Monolithic Substrate

Abstract

The monolithic substrate comprises a product obtained by extruding an extrudable paste and subjecting it to a drying and / or curing process. The extrudable paste comprises a hollow and / or porous material. The extrudable paste further comprises a binder. The monolithic substrate has a bulk density of 60 g / L to 170 g / L.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims the benefit of priority under 35 U.S.C. § 119 of U.S. Provisional Patent Application No. 63 / 417,725, filed October 20, 2022, the entire disclosure of which is incorporated herein by reference. [Technical Field]

[0002] The present disclosure relates to monolithic substrates. [Background technology]

[0003] Climate change is a growing concern. There is a growing global need to reduce CO2 emissions (CO2 footprint). To achieve this, it is necessary to find alternatives to processes that generate CO2 or to capture released CO2 from its source or from the atmosphere. Negative emission technologies for removing CO2 include afforestation, reforestation, direct air capture (e.g., technology that removes CO2 from the atmosphere), and BECCS (bioenergy with carbon capture and storage: a technology that combines the use of biomass energy with carbon capture and storage).

[0004] One method for removing CO2 from sources or the atmosphere involves passing a CO2-containing gas stream through a monolith containing a CO2-adsorbing adsorbent. The adsorbed CO2 is then removed from the adsorbent by desorption (e.g., by heating the monolith). However, conventional monolith-based CO2 removal methods are limited by the bulk density (heat capacity) of the monolith, which requires a large amount of heating energy for CO2 desorption. Furthermore, the limited amount of adsorbent that can be added to the monolith further limits CO2 removal efficiency. Furthermore, the mechanical strength of the monolith material also affects its durability during subsequent processing steps, such as applying the adsorbent, introducing the monolith into the system, and regeneration, which involves removing the used adsorbent from the monolith fragments and reapplying new adsorbent. The mechanical strength of a monolith depends on the number and thickness of its walls, both of which determine the density and heat capacity of the resulting monolith. Summary of the Invention

[0005] In various aspects, the present invention provides a monolithic substrate comprising a product obtained by extruding an extrudable paste and subjecting it to a drying and / or curing process. The extrudable paste comprises a hollow and / or porous material. The extrudable paste further comprises a binder. The monolithic substrate has a bulk density of 60 g / L to 170 g / L.

[0006] In various aspects, the present invention provides a monolithic substrate comprising a product obtained by extruding, drying, and curing an extrudable paste. The extrudable paste comprises hollow and / or porous materials, including hollow glass beads, hollow plastic beads, hollow glass-ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, other hollow or porous particles, or combinations thereof. The extrudable paste further comprises a binder, including a polymer, an inorganic binder, a thermosetting resin, or combinations thereof. The monolithic substrate has a bulk density of 60 g / L to 170 g / L and a frontal open area of ​​80 to 95%.

[0007] In various aspects, the present invention provides methods of forming the monolithic substrates of the present invention, the methods comprising the step of extruding the extrudable paste described above, and the method further comprising the step of drying and / or curing the extruded extrudable paste.

[0008] In various aspects, the present invention provides methods of using the monolithic substrates of the present invention. The methods include exposing the monolithic substrate to a gas stream containing CO2, and causing at least a portion of the CO2 in the gas stream to adsorb onto a coating on the monolithic substrate. The coating includes a material that adsorbs and desorbs CO2. The methods also include desorbing CO2 from the coating on the monolithic substrate.

[0009] In various aspects, the present invention provides a carbonized monolithic substrate comprising the product obtained by subjecting the monolithic substrate of the present invention to a carbonization process.

[0010] In various aspects, the present invention provides a carbonized monolithic substrate comprising a product obtained by extruding an extrudable paste, followed by drying, curing, and carbonization. The extrudable paste comprises hollow and / or porous materials, including hollow glass beads, hollow plastic beads, hollow glass-ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof. The extrudable paste further comprises a binder, including a polymer, an inorganic binder, a thermosetting resin, or combinations thereof. The carbonized monolithic substrate has a bulk density of 60 g / L to 170 g / L and a frontal open area of ​​80 to 95%.

[0011] In various aspects, the present invention provides a method for forming the carbonized monolithic substrate of the present invention. The method includes subjecting the monolithic substrate of the present invention to a carbonization process. In various aspects, the carbonized monolithic substrate can be electrically conductive.

[0012] In various aspects, the present invention provides methods of using the carbonized monolithic substrates of the present invention. The methods include exposing the carbonized monolithic substrate to a gas stream containing CO2, and causing at least a portion of the CO2 in the gas stream to adsorb onto a coating on the carbonized monolithic substrate. The coating includes a material that adsorbs and desorbs CO2. The methods also include desorbing CO2 from the coating on the carbonized monolithic substrate.

[0013] In various aspects, the present invention provides a carbonized, activated monolithic substrate comprising the product obtained by subjecting the monolithic substrate of the present invention to a carbonization and activation process.

[0014] In various aspects, the present invention provides a carbonized, activated monolithic substrate comprising a product obtained by extruding an extrudable paste and subjecting it to drying, curing, carbonizing, and activating processes. The extrudable paste comprises hollow and / or porous materials, including hollow glass beads, hollow plastic beads, hollow glass-ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof. The extrudable paste also comprises a binder, including a polymer, an inorganic binder, a thermosetting resin, or combinations thereof. The extrudable paste also comprises an adsorbent, a sorbent aid, an adsorbent precursor, and / or a sorbent aid precursor. The sorbent aid includes Al2O3, TiO2, SiO2, or combinations thereof. The adsorbent includes zeolite, sodium carbonate, activated carbon, carbon nanotubes, metal-organic frameworks (MOFs), amines, or combinations thereof. The adsorbent precursor and / or sorbent aid precursor includes an Al2O3 precursor, a TiO2 precursor, a SiO2 precursor, or combinations thereof. The carbonized activated monolithic substrate has a bulk density of 60 g / L to 170 g / L and a front surface open area ratio of 80 to 95%.

[0015] In various aspects, the present invention provides a method for forming the carbonized activated monolithic substrate of the present invention, the method comprising the step of subjecting the carbonized monolithic substrate of the present invention to an activation treatment.

[0016] In various aspects, the present invention provides methods of using the carbonized-activated monolithic substrates of the present invention. The methods include exposing the carbonized-activated monolithic substrate to a gas stream containing CO2, and causing at least a portion of the CO2 in the gas stream to adsorb onto a coating on the carbonized-activated monolithic substrate. The coating comprises a material that adsorbs and desorbs CO2. The methods also include desorbing CO2 from the coating on the carbonized-activated monolithic substrate.

[0017] In various aspects, the monoliths (e.g., monoliths, carbonized monoliths, and / or carbonization-activated monoliths) of the present invention, and methods for making and using the same, can have certain advantages over other monoliths and methods for making and using the same. For example, in various aspects, the monoliths, carbonized monoliths, and / or carbonization-activated monoliths of the present invention can be characterized by a lower mass per unit area (e.g., due to a lower wall thickness and / or a higher porosity) and, in addition to or instead of this, a lower thermal mass (i.e., less energy required to heat per unit mass) compared to other CO2 removal monoliths. In various aspects, the monoliths, carbonized monoliths, and / or carbonization-activated monoliths of the present invention can achieve improved mechanical strength and / or reduced density before or after curing, thereby enabling extrusion shapes (e.g., extrusion shapes having geometries with a lower wall thickness, a higher porosity, or both) that are difficult to achieve with other monoliths, such as cordierite monoliths. In various embodiments, the monoliths, carbonized monoliths, and / or carbonization-activated monoliths of the present invention have a larger surface area per unit volume than other monoliths, such as monoliths formed from cordierite materials, which can improve CO capture efficiency. In various embodiments, the larger surface area per unit volume of the monoliths, carbonized monoliths, and / or carbonization-activated monoliths of the present invention compared to other monoliths also provides a larger surface area of ​​the adsorbent coating per unit volume, further improving CO removal efficiency.

[0018] In various embodiments, the monoliths, carbonized monoliths, and / or carbonization-activated monoliths of the present invention can incorporate or be coated with adsorbents, adsorption aids, adsorbent precursors, and / or adsorption aid precursors to provide high surface area, excellent adsorption properties, or a combination of these properties. Additionally, in various embodiments, the monoliths, carbonized monoliths, and / or carbonization-activated monoliths of the present invention can provide lower pressure drop than other monoliths, such as monoliths formed from cordierite materials. Furthermore, in various embodiments, the monoliths, carbonized monoliths, and / or carbonization-activated monoliths of the present invention can be manufactured at a lower cost than other monoliths, such as monoliths formed from cordierite materials, when compared to monoliths of comparable size. [Brief explanation of the drawings]

[0019] The following drawings illustrate various aspects of the present invention in a schematic manner, by way of example and not by way of limitation: [Figure 1] Photographs showing two pastes made using different recipes, according to various embodiments. [Figure 2] Photographs showing sheets of two thicknesses made from two different pastes through a molding and curing process according to various embodiments. [Figure 3] Photographs showing sheets made from two types of paste through molding and hardening processes floating on water, according to various embodiments. [Figure 4] SEM images showing cross sections of sheets produced by the forming and curing process according to various embodiments. [Figure 5] Photographs showing side and top views of extruded honeycomb monoliths according to various embodiments. [Figure 6] Photographs showing side and top views of a honeycomb monolith obtained by extrusion molding and carbonizing the monolith according to various embodiments. [Figure 7] Photographs showing side and top views of a honeycomb monolith obtained by extrusion molding and carbonizing the monolith according to various embodiments. DETAILED DESCRIPTION OF THE INVENTION

[0020] Certain aspects of the subject matter of the present disclosure will now be described in detail. While the subject matter of the present disclosure will be described below in conjunction with the claims, as defined by the claims, it will be understood that the subject matter disclosed in the following description is exemplary and is not intended to limit the scope of the claims to such subject matter.

[0021] Throughout this specification, when values ​​are described in range format, in addition to the numerical values ​​explicitly stated as the upper and lower limits of the range, all individual numerical values ​​or subranges within the range are also included, and should be interpreted flexibly as if each numerical value and subrange were explicitly stated. For example, the range "about 0.1% to about 5%" or "about 0.1% to 5%" should be interpreted to include not only the range of about 0.1% to about 5%, but also individual values ​​(e.g., 1%, 2%, 3%, 4%) and subranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the range. Furthermore, unless otherwise specified, the expression "about X to Y" is synonymous with "about X to about Y." Similarly, unless otherwise specified, the expression "about X, Y, or about Z" is synonymous with "about X, about Y, or about Z."

[0022] As used herein, the terms "a," "an," and "the" include one or more unless the context clearly dictates otherwise. The term "or" is used in a nonexclusive sense unless otherwise noted. The phrases "at least one of A and B" or "at least one of A or B" are synonymous with "A, B, or A and B." It should be understood that the phrases and terms used herein, unless otherwise defined, are for descriptive purposes only and are not intended to be limiting. Furthermore, section headings may be used to facilitate the reading of this specification and should not be construed as limiting. Information contained within a section heading may be found within or outside that section.

