the adsorbent product comprises functional structures, such as thinwalled structural parts, e.g. for increasing flow and / or turbulence. In one embodiment, the adsorbent agent is arranged to the surfaces of the structural parts in the adsorbent product, preferably during the forming and / or shaping of the adsorbent product. In one embodiment, the surface of the adsorbent product comprises different surface shapes. In one embodiment, the surface comprises roughness, pores or the like . The adsorbent product is formed from the polymer matrix and powder of the adsorbent agent to form a three-dimensional product. The adsorbent product may be a final product or a part of the final product. In one embodiment, the adsorbent product is a final product. In one embodiment, the adsorbent product is a part of a final product. In one embodiment, a final product is a modular structure, and the adsorbent product is a part of the final product. The adsorbent product is formed by shaping. In one embodiment, the adsorbent product may be formed using any suitable shaping method and / or apparatus, such as any plastic shaping. In one embodiment, the adsorbent product is formed using a 3D printing, extrusion, or injection moulding. In one embodiment, the adsorbent product is formed using the 3D printing. Any 3D printing method and / or apparatus can be used. In one embodiment, the 3D printing is a vat polymerisation, a binder jetting (BJT), a material jetting (MJT), a material extrusion (MEX), a powder bed fusion (PBF), or any combination thereof. In one embodiment, the adsorbent product is formed using a vat polymerization, e.g. vat photo polymerization (VPP). Preferebly, the desired structure and / or shape of the adsorbent product is provided during the manufacture of the adsorbent product. In one embodiment, the shape of the adsorbent product is selected and shaped using the 3D printing, and thus the desired shape can be formed easily and effectively. In one 6 embodiment, the polymer matrix and adsorbent agent can be mixed very homogeneously, when 3D printing, e.g. a vat photo polymerization (VPP), is used. In one embodiment, the adsorbent product is formed using the extrusion. Any extrusion method and / or apparatus can be used. In one embodiment, the adsorbent product is formed using the injection moulding. Any injection moulding method and / or apparatus can be used. In one embodiment, the mixture is formed in connection with the shaping, e.g. during the shaping method such as during the 3D printing, extrusion or injection moulding, or in the 3D printing apparatus, extruder or injection moulding apparatus. In one embodiment, the mixture is formed before the shaping. In the mixing it is important that the powdered adsorbent agent is mixed to the polymer matrix. In one embodiment, the powdered adsorbent agent is mixed to the liquid polymer matrix to form the mixture. In one embodiment, the powdered adsorbent agent is mixed to the powdered polymer matrix to form the mixture. In one embodiment, particles of the adsorbent agent are smaller than particles of the polymer matrix. In one embodiment, particles of the polymer matrix are smaller than particles of the adsorbent agent. Preferably, the adsorbent agent is mixed to the polymer matrix homogeneously. Preferably, the adsorbent agent is bound to the polymer matrix during the forming of the adsorbent product. The binding of the adsorbent agent can be made by chemically or mechanically to the polymer matrix. In one embodiment, the binding can be performed by a thermal reaction and / or by a chemical reaction. In one embodiment, the binding can be performed by a thermal reaction and / or by a chemical reaction during the 3D printing. In one embodiment, the adsorbent product is cooled and / or solidified to keep the shape of the adsorbent product. In one embodiment, the method further 7 comprises cooling and / or solidifying the adsorbent product . In one embodiment, the adsorbent product is hardened. In one embodiment, the hardening is made by chemically and / or by thermally. In one embodiment, the hardening is carried out by an ultraviolet light (UV) , laser, heat or any combination thereof. In one embodiment, the polymer matrix comprises resin which can be hardened by UV-light. In one embodiment, the method further comprises hardening the adsorbent product. In one embodiment, the adsorbent product is a 3D-printed product. In one embodiment, the adsorbent product is an extruded product. In one embodiment, the adsorbent product is an injection moulded product. In one embodiment, the adsorbent agent can be arranged to the surfaces of the structural parts in the adsorbent product, when the thin structural parts and / or thin-walled structural parts of the adsorbent product are formed in the shaping. Further, in one embodiment, the adsorbent agent can be arranged to the surfaces of the structural parts in the adsorbent product, when the powdered adsorbent agent is used in the manufacturing of the adsorbent product. When the adsorbent agent is arranged to the surfaces of the structural parts in the adsorbent product, the adsorbent agent is contact with components of streams which are recovered from the streams. Then the recovered components can be adsorbed better to the surface of the adsorbent product. In a preferred embodiment, the adsorbent agent has a large surface area and thin-walled structural parts. In one embodiment, the thin-walled adsorbtion products are formed by shaping. In one embodiment, the thin-walled adsorbtion products are formed using 3D printing, e.g. vat polymerization. The adsorbent product can be arranged into a predetermined apparatus, e.g. reactor or the like, for 8 recovering desired component (s) and / or purifying stream (s) . In one embodiment, the method comprises: i) providing an adsorbent product as defined; ii) arranging the adsorbent product to contact a stream; and iii) recovering one or more components from the stream. In one embodiment, in ii), preferably a predefined reaction temperature is used, and the reaction