[0023] In the methods described herein, the actions may be performed in the particular order described herein. Alternatively, unless a chronological or process order is explicitly stated for certain actions, the actions may be performed in any order in any aspect disclosed herein without departing from the principles of the invention. Furthermore, unless a claim contains explicit language stating that certain actions must be performed separately, or unless the ordinary meaning of the claim language clearly dictates that these actions must be performed separately, these actions may be performed simultaneously. For example, an action of performing X as defined in a claim and an action of performing Y as defined in a claim may be performed simultaneously in a single step, and the resulting process would still be within the literal scope of the process as defined in the claim.

[0024] As used herein, the term "about" allows for some degree of variation in the value or range described thereafter, for example, a variation within 10%, 5%, or 1% of the upper or lower limit of the described value or range. Furthermore, the term "about" also includes the described value or range itself.

[0025] As used herein, the term "substantially" means "a majority of" or "mostly," and means, for example, at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%. As used herein, the expression "substantially free of" means that a certain material is not present, or if present, the amount is so small that it does not affect the properties of a composition containing the material. That is, this means that the content of the material in the composition is about 0% by mass to about 5% by mass, or about 0% by mass to about 1% by mass, or about 5% by mass or less, or about 4.5% by mass or less, about 4% by mass or less, about 3.5% by mass or less, about 3% by mass or less, about 2.5% by mass or less, about 2% by mass or less, about 1.5% by mass or less, about 1% by mass or less, about 0.9% by mass or less, about 0.8% by mass or less, about 0.7% by mass or less, about 0.6% by mass or less, about 0.5% by mass or less, about 0.4% by mass or less, about 0.3% by mass or less, about 0.2% by mass or less, about 0.1% by mass or less, about 0.01% by mass or less, or about 0.001% by mass or less, or about 0% by mass.

[0026] Monolithic Substrate In various aspects, the present invention provides a monolithic substrate. The monolithic substrate may comprise a product obtained by extruding an extrudable paste and subjecting it to a drying and / or curing process. The extrudable paste may comprise a hollow and / or porous material. The extrudable paste may further comprise a binder. The bulk density of the monolithic substrate may be between 60 g / L and 170 g / L.

[0027] The extrudable paste may have a homogeneous composition. Any suitable binder may be used. For example, the binder may include an inorganic binder, a polymer (e.g., a crosslinkable polymer), a thermosetting resin, a carbon precursor (e.g., any suitable carbonizable binder), or a combination thereof. The binder may also include a phenolic resin. The binder may be present in any suitable proportion in the extrudable paste. For example, the binder may be present in the range of 10% to 80% by weight, or 30% to 50% by weight. The binder may be present in the range of 80% by weight or less, and may be present in the range of 10% by weight or more, 15% by weight or more, 20% by weight or more, 25% by weight or more, 30% by weight or more, 35% by weight or more, 40% by weight or more, 45% by weight or more, 50% by weight or more, 55% by weight or more, 60% by weight or more, 65% by weight or more, 70% by weight or more, or 75% by weight or more.

[0028] The hollow and / or porous material can be any suitable material that is hollow, porous, or both. The hollow and / or porous material can be a particulate material. The hollow and / or porous material can include organic and / or inorganic materials. The hollow and / or porous material can also include paper, polymer, glass, glass ceramic, ceramic, or a combination thereof. The hollow and / or porous material can include hollow glass beads, hollow plastic beads (e.g., polystyrene beads or polypropylene beads), hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or a combination thereof. The hollow and / or porous material can be a particulate material having a particle size (e.g., number average particle size) of 0.1 micrometers to 500 micrometers, or 0.1 micrometers to 100 micrometers, or 10 micrometers to 200 micrometers. The particle size may be 500 micrometers or less and 0.1 micrometers or more, 0.5 micrometers or more, 1 micrometer or more, 2 micrometers or more, 4 micrometers or more, 6 micrometers or more, 8 micrometers or more, 10 micrometers or more, 20 micrometers or more, 30 micrometers or more, 40 micrometers or more, 50 micrometers or more, 60 micrometers or more, 80 micrometers or more, 100 micrometers or more, 120 micrometers or more, 140 micrometers or more, 160 micrometers or more, 180 micrometers or more, 200 micrometers or more, 250 micrometers or more, 300 micrometers or more, 350 micrometers or more, 400 micrometers or more, or 450 micrometers or more. The proportion of hollow and / or porous material in the extrudable paste may be any appropriate ratio, for example, 5% to 70% by mass, 10% to 50% by mass, or 25% to 35% by mass.Furthermore, this proportion may be 70% by mass or less and may be in the range of 5% by mass or more, 10% by mass or more, 15% by mass or more, 20% by mass or more, 25% by mass or more, 30% by mass or more, 35% by mass or more, 40% by mass or more, 45% by mass or more, 50% by mass or more, 55% by mass or more, 60% by mass or more, or 65% by mass or more.

[0029] In various embodiments, the monolithic substrate includes a sorbent, a sorbent aid, or both. Such sorbents or sorbent aids can be included as components of the extrudable paste prior to extrusion. Additionally or alternatively, they can be added to the extruded monolithic substrate, for example, before or after curing or drying. The inclusion of a sorbent aid can increase the surface area of ​​one or more of the monolithic substrate, the carbonized monolithic substrate, and the carbonized activated monolithic substrate produced therefrom. The inclusion of a sorbent can also improve the adsorption properties of one or more of the monolithic substrate, the carbonized monolithic substrate, and the carbonized activated monolithic substrate produced therefrom. The sorbent aid can include Al2O3, TiO2, SiO2, or a combination thereof. The sorbent can include zeolites, sodium carbonate, activated carbon, carbon nanotubes, metal-organic frameworks (MOFs), amines, or a combination thereof.

[0030] In various embodiments, the monolithic substrate includes a sorbent precursor, a sorbent aid precursor, or both. Such a sorbent precursor or sorbent aid precursor can be included as a component of an extrudable paste prior to extrusion. Additionally or alternatively, it can be added to the extruded monolithic substrate, for example, before or after curing or drying. The inclusion of a sorbent precursor or sorbent aid precursor can increase the surface area of ​​one or more of the monolithic substrate, the carbonized monolithic substrate, and / or the carbonized activated monolithic substrate produced therefrom. The sorbent precursor or sorbent aid precursor can be converted to a sorbent or sorbent aid during carbonization of the monolithic substrate, a subsequent activation step, or both. The sorbent precursor, sorbent aid precursor, or both can include an Al2O3 precursor, a TiO2 precursor, a SiO2 precursor, or a combination thereof. Additionally, the sorbent precursor, the sorbent aid precursor, or both, can include isopropoxyaluminum, isopropoxytitanium, butoxytitanium, tetraethoxysilane, tetrabutoxysilane, or combinations thereof.

[0031] The monolithic substrate can include an adsorbent, a sorption aid, an adsorbent precursor, a sorption aid precursor, or a combination thereof. The mass ratio of the adsorbent, the sorption aid, the adsorbent precursor, the sorption aid precursor, or a combination thereof to the hollow and / or porous material can be any suitable ratio, such as 0.01:1 to 2:1, or 0.1:1 to 1:1. The mass ratio can also be an appropriate ratio in the range of 2:1 or less and 0.01:1 or more, or 0.05:1 or more, or 0.1:1 or more, or 0.2:1 or more, or 0.3:1 or more, or 0.4:1 or more, or 0.5:1 or more, or 0.6:1 or more, or 0.7:1 or more, or 0.8:1 or more, or 0.9:1 or more. The content of the adsorbent, adsorption aid, adsorbent precursor, adsorption aid precursor, or combination thereof in the extrudable composition can be 0.001% to 10% by weight, or 0.01% to 5% by weight, or the content can be 10% by weight or less and 0.001% by weight or more, 0.005% by weight or more, 0.01% by weight or more, 0.05% by weight or more, 0.1% by weight or more, 0.5% by weight or more, 1% by weight or more, 2% by weight or more, 3% by weight or more, 4% by weight or more, 5% by weight or more, 6% by weight or more, or 8% by weight or more.

[0032] The extrudable paste can optionally include a viscosity modifier, such as a cellulose derivative. The cellulose derivative can be a methylcellulose derivative, such as methylcellulose and / or hydroxypropylmethylcellulose polymer. The content of the viscosity modifier in the extrudable paste can be 1% to 15% by weight, or 3% to 10% by weight.

[0033] The extrudable paste may optionally contain sodium stearate, the content of which in the extrudable paste may be 0.1 to 3% by weight, or 0.1 to 1% by weight.

[0034] The extrudable paste contains a solvent. The solvent can be any suitable solvent, such as an organic solvent or an aqueous solvent, and may be, for example, water. The proportion of the solvent in the extrudable paste can be any suitable ratio, for example, 5% to 50% by mass, or 10% to 40% by mass. The proportion can also be 50% by mass or less and in the range of 6% by mass or more, 8% by mass or more, 10% by mass or more, 12% by mass or more, 14% by mass or more, 16% by mass or more, 18% by mass or more, 20% by mass or more, 22% by mass or more, 24% by mass or more, 26% by mass or more, 28% by mass or more, 30% by mass or more, 32% by mass or more, 34% by mass or more, 36% by mass or more, 38% by mass or more, 40% by mass or more, 42% by mass or more, 44% by mass or more, 46% by mass or more, or 48% by mass or more.

[0035] The product obtained by extruding an extrudable paste and drying and / or curing may be a product obtained by extruding an extrudable paste and drying, a product obtained by extruding an extrudable paste and curing, or a product obtained by both drying and curing an extrudable paste. Any suitable drying or curing process may be used for the drying and / or curing. The drying process may include heating or allowing to dry. The curing process may include heating. The drying and curing processes may be performed in the same process, or the drying and curing processes may be performed as separate heating processes. In various embodiments, the drying and / or curing treatment can include a heat treatment, and such heat treatment can be carried out at a temperature range of 50°C to 400°C (e.g., a temperature range of 400°C or less and 50°C or more, 60°C or more, 80°C or more, 100°C or more, 120°C or more, 140°C or more, 160°C or more, 180°C or more, 200°C or more, 220°C or more, 240°C or more, 260°C or more, 280°C or more, 300°C or more, 320°C or more, 340°C or more, 360°C or more, or 380°C or more), for a treatment time of 1 minute to 2 hours (e.g., a treatment time of 2 hours or less and 1 minute or more, 10 minutes or more, 20 minutes or more, 30 minutes or more, 40 minutes or more, 50 minutes or more, 1 hour or more, 1.2 hours or more, 1.4 hours or more, 1.6 hours or more, or 1.8 hours or more).

[0036] The monolithic substrate can have any suitable bulk density. The bulk density is the mass of the substrate divided by the total occupied volume of the substrate. The total occupied volume of the substrate includes the volume of the particles, the volume of the voids between the particles, and the volume of the internal pores. For example, the bulk density of the monolithic substrate can be in the range of 60 g / L to 170 g / L, 80 g / L to 140 g / L, or 80 g / L to 120 g / L. In addition, the bulk density is 170 g / L or less and is 60 g / L or more, 65 g / L or more, 70 g / L or more, 72 g / L or more, 74 g / L or more, 76 g / L or more, 78 g / L or more, 80 g / L or more, 82 g / L or more, 84 g / L or more, 86 g / L or more, 88 g / L or more, 90 g / L or more, 92 g / L or more, 94 g / L or more, 96 g / L or more, 98 g / L or more, 10 The range may also be 0 g / L or more, 102 g / L or more, 104 g / L or more, 106 g / L or more, 108 g / L or more, 110 g / L or more, 112 g / L or more, 114 g / L or more, 116 g / L or more, 118 g / L or more, 120 g / L or more, 122 g / L or more, 124 g / L or more, 126 g / L or more, 128 g / L or more, 130 g / L or more, or 135 g / L or more.

[0037] The bulk density of the extrudable paste prior to hardening and drying can be any suitable density less than 1000 g / L, for example, any suitable density in the range of less than 1000 g / L and greater than or equal to 200 g / L, greater than or equal to 250 g / L, greater than or equal to 300 g / L, greater than or equal to 350 g / L, greater than or equal to 400 g / L, greater than or equal to 450 g / L, greater than or equal to 500 g / L, greater than or equal to 550 g / L, greater than or equal to 600 g / L, greater than or equal to 650 g / L, greater than or equal to 700 g / L, greater than or equal to 750 g / L, greater than or equal to 800 g / L, greater than or equal to 820 g / L, greater than or equal to 840 g / L, greater than or equal to 860 g / L, greater than or equal to 880 g / L, greater than or equal to 900 g / L, greater than or equal to 920 g / L, greater than or equal to 940 g / L, greater than or equal to 960 g / L, greater than or equal to 980 g / L, or greater than or equal to 990 g / L.

[0038] When extrudable paste is extruded horizontally to form a monolithic substrate, the gap distance that the extrudable paste can span unsupported without sagging or deformation can be in the range of 0.1 m to 10 m, or can be 10 m or less and in the range of 0.1 m or more, 0.2 m or more, 0.3 m or more, 0.4 m or more, 0.5 m or more, 0.6 m or more, 0.7 m or more, 0.8 m or more, 0.9 m or more, 1 m or more, 1.2 m or more, 1.4 m or more, 1.6 m or more, 1.8 m or more, 2 m or more, 2.5 m or more, 3 m or more, 3.5 m or more, 4 m or more, 4.5 m or more, 5 m or more, 6 m or more, 7 m or more, 8 m or more, or 9 m or more.

[0039] In various embodiments, the extrudable paste may be extruded, dried, and / or cured to produce a conductive product, which may also result in a conductive monolithic substrate. The monolithic substrate may be sufficiently conductive to allow resistive heating by passing an electrical current through the substrate. As described below, in various embodiments, such resistive heating may be used to heat the monolithic substrate to carbonize, activate, or both.

[0040] The monolithic substrate, carbonized monolithic substrate, and carbonized activated monolithic substrate can have any suitable physical shape. In various embodiments, the physical shape is a tubular shape having a plurality of cells therein, the cells being made up of parallel channels extending longitudinally through the tubular shape. The tubular shape can have any suitable outer periphery, such as a circle, oval, square, rectangle, polygon, or irregular shape. Furthermore, the shape of the cells when viewed from an end of the tubular shape can have any suitable shape, such as a honeycomb shape. The area of ​​the tubular shape that comprises one square inch (approximately 645.2 mm) can be any suitable shape, such as a honeycomb shape. 2 The number of cells per square inch (e.g., measured edge-on) can be any suitable number, for example, 1 / 2 square inch (approximately 645.2 mm 2The number of particles per square inch (approximately 645.2 mm) can be in the range of 50 to 400, or 80 to 220. 2 The number of cells per tubular shape may be 400 or less, and may range from 50 or more, 60 or more, 80 or more, 100 or more, 120 or more, 140 or more, 160 or more, 180 or more, 200 or more, 220 or more, 240 or more, 260 or more, 280 or more, 300 or more, 320 or more, 340 or more, 360 or more, or 380 or more. The wall thickness of the cells within the tubular shape may be any suitable thickness, for example, from 0.001 inch (0.0254 mm) to 0.02 inch (0.508 mm), or from 0.002 inch (0.0508 mm) to 0.02 inch (0.508 mm), or from 0.003 inch (0.0762 mm) to 0.01 inch (0.254 mm). In addition, the wall thickness is 0.02 inches (0.508 mm) or less, or 0.01 inches (0.254 mm) or less, and is 0.001 inches (0.0254 mm) or more, 0.002 inches (0.0508 mm) or more, 0.003 inches (0.0762 mm) or more, 0.004 inches (0.1016 mm) or more, 0.005 inches (0.127 mm) or more, 0.006 inches (0.1524 mm) or more, 0.007 inches (0.1778 mm) or more, 0.008 inches (0.2032 mm) or more, 0.009 inches ( The cell size may range from 0.2286 mm or more, 0.01 inch (0.254 mm) or more, 0.011 inch (0.2794 mm) or more, 0.012 inch (0.3048 mm) or more, 0.013 inch (0.3302 mm) or more, 0.014 inch (0.3556 mm) or more, 0.015 inch (0.381 mm) or more, 0.016 inch (0.4064 mm) or more, 0.017 inch (0.4318 mm) or more, 0.018 inch (0.4572 mm) or more, or 0.019 inch (0.4826 mm) or more. In various embodiments, the cell geometry within the tubular shape (1 square inch (approximately 645.2 mm)) can be adjusted to suit the cell size. 2 The combination of cells per 100 / wall thickness (0.001 inches (0.0254 mm)) can be 100 / 9.5, 100 / 7.5, 100 / 5.5, or 200 / 4, for example.

[0041] The monolithic substrate can have any suitable open frontal area (OFA). The open frontal area is the percentage (%) of the cross-sectional area available for gas passage. For example, the open frontal area of ​​the monolithic substrate can be in the range of 80% to 95%, 80% to 90%, 90% to 95%, or 85% to 95%. Alternatively, the percentage can be less than 95% and in the range of 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, 85% or more, 86% or more, 87% or more, 88% or more, 89% or more, 90% or more, 91% or more, 92% or more, 93% or more, or 94% or more.

[0042] The monolithic substrate, carbonized monolithic substrate, and / or carbonized activated monolithic substrate can have any suitable geometric surface area (GSA). Geometric surface area is the total surface area of ​​the flow channels per unit volume of the substrate. The geometric surface area of ​​the monolithic substrate, carbonized monolithic substrate, and / or carbonized activated monolithic substrate can be 1.3 m 2 / L~3m 2 / L, or 1.4m 2 / L~2.2m 2 / L. The geometric surface area can be in the range of 3 m 2 / L or less and 1.3m 2 / L or more, 1.4m 2 / L or more, 1.5m 2 / L or more, 1.6m 2 / L or more, 1.7m 2 / L or more, 1.8m 2 / L or more, 1.9m 2 / L or more, 2m 2 / L or more, 2.1m 2 / L or more, 2.2m 2 / L or more, 2.3m 2 / L or more, 2.4m 2 / L or more, 2.5m 2 / L or more, 2.6m 2 / L or more, 2.7m 2 / L or more, 2.8m 2 / L or more, or 2.9m 2 / L or more.

[0043] The porosity of the monolithic substrate, carbonized monolithic substrate, and / or carbonized activated monolithic substrate can be any suitable value, for example, the open porosity can be in the range of 0% to 5%, or 0% to 1%, or 40% to 90%, or 50% to 80%. Furthermore, such open porosity can be 90% or less and can be 0% or more, 0.01% or more, 0.05% or more, 0.1% or more, 0.2% or more, 0.4% or more, 0.6% or more, 0.8% or more, 1% or more, 1.5% or more, 2% or more, 3% or more, 4% or more, 5% or more, 6% or more, 7% or more, 8% or more, 9% or more, 10% or more, 12% or more, 14% or more, 16% or more, 18% or more, 20% or more, 25% or more, 30% or more, 32% or more, or the like. The open porosity may be in the range of 34% or more, 36% or more, 38% or more, 40% or more, 42% or more, 44% or more, 46% or more, 48% or more, 50% or more, 52% or more, 54% or more, 56% or more, 58% or more, 60% or more, 62% or more, 64% or more, 66% or more, 68% or more, 70% or more, 72% or more, 74% or more, 76% or more, 78% or more, 80% or more, 82% or more, 84% or more, 86% or more, or 88% or more. As used herein, "open porosity" refers to the percentage (%) of voids excluding the volume of internal pores, and indicates the percentage (%) of the total volume of voids accessible to gas relative to the volume of the substrate. Intact porous and / or hollow materials tend to have low open porosity, but the open porosity can be increased by damaging (destroying) them. In various embodiments, porous and / or hollow materials (e.g., hollow glass beads or hollow plastic beads) can be fractured (broken) through a heat treatment (e.g., a heat treatment such as a carbonization process or an activation process).

[0044] The maximum matrix specific heat capacity of the monolithic substrate, carbonized monolithic substrate, and / or carbonized activated monolithic substrate at 25°C to 100°C can be any suitable value, such as less than 140 kJ / kgK, or less than 100 kJ / kgK, or in the range of 50 kJ / kgK to 140 kJ / kgK, or 50 kJ / kgK to 100 kJ / kgK. In addition, the maximum matrix specific heat capacity can be 140 kJ / kgK or less and in the range of 50 kJ / kgK or more, 55 kJ / kgK or more, 60 kJ / kgK or more, 65 kJ / kgK or more, 70 kJ / kgK or more, 75 kJ / kgK or more, 80 kJ / kgK or more, 85 kJ / kgK or more, 90 kJ / kgK or more, 95 kJ / kgK or more, 100 kJ / kgK or more, 105 kJ / kgK or more, 110 kJ / kgK or more, 115 kJ / kgK or more, 120 kJ / kgK or more, 125 kJ / kgK or more, 130 kJ / kgK or more, or 135 kJ / kgK or more.

[0045] In various embodiments, the monolithic substrate includes a high surface area material on its surface. The high surface area material can be added to the monolithic substrate after the extrudable paste has been dried and / or cured, before the extrudable paste has been dried and / or cured, or any combination thereof. The high surface area material can be generated on the monolithic substrate surface by subjecting the monolithic substrate to a heat treatment or, in addition to or instead of, by a chemical reaction at the substrate surface.

[0046] In various embodiments, the monolithic substrate has a coating on its surface that includes a material that adsorbs and desorbs CO. Such material can be any suitable material that adsorbs and desorbs CO, including, for example, an amine-based adsorbent (e.g., polyethyleneimine), a metal-organic framework (MOF), a carbon-based adsorbent, a silica-based adsorbent, an alumina-based adsorbent, a zeolite-based adsorbent, a porous crystalline solid adsorbent, a metal oxide adsorbent, or a combination thereof.