temperature is selected based on the process and / or one or more reaction products are formed. The method for recovering a predetermined component from a stream using the adsorbent product comprises forming the adsorbent product from a polymer matrix and an adsorbent agent by mixing the powdered adsorbent agent to the polymer matrix to form a mixture, and forming the adsorbent product with a three-dimensional shape by shaping from the mixture, and arranging the adsorbent product to recover the at least one predetermined component from the stream. In this context, the stream means any stream, flow or the like, which comprises one or more components which can be removed or recovered from the stream. The stream can be gaseous stream or liquid stream. In one embodiment, the adsorbent product comprises thin-walled structures, and the adsorbent agent of the thin-walled structures is arranged to contact with the stream to bind the predetermined component or components of the stream to the surface (s) of the adsorbent product. In one embodiment, the adsorbent product is regenerable. The adsorbent product can be cleaned by regenerating, and after that the adsorbent product can be re-used. In one embodiment, the adsorbent product is regenerated using an acid, e.g. HNO3. In one embodiment, the adsorbent product can be regenerated several times. Further, the recovered components can be recovered easily from the adsorbent product. The adsorbent product can be used in a desired apparatus and / or in a desired method or process. In one embodiment, the adsorbent product is used in a purification of waste water, waste stream, storm water, and / or flue gas, or in a recovery of metals, valuable substances, impurities, detrimental elements, and / or poisons, or any combination thereof, e.g. in waste water treatment, mining industry, demetallization, separating apparatuses, separators, large chromatographs, flue gas scrubbing or in other processes. The adsorbent product can be used to treat large streams, e.g. fluids or gases. Thanks to the invention high quality adsorbent product can be provided. Further, the adsorbent product can be prepared easily, and the adsorbent product can be customized easily according to a process. The invention offers a possibility to achieve easily an adsorbent product with good properties. The adsorbent product can be prepared with low material costs. The adsorbent product is easy to treat and use in the processes for recovering desired components and / or purifying streams. By means of the adsorbent product effective processes can be achieved. Further, the adsorbent product has a long life cycle. Further, the adsorbent product and its materials are easy to recycle . EXAMPLES An adsorbent product is produced by mixing a powdered adsorbent agent to a polymer matrix to form a mixture. The powdered adsorbent agent can be mixed to the liquid or powdered polymer matrix to form the mixture. The adsorbent product with a three-dimensional shape is formed by shaping from the mixture. The adsorbent product may be cooled, solidified and / or hardened. In this example, the adsorbent product is formed using a 3D printing, and hardened after the forming. Alternatively, the adsorbent product is formed using an extrusion or injection moulding. In this example, after the forming and shaping, the adsorbent product is hardened by an UV-light. Alternatively, the adsorbent product can be hardened by using laser and / or heat, or combination of UV, laser and / or heat. The adsorbent product is formed with a desired shape. Preferably, thin-walled structures are formed to provide the adsorbent product, i.e. the adsorbent product comprises thin-walled structures. Thus, the adsorbent product with a large surface area can be achieved. In this example, the adsorbent product comprises a comb shape or a lattice shape, such as a lattice structure. Especially, the adsorbent product is a non-membrane solid structure. In the forming and shaping, the adsorbent agent is attached and bounded to the polymer matrix. Further, the adsorbent agent can be provided onto the surfaces of the thin-walled structures during the forming. Example 1 In this example, the adsorbent product was produced, as above presented. The powdered adsorbent agent, 1-5 wt-%, was mixed to the liquid resin matrix to form the mixture, the adsorbent product with a three-dimensional shape was formed using 3D printing, i.e. vat photo polymerization, from the mixture, and the adsorbent product was hardened by UV light. The adsorbent agent which is suitable to adsorb Cu-metal was used as the adsorbent agent. The adsorbent product comprised a comb shape. The adsorbent product was regenerated using HNO3 between the tests. The adsorbent product was tested, and it was observed that, for example Cu can be collected effectively from water by means of the adsorbent product. Further, it was observed that the recovery of Cu was better using 1 % adsorbent agent compared to 0.5 % adsorbent agent in the mixture. Example 2 In this example, the adsorbent product was produced with a volume A according to example 1. The adsorbent product had a closed shape. When the closed shape of the adsorbent product was changed into a comb shape with the same volume A, the surface area of the adsorbent product can be increased significantly. Example 3 In this example, two adsorbent products were produced according to example 1. The first adsorbent product had a comb shape, and the second adsorbent product had a lattice shape. The first and second adsorbent products had the same volume. It was observed that the surface area of the second adsorbent product increased by about 67 % compared to the first adsorbent product. The invention is suitable in different embodiments for producing different adsorbent products. Further, the adsorbent product is suitable in different embodiments for different uses. The invention is not limited merely to the examples referred to above; instead, many variations are possible within the scope of the inventive idea defined by the claims.