[0047] Monolithic substrate manufacturing method Various aspects of the present invention provide methods for forming the monolithic substrates of the present invention. The methods can include extruding an extrudable paste as described herein, including a hollow and / or porous material and a binder, and optionally including a sorbent, a sorbent aid, a sorbent precursor, and / or a sorbent aid precursor. The methods can also include subjecting the extruded extrudable paste to a drying and / or curing process.

[0048] Any suitable drying or curing process can be used for the drying and / or curing process. The drying process can include heating or allowing to dry. The curing process can include heating. The drying and curing processes can be performed in the same process, or the drying and curing processes can be performed as separate heating processes. In various embodiments, the drying and / or curing treatment can include a heat treatment, and such heat treatment can be carried out at a temperature range of 50°C to 400°C (e.g., a temperature range of 400°C or less and 50°C or more, 60°C or more, 80°C or more, 100°C or more, 120°C or more, 140°C or more, 160°C or more, 180°C or more, 200°C or more, 220°C or more, 240°C or more, 260°C or more, 280°C or more, 300°C or more, 320°C or more, 340°C or more, 360°C or more, or 380°C or more), for a treatment time of 1 minute to 2 hours (e.g., a treatment time of 2 hours or less and 1 minute or more, 10 minutes or more, 20 minutes or more, 30 minutes or more, 40 minutes or more, 50 minutes or more, 1 hour or more, 1.2 hours or more, 1.4 hours or more, 1.6 hours or more, or 1.8 hours or more).

[0049] The method may also include coating the exterior surface of the extruded extrudable paste with a sorbent precursor, a sorbent, or a combination thereof, prior to drying and / or curing.

[0050] Optionally, the method can also include removing water-soluble components (e.g., optional cellulose derivatives such as methylcellulose and hydroxypropylmethylcellulose polymers) during the drying and / or curing process or as a separate process step.

[0051] How to use a monolithic substrate Various aspects of the present invention provide methods of using the monolithic substrate of the present invention. The methods can include exposing the monolithic substrate to a gas stream containing CO2 and causing at least a portion of the CO2 in the gas stream to adsorb to a coating on the monolithic substrate. The coating can include a material that adsorbs and desorbs CO2. The methods can also include desorbing CO2 from the coating on the monolithic substrate. In various aspects, desorbing CO2 from the coating on the monolithic substrate can include heating the monolithic substrate, for example, resistively heating the monolithic substrate by applying electrical current to the monolithic substrate.

[0052] Carbonized Monolithic Substrate Various aspects of the present invention provide carbonized monolithic substrates, including products obtained by subjecting the monolithic substrates of the present invention to a carbonization process. The carbonized monolithic substrates include products obtained by subjecting the monolithic substrates to a carbonization process. The monolithic substrates can include products obtained by extruding an extrudable paste and subjecting it to a drying and / or curing process. The extrudable paste can include a hollow and / or porous material. The extrudable paste can further include a binder. The bulk density of the monolithic substrate can be between 60 g / L and 170 g / L.

[0053] The product obtained by such carbonization treatment can be a product obtained by subjecting a monolithic substrate to heat treatment, for example, a product obtained by subjecting a monolithic substrate to heat treatment in an inert atmosphere. For example, the product obtained by such carbonization treatment can be a product obtained by subjecting a monolithic substrate to heat treatment in an inert atmosphere at a temperature of 400°C to 2000°C or 400°C to 1200°C. The temperature can also be 2000°C or less and in the range of 400°C or more, 500°C or more, 600°C or more, 700°C or more, 800°C or more, 900°C or more, 1000°C or more, 1100°C or more, 1200°C or more, 1300°C or more, 1400°C or more, 1500°C or more, 1600°C or more, 1700°C or more, 1800°C or more, or 1900°C or more.

[0054] In various aspects, the carbonized monolithic substrate can be electrically conductive, such that it can be resistively heated by passing an electric current through it.

[0055] The carbonized monolithic substrate can further include a coating comprising a material that adsorbs and desorbs CO2 gas. The material that adsorbs and desorbs CO2 gas can be any suitable material that adsorbs and desorbs CO2, and can include, for example, an amine-based adsorbent (e.g., polyethyleneimine), a metal-organic framework (MOF), a carbon-based adsorbent, a silica-based adsorbent, an alumina-based adsorbent, a zeolite-based adsorbent, a porous crystalline solid adsorbent, a metal oxide adsorbent, or a combination thereof.

[0056] The carbonized monolithic substrate can have any appropriate bulk density. For example, the bulk density of the carbonized monolithic substrate can be in the range of 60 g / L to 170 g / L, 80 g / L to 140 g / L, or 80 g / L to 120 g / L. Furthermore, such bulk density can be 170 g / L or less and 60 g / L or more, 65 g / L or more, 70 g / L or more, 72 g / L or more, 74 g / L or more, 76 g / L or more, 78 g / L or more, 80 g / L or more, 82 g / L or more, 84 g / L or more, 86 g / L or more, 88 g / L or more, 90 g / L or more, 92 g / L or more, 94 g / L or more, 96 g / L or more, 98 g / L or more, 10 g / L or more, 110 g / L or more, 120 g / L or more, 130 g / L or more, 140 g / L or more, 150 g / L or more, 160 g / L or more, 170 g / L or more, 180 g / L or more, 190 g / L or more, 200 g / L or more, 210 g / L or more, 220 g / L or more, 230 g / L or more, 240 g / L or more, 250 g / L or more, 260 g / L or more, 270 g / L or more, 280 g / L or more, 290 g / L or more, 300 g / L or more, 310 g / L or more, 320 g / L or more, 330 g / L or more, 340 g / L or more, 350 g / L or more, 3 The range may also be 0 g / L or more, 102 g / L or more, 104 g / L or more, 106 g / L or more, 108 g / L or more, 110 g / L or more, 112 g / L or more, 114 g / L or more, 116 g / L or more, 118 g / L or more, 120 g / L or more, 122 g / L or more, 124 g / L or more, 126 g / L or more, 128 g / L or more, 130 g / L or more, or 135 g / L or more.

[0057] The carbonized monolithic substrate can have any appropriate front surface area ratio. For example, the front surface area ratio of the carbonized monolithic substrate can be in the range of 80% to 95%, 80% to 90%, 90% to 95%, or 85% to 95%. Alternatively, this ratio can be less than 95% and in the range of 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, 85% or more, 86% or more, 87% or more, 88% or more, 89% or more, 90% or more, 91% or more, 92% or more, 93% or more, or 94% or more.

[0058] It should be noted that other properties of the carbonized monolithic substrate may be the same as those disclosed for the monolithic substrate herein unless otherwise specified.

[0059] Method for manufacturing carbonized monolithic substrates Various aspects of the present invention provide methods for forming the carbonized monolithic substrates of the present invention, which may include subjecting the monolithic substrates of the present invention to a carbonization process.

[0060] The carbonization treatment may include a heat treatment carried out at an appropriate temperature, and the heat treatment may be carried out, for example, in an inert atmosphere (e.g., argon). The carbonization treatment may include a heat treatment carried out in an inert atmosphere at a temperature range of 400°C to 2000°C or 400°C to 1200°C. The temperature may be 2000°C or less and may be 400°C or more, 500°C or more, 600°C or more, 700°C or more, 800°C or more, 900°C or more, 1000°C or more, 1100°C or more, 1200°C or more, 1300°C or more, 1400°C or more, 1500°C or more, 1600°C or more, 1700°C or more, 1800°C or more, or 1900°C or more.

[0061] How to use carbonized monolithic substrates Various aspects of the present invention provide methods of using the carbonized monolithic substrates of the present invention. The methods can include exposing the carbonized monolithic substrate to a gas stream containing CO2 and causing at least a portion of the CO2 in the gas stream to adsorb to a coating on the carbonized monolithic substrate. The coating can include a material that adsorbs and desorbs CO2. The methods can also include desorbing CO2 from the coating on the carbonized monolithic substrate. In various aspects, desorbing CO2 from the coating on the carbonized monolithic substrate can include heating the carbonized monolithic substrate, for example, resistively heating the carbonized monolithic substrate by applying electrical current to the carbonized monolithic substrate.

[0062] Carbonized activated monolithic substrate Various aspects of the present invention provide carbonized activated monolithic substrates, including the product obtained by subjecting the monolithic substrate of the present invention to carbonization and activation. The carbonized activated monolithic substrate includes the product obtained by subjecting the monolithic substrate to carbonization and activation. The monolithic substrate can include the product obtained by extruding an extrudable paste and subjecting it to drying and / or curing. The extrudable paste can include a hollow and / or porous material. The extrudable paste can further include a binder. The bulk density of the monolithic substrate can be between 60 g / L and 170 g / L.

[0063] The product obtained by such carbonization and activation treatments can be a product obtained by subjecting a monolithic substrate or a carbonized monolithic substrate to heat treatment, for example, in an inert atmosphere, in the presence of steam, in the presence of CO2, or any combination thereof. For example, the product obtained by such carbonization and activation treatments can be a product obtained by subjecting a monolithic substrate to heat treatment in an inert atmosphere at 400°C to 2000°C or 400°C to 1200°C, followed by heat treatment in the presence of steam, CO2, or both at 500°C to 1500°C or 500°C to 1200°C. Alternatively, the product obtained by such carbonization and activation treatments can be a product obtained by subjecting a monolithic substrate to heat treatment in an inert atmosphere at 700°C to 1000°C, followed by heat treatment in the presence of steam, CO2, or both at 700°C to 900°C.

[0064] The carbonized activated monolithic substrate can have any suitable open porosity. For example, the open porosity of the carbonized activated monolithic substrate can range from 0% to 90%, or from 0% to 1%, or from 1% to 90%. The open porosity may also be 90% or less and in the range of 0% or more, 0.001% or more, 0.005% or more, 0.01% or more, 0.05% or more, 0.1% or more, 0.2% or more, 0.4% or more, 0.6% or more, 0.8% or more, 0.9% or more, 1% or more, 1.1% or more, 1.2% or more, 1.3% or more, 1.4% or more, 1.5% or more, 1.6% or more, 1.8% or more, 2% or more, 4% or more, 6% or more, 8% or more, 10% or more, 15% or more, 20% or more, 25% or more, 30% or more, 35% or more, 40% or more, 45% or more, 50% or more, 55% or more, 60% or more, 65% or more, 70% or more, 75% or more, 80% or more, 82% or more, 84% or more, 86% or more, or 88% or more. In various embodiments, high open porosity can be achieved by breaking (fracturing) the hollow and / or porous material during the carbonization or activation process, and / or by employing porous materials as the hollow and / or porous material.

[0065] The surface area of ​​the carbonized activated monolithic substrate can be any suitable value, for example, 50 m 2 / g or more, or 50m 2 / g~400m 2 / g, and the surface area can be in the range of 400 m 2 / g or less and 50m 2 / g or more, 60m 2 / g or more, 80m 2 / g or more, 100m 2 / g or more, 120m 2 / g or more, 140m 2 / g or more, 160m 2 / g or more, 180m 2 / g or more, 200m 2 / g or more, 220m 2 / g or more, 240m 2 / g or more, 260m 2 / g or more, 280m 2 / g or more, 300m2 / g or more, 320m 2 / g or more, 340m 2 / g or more, 360m 2 / g or more, 380m 2 / g range.

[0066] The carbonization-activated monolithic substrate can further include a coating comprising a material that adsorbs and desorbs CO2 gas. The material that adsorbs and desorbs CO2 gas can be any suitable material that adsorbs and desorbs CO2, including, for example, an amine-based adsorbent (e.g., polyethyleneimine), a metal-organic framework (MOF), a carbon-based adsorbent, a silica-based adsorbent, an alumina-based adsorbent, a zeolite-based adsorbent, a porous crystalline solid adsorbent, a metal oxide adsorbent, or a combination thereof.

[0067] The carbonized activated monolithic substrate can have any suitable bulk density. For example, the bulk density of the carbonized activated monolithic substrate can be in the range of 60 g / L to 170 g / L, 80 g / L to 140 g / L, or 80 g / L to 120 g / L. Furthermore, such bulk density can be 170 g / L or less and 60 g / L or more, 65 g / L or more, 70 g / L or more, 72 g / L or more, 74 g / L or more, 76 g / L or more, 78 g / L or more, 80 g / L or more, 82 g / L or more, 84 g / L or more, 86 g / L or more, 88 g / L or more, 90 g / L or more, 92 g / L or more, 94 g / L or more, 96 g / L or more, 98 g / L or more, 10 g / L or more, or 120 g / L or more. The range may also be 0 g / L or more, 102 g / L or more, 104 g / L or more, 106 g / L or more, 108 g / L or more, 110 g / L or more, 112 g / L or more, 114 g / L or more, 116 g / L or more, 118 g / L or more, 120 g / L or more, 122 g / L or more, 124 g / L or more, 126 g / L or more, 128 g / L or more, 130 g / L or more, or 135 g / L or more.

[0068] The carbonized activated monolithic substrate can have any suitable front surface area ratio. For example, the front surface area ratio of the carbonized activated monolithic substrate can be in the range of 80% to 95%, 80% to 90%, 90% to 95%, or 85% to 95%. Alternatively, the ratio can be less than 95% and in the range of 80% or more, 81% or more, 82% or more, 83% or more, 84% or more, 85% or more, 86% or more, 87% or more, 88% or more, 89% or more, 90% or more, 91% or more, 92% or more, 93% or more, or 94% or more.

[0069] It should be noted that other properties of the carbonized activated monolithic substrate can be the same as those disclosed herein for the carbonized monolithic substrate and the monolithic substrate, unless otherwise specified.

[0070] Method for producing carbonized activated monolithic substrates Various aspects of the present invention provide methods for forming the carbonized activated monolithic substrates of the present invention, which may include subjecting the carbonized monolithic substrates of the present invention to an activation treatment.

[0071] The activation treatment can include a heat treatment at an appropriate temperature. The heat treatment can be carried out, for example, in the presence of a gas flow that activates the carbonized monolithic substrate (increases the surface area of ​​the carbonized monolithic substrate), such as steam, CO2, or a combination thereof. The activation treatment can include a heat treatment in the presence of a gas flow such as steam, CO2, or a combination thereof, at a temperature range of 500°C to 1500°C, or 700°C to 900°C. The temperature can also be in the range of 1500° C. or less and 500° C. or more, 550° C. or more, 600° C. or more, 650° C. or more, 700° C. or more, 750° C. or more, 800° C. or more, 850° C. or more, 900° C. or more, 950° C. or more, 1000° C. or more, 1050° C. or more, 1100° C. or more, 1150° C. or more, 1200° C. or more, 1250° C. or more, 1300° C. or more, 1350° C. or more, 1400° C. or more, or 1450° C. or more. In various embodiments, the heat treatment can include resistively heating the carbonized monolithic substrate by passing an electric current through it.

[0072] The method for forming a carbonized activated monolithic substrate can further include applying a coating to the activated carbonized monolithic substrate, the coating including a material that adsorbs and desorbs CO2 gas. Such a coating can include any suitable material that adsorbs and desorbs CO2 gas, such as an amine-based adsorbent (e.g., polyethyleneimine), a metal-organic framework (MOF), a carbon-based adsorbent, a silica-based adsorbent, an alumina-based adsorbent, a zeolite-based adsorbent, a porous crystalline solid adsorbent, a metal oxide adsorbent, or a combination thereof.

[0073] Methods for using carbonized activated monolithic substrates Various aspects of the present invention provide methods of using the carbonized-activated monolithic substrates of the present invention. The methods can include exposing the carbonized-activated monolithic substrate to a gas stream containing CO2, and causing at least a portion of the CO2 in the gas stream to adsorb to a coating on the carbonized-activated monolithic substrate. The coating can include a material that adsorbs and desorbs CO2. The methods can also include desorbing CO2 from the coating on the carbonized-activated monolithic substrate. In various aspects, desorbing CO2 from the coating on the carbonized-activated monolithic substrate includes heating the carbonized-activated monolithic substrate, for example, resistively heating the carbonized-activated monolithic substrate by applying electrical current to the carbonized-activated monolithic substrate.

[0074] The methods of use of the monolithic substrates, carbonized monolithic substrates, and carbonized activated monolithic substrates described herein can be applied to any suitable CO2 removal method, such as direct air capture (DAC) or source-based CO2 capture. The monolithic substrates, carbonized monolithic substrates, and carbonized activated monolithic substrates described herein can withstand high temperatures of 200°C or greater and humid environments. Furthermore, in embodiments of the monolithic substrates, carbonized monolithic substrates, and carbonized activated monolithic substrates comprising a sorbent coating on the substrate, the sorbent coating does not substantially penetrate the substrate interior but acts as a wall coating, thereby increasing or maximizing the contact area with passing gases. [Example]

[0075] The following exemplary embodiments are provided for illustrative purposes only, and various aspects of the present invention may be better understood with reference to these embodiments, although the present invention is not limited to the embodiments set forth herein.

[0076] Part 1: Inert substrate Example 1-1: Composition containing hollow glass beads (phenolic resin blend) Two pastes were prepared using the recipes listed in Table 1. Each paste was made by mixing the ingredients listed in the recipe.

[0077] [Table 1]

[0078] Figure 1 shows photographs of the paste prepared using recipe 1 (left) and the paste prepared using recipe 2 (right). Both pastes were extrusion moldable.

[0079] Each paste was then manually molded into sheets of two thicknesses (approximately 0.7 mm and 2 mm) and cured using a thermal cycle consisting of 85°C for 30 minutes, 100°C for 30 minutes, and 150°C for 30 minutes. Figure 2 shows sheets of two thicknesses formed and cured from the pastes of the two recipes. The left side shows a sheet made using Recipe 1, and the right side shows a sheet made using Recipe 2. The top row shows sheets with a thickness of approximately 2 mm, while the bottom row shows sheets with a thickness of approximately 0.7 mm. After curing, each sheet possessed rigidity and mechanical strength. Figure 3 shows that sheets prepared using Recipe 1 and cured using Recipe 2 (left) and Recipe 2 and cured using Recipe 2 (right) float on water. This indicates that the specific gravity of the formed and cured sheets is less than 1.

[0080] The samples shown in Figure 3 were floated in water for 12 days, then removed and dried at 150°C for 40 minutes. Both samples lost weight after curing, with Recipe 1 losing 3.3% and Recipe 2 losing 3.6%. This is likely due to leaching of Culminal 724 and / or LIGA. Nevertheless, both samples remained intact and maintained their mechanical strength.

[0081] FIG. 4 shows a scanning electron microscope (SEM) image of a cross section of a sheet produced by a forming and curing process using a recipe identical to Recipe 1, except that it did not contain the phenolic resin.

[0082] Example 1-2: Formulation containing hollow polymer beads (phenolic resin formulation) Example 1 was repeated, substituting hollow polymer beads for the hollow glass beads, and the resulting paste was extrudable and could be formed and cured to form a sheet that was rigid, mechanically strong, and buoyant.

[0083] Part 2: Sorbent-ready substrates Example 2-1: Pyrolysis and activation treatments were performed on a compound composition (phenolic resin compound) containing hollow glass beads The paste of Example 1-1 was extruded into a monolithic honeycomb structure and cured using the same protocol as described in Example 1-1. The extruded and cured paste was then carbonized in an inert atmosphere (e.g., N or Ar) at a temperature ranging from 700°C to 1000°C for 1 hour, followed by activation in steam or CO at a temperature ranging from 700°C to 900°C for 1 hour to obtain a high surface area structure. Note that the curing, carbonization, and activation steps may be performed separately or integrated into a single process.

[0084] The mass and thermal mass of the monolithic body after the curing, carbonization, and activation processes was less than that of a cordierite honeycomb structure having the same physical geometry.

[0085] Example 2-2: Composition containing hollow glass beads (phenolic resin and Al 2 O 3 Precursor compound) is subjected to thermal decomposition and activation treatment In Example 2-2, the same process as in Example 2-1 was carried out, except that the paste further contained an alumina precursor. The alumina precursor may be, for example, an aluminum alkoxide (e.g., isopropoxyaluminum), alumina particles, or both. The mass ratio of the alumina precursor and / or alumina to the hollow glass beads was 1:10 to 1:1.

[0086] The mass and thermal mass of the monolithic body after the curing, carbonization, and activation processes was less than that of a cordierite honeycomb structure having the same physical geometry.

[0087] Example 2-3: Formulation containing hollow glass beads (phenolic resin and TiO 2 Precursor compound) is subjected to thermal decomposition and activation treatment In Example 2-3, the same process as in Example 2-2 was carried out, except that the paste used to produce the monolithic molded body further contained a titania precursor. The titania precursor may be, for example, a titanium alkoxide (e.g., isopropoxytitanium or butoxytitanium), titania particles, or both. The mass ratio of the titania precursor and / or titania to the hollow glass beads was 1:10 to 1:1.

[0088] The mass and thermal mass of the monolithic body after the curing, carbonization, and activation processes was less than that of a cordierite honeycomb structure having the same physical geometry.

[0089] Example 2-4: Formulation containing hollow glass beads (phenolic resin and SiO 2 Precursor compound) is subjected to thermal decomposition and activation treatment In Example 2-4, the same process as in Example 2-2 was carried out, except that the paste used to produce the monolithic compact further contained a silica (SiO2) precursor. The silica precursor may be, for example, an alkoxysilane (e.g., tetraethoxysilane or tetrabutoxysilane), silica particles, or both. The ratio of silica precursor and / or silica to hollow glass beads was 1:10 to 1:1 by mass.

[0090] The mass and thermal mass of the monolithic body after the curing, carbonization, and activation processes was less than that of a cordierite honeycomb structure having the same physical geometry.

[0091] Table 2 shows the properties of the reference material and the materials and substrates of the present invention. In Table 2, "GSA" means geometric surface area, and "OFA" means frontal open area (open cross-sectional area available for fluid passage). Unless otherwise noted, the cell geometry is 100 / 7.5.