Claims

1. An adsorbent product, characterized in that the adsorbent product comprises a polymer matrix and an adsorbent agent, in which the powdered adsorbent agent is mixed to the polymer matrix to form a mixture and the adsorbent product with a threedimensional shape is formed by shaping from the mixture.

2. The adsorbent according to claim 1, characterized in that the adsorbent product comprises a comb shape or a lattice shape.

3. The adsorbent according to claim 1 or 2, characterized in that the adsorbent product has a solid structure comprising thin structural parts.

4. The adsorbent according to any one of claims 1 to 3, characterized in that the adsorbent product is formed using a 3D printing, extrusion or injection moulding.

5. The adsorbent according to any one of claims 1 to 4, characterized in that the adsorbent product is formed using a vat polymerization.

6. The adsorbent according to any one of claims 1 to 5, characterized in that the adsorbent product is cooled and / or solidified.

7. The adsorbent according to any of claims 1 to 6, characterized in that the adsorbent product is hardened.

8. The adsorbent according to claim 7, characterized in that the hardening is carried out by an ultraviolet light, laser, heat or any combination thereof.

9. A method for producing an adsorbent product, characterized in that the method comprises- mixing a powdered adsorbent agent to a polymer matrix to form a mixture; and- forming the adsorbent product with a three-dimensional shape by shaping from the mixture.

10. The method according to claim 9, characterized in that the adsorbent product is shaped such that a surface area of the adsorbent product is maximised with relation to a volume of the product.

11. The method according to claim 9 or 10, characterized in that the adsorbent product is formed using a 3D printing, extrusion or injection moulding.

12. The method according to any one of claims 9 to 11, characterized in that the adsorbent product is formed using a vat polymerization.

13. The method according to any one of claims 9 to 12, characterized in that the method further comprises cooling and / or solidifying the adsorbent product.

14. The method according to any one of claims 9 to 13, characterized in that the method further comprises hardening the adsorbent product, and the hardening is carried out by an ultraviolet light, laser, heat or any combination thereof.

15. A method for recovering a predetermined component from a stream using an adsorbent product, characterized in that the method comprises- forming the adsorbent product from a polymer matrix and an adsorbent agent by mixing the powdered adsorbent agent to the polymer matrix to form a mixture, and forming the adsorbent product with a three-dimensional shape by shaping from the mixture; and- arranging the adsorbent product to recover the at least one predetermined component from the stream.

16. The method according to claim 15, characterized in that the adsorbent product comprises thin-walled structures, and the adsorbent agent of thethin-walled structures is arranged to contact with the stream to bind the predetermined component of the stream to the surfaces of the adsorbent product.

17. A use of the adsorbent product according5 to any one of claims 1 to 8, characterized in that the adsorbent product is used in a purification of waste water, waste stream, storm water and / or flue gas, or in a recovery of metals, valuable substances, impurities, detrimental elements and / or poisons, or any combi-10 nation thereof.