[0092] [Table 2]

[0093] Example 2-5: A compound composition containing hollow glass beads (phenolic resin compounded) was extruded to form a honeycomb structure, and carbonized at 400°C, 800°C, and 970°C. Recipe 1 of Example 1-1 was prepared in 50 times the amount, and was measured and mixed using a ProcessAll mixer. Next, the paste was extrusion molded using a small ram extruder equipped with a 200 / 12 die with a diameter of 1 inch (25.4 mm). The extrusion molding was carried out without any problems. Next, the honeycomb structure obtained by extrusion molding was subjected to a hardening treatment at 150°C for 1 hour. The hardening treatment imparted mechanical strength to the honeycomb structure. Figure 5 shows top and side view photographs of the honeycomb structure obtained by extrusion molding.

[0094] Next, two honeycomb structures after the hardening treatment were carbonized at 400°C in a N2 atmosphere. Figure 6 shows side and top photographs of the honeycomb structures that had been hardened and carbonized. The mass loss due to carbonization was approximately 11%, and the estimated carbon yield was approximately 76%.

[0095] Furthermore, two honeycomb structures after the hardening treatment were subjected to a carbonization treatment at 800°C in an N2 atmosphere. Figure 7 shows side and top photographs of the honeycomb structure that had been subjected to the hardening treatment and carbonization treatment. The mass loss due to carbonization was approximately 23.2%, and the estimated carbon yield was approximately 48.5%. Furthermore, another honeycomb structure after the hardening treatment was also subjected to a carbonization treatment at 970°C in an N2 atmosphere (not shown).

[0096] These honeycomb structures are considered to have thermal conductivity. Furthermore, measurements have confirmed that the honeycomb structures carbonized at 800°C and 970°C have electrical conductivity.

[0097] The terms and expressions used in the above description are for the purpose of description rather than limitation, and are not intended to exclude equivalents of the features shown or described or portions thereof. It should be recognized that various modifications are possible within the scope of the aspects of the present invention. Therefore, although the present invention has been specifically disclosed in the above description by showing specific aspects and optional functions, it should be understood that those skilled in the art can make modifications or variations based on the concepts disclosed herein, and that such modifications and variations are also considered to be within the scope of the aspects of the present invention.

[0098] Exemplary Embodiments Exemplary aspects are set forth below, and it should be noted that the numbering of the following aspects should not be construed as an indication of importance.

[0099] Aspect 1 provides a monolithic substrate. the monolithic substrate comprises a product obtained by extruding an extrudable paste and subjecting it to a drying and / or curing process; The extrudable paste comprises: a hollow and / or porous material; and a binder. The monolithic substrate has a bulk density of 60 g / L to 170 g / L.

[0100] Aspect 2 provides a monolithic substrate according to aspect 1, wherein the product obtained by extruding the extrudable paste and subjecting it to a drying process and / or curing process is a product obtained by extruding the extrudable paste and subjecting it to a drying process.

[0101] Aspect 3 provides a monolithic substrate according to aspect 1 or 2, wherein the product obtained by extruding the extrudable paste and subjecting it to a drying and / or curing process is a product obtained by extruding the extrudable paste and subjecting it to a curing process.

[0102] Aspect 4 provides a monolithic substrate according to any one of aspects 1 to 3, wherein the product obtained by extruding the extrudable paste and subjecting it to a drying treatment and / or a curing treatment is a product obtained by extruding the extrudable paste and subjecting it to a drying treatment and a curing treatment.

[0103] A fifth aspect provides a monolithic substrate according to any one of the first to fourth aspects, which has a bulk density of 80 g / L to 140 g / L.

[0104] A sixth aspect provides a monolithic substrate according to any one of the first to fifth aspects, which has a bulk density of 80 g / L to 120 g / L.

[0105] A seventh aspect provides the monolithic substrate of any one of the first to sixth aspects, wherein the extrudable paste has a bulk density of less than 1000 g / L.

[0106] Aspect 8 provides a monolithic substrate according to any one of aspects 1 to 7, wherein when the extrudable paste is extruded horizontally to form the monolithic substrate, the extrudable paste can straddle a gap of 0.1 m to 10 m without sagging or deformation.

[0107] A ninth aspect provides a monolithic substrate according to any one of the first to eighth aspects, wherein the product obtained by extruding the extrudable paste and subjecting it to a drying treatment and / or curing treatment has electrical conductivity.

[0108] A tenth aspect provides the monolithic substrate of any one of the first to ninth aspects, wherein the hollow and / or porous material comprises paper, polymer, glass, glass-ceramic, ceramic, or a combination thereof.

[0109] Aspect 11 provides the monolithic substrate according to any one of Aspects 1 to 10, wherein the hollow and / or porous material is a particulate material having a particle size of 0.1 micrometers to 500 micrometers, or 0.1 micrometers to 100 micrometers.

[0110] A twelfth aspect provides the monolithic substrate according to the eleventh aspect, wherein the particulate material has a particle size of 10 micrometers to 200 micrometers.

[0111] A thirteenth aspect provides the monolithic substrate of any one of the first to twelfth aspects, wherein the hollow and / or porous material comprises hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof.

[0112] A fourteenth aspect provides the monolithic substrate according to any one of the first to thirteenth aspects, further comprising an adsorbent and / or an adsorption aid.

[0113] Aspect 15 provides the monolithic substrate of aspect 14, wherein the extrudable paste is a homogeneous mixture including the adsorbent and / or the adsorption aid.

[0114] Aspect 16 provides the monolithic substrate of aspect 14 or 15, wherein the adsorbent and / or adsorption aid is added after the extrudable paste has been extruded and cured and / or dried.

[0115] Aspect 17 provides the monolithic substrate of any one of Aspects 14 to 16, wherein the adsorption aid comprises Al2O3, TiO2, SiO2, or a combination thereof, and the adsorbent comprises zeolite, sodium carbonate, activated carbon, carbon nanotubes, a metal-organic framework (MOF), an amine, or a combination thereof.

[0116] An eighteenth aspect provides the monolithic substrate according to any one of the first to seventeenth aspects, further comprising an adsorbent precursor and / or an adsorption aid precursor.

[0117] Example 19 provides the monolithic substrate of Example 18, wherein the extrudable paste is a homogeneous mixture comprising the adsorbent precursor and / or the sorbent aid precursor.

[0118] Example 20 provides the monolithic substrate of Example 18 or Example 19, wherein the sorbent precursor and / or the sorbent aid precursor is added after the extrudable paste has been extruded and cured and / or dried.

[0119] A twenty-first aspect provides the monolithic substrate of any one of the eighteenth to twenty aspects, wherein the adsorbent precursor and / or the adsorption aid precursor comprises an Al2O3 precursor, a TiO2 precursor, a SiO2 precursor, or a combination thereof.

[0120] Aspect 22 provides the monolithic substrate of any one of Aspects 18 to 21, wherein the adsorbent precursor and / or the adsorption aid precursor comprises an aluminum alkoxide, a titanium alkoxide, an alkoxysilane, or a combination thereof.

[0121] A twenty-third aspect provides the monolithic substrate of any one of the eighteenth to twenty-second aspects, wherein the adsorbent precursor and / or the adsorption aid precursor comprises isopropoxyaluminum, isopropoxytitanium, butoxytitanium, tetraethoxysilane, tetrabutoxysilane, or a combination thereof.

[0122] A twenty-fourth aspect provides the monolithic substrate according to any one of the eighteenth to twenty-third aspects, wherein the mass ratio of the adsorbent precursor and / or the adsorption aid precursor to the hollow and / or porous material is 0.01:1 to 2:1.

[0123] Aspect 25 provides the monolithic substrate according to any one of Aspects 18 to 24, wherein the mass ratio of the adsorbent precursor and / or the adsorption aid precursor to the hollow and / or porous material is 0.1:1 to 1:1.

[0124] Example 26 provides the monolithic substrate of any one of Examples 1 to 25, wherein the binder comprises an inorganic binder, a polymer, a thermosetting resin, or a combination thereof.

[0125] A twenty-seventh aspect provides the monolithic substrate of any one of the first to twenty-sixth aspects, wherein the binder comprises a phenolic resin.

[0126] A twenty-eighth embodiment provides the monolithic substrate according to any one of the first to twenty-seventh embodiments, which has a honeycomb shape.

[0127]

[0033] A twenty-ninth aspect of the present invention relates to a monolithic substrate according to the twenty-eighth aspect, wherein the honeycomb shape is 1 square inch (approximately 645.2 mm 2 The present invention provides a monolithic substrate containing 50 to 400 cells per substrate.

[0128] A thirty-first aspect of the present invention is the monolithic substrate of any one of the twenty-eighth to twenty-ninth aspects, wherein the honeycomb shape is 1 square inch (approximately 645.2 mm 2 The present invention provides a monolithic substrate containing 80 to 220 cells per substrate.

[0129] A thirty-first embodiment provides the monolithic substrate of any one of the twenty-eight to thirty embodiments, wherein the honeycomb shape has a wall thickness of 0.001 inches (0.0254 mm) to 0.02 inches (0.508 mm).

[0130] A thirty-second embodiment provides the monolithic substrate of any one of the twenty-eight to thirty-first embodiments, wherein the honeycomb shape has a wall thickness of 0.003 inches (0.0762 mm) to 0.01 inches (0.254 mm).

[0131]

[0033] A thirty-third aspect of the present invention is the monolithic substrate of any one of the twenty-eight to thirty-second aspects, wherein the honeycomb-shaped geometric configuration (1 square inch (approximately 645.2 mm) 2 The present invention provides a monolithic substrate having a cell count / wall thickness (combination of cells per 0.001 inch (0.0254 mm)) of 100 / 9.5, 100 / 7.5, 100 / 5.5, or 200 / 4.

[0132] A thirty-fourth aspect provides a monolithic substrate according to any one of the first to thirty-third aspects, which has a front surface opening ratio of 80 to 95%.

[0133] A thirty-fifth embodiment is the monolithic substrate according to any one of the first to thirty-fourth embodiments, 2 / L~3m 2The present invention provides a monolithic substrate having a geometric surface area of ​​1 / L.

[0134] A thirty-sixth embodiment is the monolithic substrate according to any one of the first to thirty-five embodiments, 2 / L~2.2m 2 The present invention provides a monolithic substrate having a geometric surface area of ​​1 / L.

[0135] A thirty-seventh embodiment provides a monolithic substrate according to any one of the first to thirty-sixth embodiments, the monolithic substrate having an open porosity of 0% to 5%.

[0136] A thirty-eighth embodiment provides a monolithic substrate according to any one of the first to thirty-seventh embodiments, the monolithic substrate having an open porosity of 0% to 1%.

[0137] A thirty-ninth embodiment provides a monolithic substrate according to any one of the first to thirty-eighth embodiments, the monolithic substrate having an open porosity of 40% to 90%.

[0138] A fortieth embodiment provides a monolithic substrate according to any one of the first to thirty-ninth embodiments, the monolithic substrate having an open porosity of 50% to 80%.

[0139] Aspect 41 provides a monolithic substrate according to any one of aspects 1 to 40, wherein the product obtained by extruding the extrudable paste and subjecting it to a drying treatment and / or curing treatment is a product obtained by subjecting it to a heat treatment at 50°C to 400°C for 1 minute to 2 hours.

[0140] Example 42 provides the monolithic substrate of any one of Examples 1-41, further comprising a high surface area material on the surface thereof.

[0141] A forty-third embodiment provides the monolithic substrate according to any one of the first to forty-second embodiments, further comprising a coating on the substrate, the coating containing a material that adsorbs and desorbs CO2.

[0142] Embodiment 44 provides a monolithic substrate. The monolithic substrate comprises a product obtained by extruding an extrudable paste and subjecting it to a drying and curing process; The extrudable paste comprises: a hollow and / or porous material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof; and a binder comprising a polymer, an inorganic binder, a thermosetting resin, or a combination thereof. The monolithic substrate has a bulk density of 60 g / L to 170 g / L and a front opening ratio of 80 to 95%.

[0143] A forty-fifth embodiment provides a carbonized monolithic substrate comprising a product obtained by subjecting the monolithic substrate according to any one of the first to forty-fourth embodiments to a carbonization treatment.

[0144] A forty-sixth embodiment provides the carbonized monolithic substrate of the forty-fifth embodiment, wherein the carbonized monolithic substrate is electrically conductive.

[0145] Aspect 47 provides the carbonized monolithic substrate of aspect 45 or 46, further comprising a coating including a material that adsorbs and desorbs CO2 gas.

[0146] Aspect 48 provides a carbonized monolithic substrate according to any one of aspects 45 to 47, wherein the product obtained by the carbonization treatment is a product obtained by performing a heat treatment at 400°C to 2000°C under an inert atmosphere.

[0147] Aspect 49 provides a carbonized monolithic substrate according to any one of aspects 45 to 48, wherein the product obtained by the carbonization treatment is a product obtained by performing a heat treatment at 400°C to 1200°C under an inert atmosphere.

[0148] Embodiment 50 provides a carbonized monolithic substrate. The carbonized monolithic substrate comprises a product obtained by extruding an extrudable paste, followed by drying, curing, and carbonizing; The extrudable paste comprises: a hollow and / or porous material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof; and a binder comprising a polymer, an inorganic binder, a thermosetting resin, or a combination thereof. The carbonized monolithic substrate has a bulk density of 60 g / L to 170 g / L and a front opening ratio of 80 to 95%.

[0149] A fifty-first embodiment provides a carbonized and activated monolithic substrate comprising a product obtained by subjecting the monolithic substrate according to any one of the first to forty-fourth embodiments to a carbonization treatment and an activation treatment.

[0150] Example 52 is the carbonized and activated monolithic substrate of Example 51, wherein the product of the carbonization and activation processes is: a product obtained by heat treatment at a temperature between 400°C and 2000°C in an inert atmosphere and a heat treatment at a temperature between 500°C and 1500°C in the presence of steam, CO2, or both; or The present invention provides a carbonized activated monolithic substrate, which is the product of a heat treatment at a temperature between 400°C and 1200°C in an inert atmosphere and a heat treatment at a temperature between 500°C and 1200°C in the presence of steam, CO2, or both.

[0151] Aspect 53 provides a carbonized activated monolithic substrate according to aspect 51 or 52, wherein the product obtained by the carbonization and activation processes is a product obtained by performing a heat treatment at a temperature between 700°C and 1000°C in an inert atmosphere, and a heat treatment at a temperature between 700°C and 900°C in the presence of steam, CO2, or both.

[0152] Example 54 provides a carbonized activated monolithic substrate according to any one of Examples 51-53, wherein the carbonized activated monolithic substrate has an open porosity of 0% to 1%.

[0153] Example 55 provides a carbonized activated monolithic substrate according to any one of Examples 51-54, wherein the carbonized activated monolithic substrate has an open porosity between 1% and 90%.

[0154] A fifty-sixth embodiment provides a carbonization-activated monolithic substrate according to any one of the fifty-first to fifteenth embodiments, further comprising a coating containing a material that adsorbs and desorbs CO2 gas.

[0155] Example 57 provides the carbonization-activated monolithic substrate of Example 56, wherein the coating comprises polyethyleneimine.

[0156] Example 58 is a carbonized activated monolithic substrate according to any one of Examples 51-57, comprising 50 m 2 / g~400m 2 The present invention provides a carbonized activated monolithic substrate having a surface area of ​​1 / g.

[0157] Embodiment 59 provides a carbonized activated monolithic substrate. the carbonized activated monolithic substrate comprises a product obtained by extruding an extrudable paste and subjecting it to drying, curing, carbonizing, and activating processes; The extrudable paste comprises: a hollow and / or porous material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof; a binder comprising a polymer, an inorganic binder, a thermosetting resin, or a combination thereof; adsorbent, adsorption aid, adsorbent precursor, and / or adsorption aid precursor. The adsorption aid comprises Al2O3, TiO2, SiO2, or a combination thereof; the adsorbent comprises zeolite, sodium carbonate, activated carbon, carbon nanotubes, metal organic frameworks (MOFs), amines, or a combination thereof; and the adsorbent precursor and / or the adsorption aid precursor comprises an Al2O3 precursor, a TiO2 precursor, a SiO2 precursor, or a combination thereof. The carbonized activated monolithic substrate has a bulk density of 60 g / L to 170 g / L and a front surface opening ratio of 80 to 95%.

[0158] A sixty-first aspect provides a method for forming a monolithic substrate according to any one of the first to forty-fourth aspects, the method comprising: extruding the extrudable paste; and subjecting the extruded extrudable paste to a drying and / or hardening process.

[0159] Example 61 provides the method of Example 60, further comprising coating an outer surface of the extruded extrudable paste with a sorbent precursor and / or a sorbent aid precursor before performing the curing process.

[0160] Aspect 62 provides a method according to any one of aspects 60 to 61, further comprising the step of coating the outer surface of the extruded extrudable paste with an adsorbent and / or adsorption aid after the hardening treatment.

[0161] Aspect 63 provides a method according to any one of aspects 60 to 62, wherein the hardening treatment and / or the drying treatment includes a heat treatment at a temperature in the range of 50°C to 400°C for a treatment time of 1 minute to 2 hours.

[0162] A sixty-fourth embodiment provides a method for forming a carbonized monolithic substrate according to any one of the forty-fifth to fiftyth embodiments, the method comprising: The method includes a step of subjecting the monolithic substrate according to any one of aspects 1 to 44 to a carbonization treatment.

[0163] Aspect 65 is the method of Aspect 64, wherein the carbonization treatment includes a heat treatment at 400°C to 2000°C or 400°C to 1200°C under an inert atmosphere.

[0164] Aspect 66 provides the method of aspect 64 or 65, wherein the carbonization treatment comprises a heat treatment in an inert atmosphere or at 400°C to 1200°C.

[0165] A sixty-seventh embodiment provides a method for forming a carbonized activated monolithic substrate according to any one of the fifty-first to fifty-nine embodiments, the method comprising: The method includes a step of subjecting the carbonized monolithic substrate according to any one of Aspects 45 to 50 to an activation treatment.

[0166] Example 68 provides the method of Example 67, wherein the activation treatment comprises a heat treatment in the presence of steam, CO2, or both at a temperature between 500°C and 1500°C.

[0167] Example 69 provides the method of example 67 or 68, wherein the activation treatment comprises a heat treatment at a temperature between 700°C and 900°C in the presence of steam, CO2, or both.

[0168] A seventyth embodiment provides the method of any one of the sixty-seventh to sixty-nineth embodiments, wherein the activation treatment comprises resistively heating the carbonized monolithic substrate by passing an electric current through the carbonized monolithic substrate.

[0169] Aspect 71 provides a method according to any one of aspects 67 to 70, further comprising the step of adding a coating containing a material that adsorbs and desorbs CO2 gas to the carbonized monolithic substrate that has been subjected to the activation treatment.

[0170] Example 72 provides the method of example 71, wherein the coating comprises polyethyleneimine.

[0171] A seventy-third embodiment provides a method of using the monolithic substrate of any one of the first to forty-fourth embodiments, the method comprising: exposing the monolithic substrate to a gas stream containing CO2, and causing at least a portion of the CO2 in the gas stream to be adsorbed onto a coating on the monolithic substrate, the coating comprising a material that adsorbs and desorbs CO2; and desorbing CO2 from the coating on the monolithic substrate.

[0172] A seventy-fourth embodiment provides a method of using the carbonized monolithic substrate of any one of the forty-fifth to fiftyth embodiments, the method comprising: exposing the carbonized monolithic substrate to a gas stream containing CO2, and causing at least a portion of the CO2 in the gas stream to be adsorbed onto a coating on the carbonized monolithic substrate, the coating comprising a material that adsorbs and desorbs CO2; and desorbing CO2 from the coating on the carbonized monolithic substrate.

[0173] Example 75 provides a method of using the carbonized activated monolithic substrate of any one of Examples 51-59, comprising: exposing the carbonized activated monolithic substrate to a gas stream containing CO2, so that at least a portion of the CO2 in the gas stream is adsorbed onto a coating on the carbonized activated monolithic substrate, the coating comprising a CO2 adsorbing and desorbing material; and desorbing CO2 from the coating on the carbonized activated monolithic substrate.

[0174] Example 76 provides a monolithic substrate, a carbonized monolithic substrate, a carbonized activated monolithic substrate, or a method that can be optionally configured to enable or select all of the elements or options described in any one or any combination of Examples 1-75.

[0175] A seventy-seventh aspect provides a monolithic substrate, a carbonized monolithic substrate, a carbonized activated monolithic substrate, or a method according to any one or combination of aspects one to seventy-five, wherein the maximum matrix specific heat capacity at 25°C to 100°C is less than 140 kJ / kgK.

[0176] A seventy-eighth embodiment provides a monolithic substrate, a carbonized monolithic substrate, a carbonized activated monolithic substrate, or a method according to any one or combination of embodiments one to seventy-five, wherein the maximum matrix specific heat capacity at 25°C to 100°C is less than 100 kJ / kgK.

[0177] Preferred embodiments of the present invention will be described below in detail.

[0178] Embodiment 1 1. A monolithic substrate comprising a product obtained by extruding an extrudable paste and subjecting it to a drying and / or curing process, comprising: the extrudable paste a hollow and / or porous material; a binder; The monolithic substrate has a bulk density of 60 g / L to 170 g / L and a front opening ratio of 80 to 95%.

[0179] Embodiment 2 the hollow and / or porous material is a particulate material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof; 2. The monolithic substrate of embodiment 1, wherein the particulate material has a particle size of 0.1 micrometers to 100 micrometers.

[0180] Embodiment 3 3. The monolithic substrate of embodiment 1 or 2, further comprising an adsorbent, a sorption aid, an adsorbent precursor, a sorption aid precursor, or a combination thereof.

[0181] Embodiment 4 the adsorbent comprises a zeolite, sodium carbonate, activated carbon, carbon nanotubes, a metal-organic framework (MOF), an amine, or a combination thereof; the adsorption aid comprises Al2O3, TiO2, SiO2, or a combination thereof; 4. The monolithic substrate of embodiment 3, wherein the sorbent precursor and / or the sorption aid precursor comprises an Al2O3 precursor, a TiO2 precursor, a SiO2 precursor, or a combination thereof.

[0182] Embodiment 5 5. The monolithic substrate of any one of embodiments 1 to 4, wherein the binder comprises an inorganic binder, a polymer, a thermosetting resin, or a combination thereof.

[0183] Embodiment 6 the monolithic substrate has a honeycomb shape; The honeycomb shape is 1 square inch (approximately 645.2 mm 2 ) contains 50 to 400 cells, 6. The monolithic substrate of any one of embodiments 1 to 5, wherein the honeycomb shape has a wall thickness of 0.001 inches (0.0254 mm) to 0.02 inches (0.508 mm).

[0184] Embodiment 7 7. The monolithic substrate according to any one of embodiments 1 to 6, further comprising a coating on the substrate, the coating containing a material that adsorbs and desorbs CO2.

[0185] Embodiment 8 A carbonized monolithic substrate comprising a product obtained by subjecting the monolithic substrate according to any one of embodiments 1 to 7 to a carbonization treatment, A carbonized monolithic substrate, wherein the product obtained by carbonization treatment is a product obtained by carrying out a heat treatment at 400°C to 1200°C in an inert atmosphere.

[0186] Embodiment 9 1. A carbonized monolithic substrate comprising a product obtained by extruding an extrudable paste, followed by drying, curing, and carbonizing, the product comprising: the extrudable paste a hollow and / or porous material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof; a binder comprising a polymer, an inorganic binder, a thermosetting resin, or a combination thereof; The carbonized monolithic substrate has a bulk density of 60 g / L to 170 g / L and a front opening ratio of 80 to 95%.

[0187] Embodiment 10 A carbonized and activated monolithic substrate comprising a product obtained by subjecting the monolithic substrate according to any one of embodiments 1 to 7 to a carbonization treatment and an activation treatment.

[0188] Embodiment 11 11. The carbonized activated monolithic substrate of embodiment 10, further comprising a coating comprising a material that adsorbs and desorbs CO2 gas.

[0189] Embodiment 12 1. A carbonized and activated monolithic substrate comprising a product obtained by extruding an extrudable paste and subjecting it to drying, curing, carbonizing, and activating processes, comprising: the extrudable paste a hollow and / or porous material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof; a binder comprising a polymer, an inorganic binder, a thermosetting resin, or a combination thereof; an adsorbent, an adsorption aid, an adsorbent precursor, and / or an adsorption aid precursor; the sorption aid comprises Al2O3, TiO2, SiO2, or a combination thereof; the adsorbent comprises zeolite, sodium carbonate, activated carbon, carbon nanotubes, metal organic frameworks (MOFs), amines, or a combination thereof; the adsorbent precursor and / or the sorption aid precursor comprises an Al2O3 precursor, a TiO2 precursor, a SiO2 precursor, or a combination thereof; The carbonized activated monolithic substrate has a bulk density of 60 g / L to 170 g / L, a frontal open area ratio of 80 to 95%, and a thickness of 50 m 2 / g~400m 2 / g of surface area of ​​the carbonized activated monolithic substrate.

[0190] Embodiment 13 The monolithic substrate of any one of embodiments 1 to 7, the carbonized monolithic substrate of embodiment 8 or 9, or the carbonized activated monolithic substrate of any one of embodiments 10 to 12, having a maximum matrix specific heat capacity between 25°C and 100°C of less than 140 kJ / kgK.

[0191] Embodiment 14 The monolithic substrate of any one of embodiments 8, 9, or 13, or the carbonized activated monolithic substrate of any one of embodiments 10-13, which is electrically conductive.

[0192] Embodiment 15 A method for forming a monolithic substrate according to any one of embodiments 1 to 7 and 13, the method comprising: extruding the extrudable paste; and subjecting the extruded extrudable paste to a drying and / or curing process; The method, wherein the drying treatment and / or the hardening treatment includes a heat treatment carried out at a temperature in the range of 50°C to 400°C for a treatment time of 1 minute to 2 hours.

[0193] Embodiment 16 14. A method for forming a carbonized monolithic substrate according to embodiment 8, 9, or 13, comprising: A method for producing a monolithic substrate according to any one of embodiments 1 to 7 and 13, comprising the steps of: The carbonization treatment comprises a heat treatment at 400°C to 1200°C in an inert atmosphere.

[0194] Embodiment 17 14. A method for forming a carbonized activated monolithic substrate according to any one of embodiments 10 to 13, the method comprising: 14. The carbonized monolithic substrate of claim 8, 9 or 13, comprising an activation treatment; The method, wherein the activation treatment comprises a heat treatment at a temperature between 500°C and 1500°C in the presence of steam, CO2, or both.

[0195] Embodiment 18 18. The method of embodiment 17, wherein the activation treatment comprises resistively heating the carbonized monolithic substrate by passing an electric current through it.

[0196] Embodiment 19 19. The method of claim 17 or 18, further comprising applying a coating to the activated carbonized monolithic substrate, the coating comprising a material that adsorbs and desorbs CO2 gas.

[0197] Embodiment 20 A method of using the monolithic substrate according to any one of embodiments 1 to 7 and 13, the method comprising: exposing the monolithic substrate to a gas stream containing CO2, and causing at least a portion of the CO2 in the gas stream to be adsorbed onto a coating on the monolithic substrate, the coating comprising a material that adsorbs and desorbs CO2; and desorbing CO2 from the coating on the monolithic substrate.

[0198] Embodiment 21 14. A method of using the carbonized monolithic substrate according to embodiment 8, 9 or 13, comprising: exposing the carbonized monolithic substrate to a gas stream containing CO2, and causing at least a portion of the CO2 in the gas stream to be adsorbed onto a coating on the carbonized monolithic substrate, the coating comprising a material that adsorbs and desorbs CO2; and desorbing CO2 from the coating on the carbonized monolithic substrate.

[0199] Embodiment 22 14. A method of using a carbonized activated monolithic substrate according to any one of embodiments 10 to 13, the method comprising: exposing the carbonized activated monolithic substrate to a gas stream containing CO2, so that at least a portion of the CO2 in the gas stream is adsorbed onto a coating on the carbonized activated monolithic substrate, the coating comprising a CO2 adsorbing and desorbing material; and desorbing CO2 from the coating on the carbonized activated monolithic substrate.

[0200] Embodiment 23 The carbonized monolithic substrate or the carbonized activated monolithic substrate has electrical conductivity. 23. The method of embodiment 21 or 22, wherein desorbing the CO2 comprises resistively heating the carbonized monolithic substrate or the carbonized activated monolithic substrate.

Claims

1. 1. A monolithic substrate comprising a product obtained by extruding an extrudable paste and subjecting it to a drying and / or curing process, comprising: the extrudable paste a hollow and / or porous material; a binder; The monolithic substrate has a bulk density of 60 g / L to 170 g / L and a front surface opening ratio of 80 to 95%.

2. the hollow and / or porous material is a particulate material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash-based hollow beads, or combinations thereof; The monolithic substrate of claim 1 , wherein the particulate material has a particle size between 0.1 micrometers and 100 micrometers.

3. The monolithic substrate of claim 1 further comprising an adsorbent, a sorption aid, an adsorbent precursor, a sorption aid precursor, or a combination thereof.

4. the adsorbent comprises a zeolite, sodium carbonate, activated carbon, carbon nanotubes, a metal organic framework (MOF), an amine, or a combination thereof; The adsorption aid is Al ２ O ３ , TiO ２ , SiO ２ or a combination thereof, The adsorbent precursor and / or the adsorption auxiliary precursor is Al ２ O ３ Precursor, TiO ２ Precursor, SiO ２ 4. The monolithic substrate of claim 3, comprising a precursor, a crystalline silicon dioxide ...

5. The monolithic substrate of claim 1 , wherein the binder comprises an inorganic binder, a polymer, a thermosetting resin, or a combination thereof.

6. the monolithic substrate has a honeycomb shape; The honeycomb shape is 1 square inch (approximately 645.2 mm ２ ) containing 50 to 400 cells per 10. The monolithic substrate of claim 1, wherein the honeycomb shape has a wall thickness between 0.001 inch (0.0254 mm) and 0.02 inch (0.508 mm).

7. CO ２ The monolithic substrate of claim 1 further comprising a coating on the substrate comprising a material that adsorbs and desorbs.

8. A carbonized monolithic substrate comprising a product obtained by subjecting the monolithic substrate of claim 1 to a carbonization treatment, A carbonized monolithic substrate, wherein the product obtained by carbonization treatment is a product obtained by carrying out a heat treatment at 400°C to 1200°C in an inert atmosphere.

9. 1. A carbonized monolithic substrate comprising a product obtained by extruding an extrudable paste, followed by drying, curing, and carbonizing, the product comprising: the extrudable paste a hollow and / or porous material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash based hollow beads, or combinations thereof; a binder comprising a polymer, an inorganic binder, a thermosetting resin, or a combination thereof; The carbonized monolithic substrate has a bulk density of 60 g / L to 170 g / L and a front surface opening ratio of 80 to 95%.

10. A carbonized and activated monolithic substrate comprising a product obtained by subjecting the monolithic substrate of claim 1 to a carbonization and activation treatment.

11. CO ２ The carbonized activated monolithic substrate of claim 10 further comprising a coating comprising a material that adsorbs and desorbs gases.

12. 1. A carbonized and activated monolithic substrate comprising a product obtained by extruding an extrudable paste and subjecting it to drying, curing, carbonizing, and activating processes, comprising: the extrudable paste a hollow and / or porous material comprising hollow glass beads, hollow plastic beads, hollow glass ceramic beads, hollow ceramic beads, cenospheres, fly ash based hollow beads, or combinations thereof; a binder comprising a polymer, an inorganic binder, a thermosetting resin, or a combination thereof; an adsorbent, an adsorption aid, an adsorbent precursor, and / or an adsorption aid precursor; The adsorption aid is Al ２ O ３ , TiO ２ , SiO ２ or a combination thereof, wherein the adsorbent comprises a zeolite, sodium carbonate, activated carbon, carbon nanotubes, a metal organic framework (MOF), an amine, or a combination thereof, and the adsorbent precursor and / or the adsorption aid precursor comprises Al ２ O ３ Precursor, TiO ２ Precursor, SiO ２ precursors, or combinations thereof, The carbonized activated monolithic substrate has a bulk density of 60 g / L to 170 g / L, a frontal open area of ​​80 to 95%, and a thickness of 50 m ２ / g~400m ２ / g of surface area of ​​the carbonized activated monolithic substrate.

13. 11. The monolithic substrate of claim 1, the carbonized monolithic substrate of claim 8, or the carbonized activated monolithic substrate of claim 10, wherein the maximum matrix specific heat capacity between 25°C and 100°C is less than 140 kJ / kgK.

14. 10. A carbonized monolithic substrate comprising a product obtained by subjecting the monolithic substrate of claim 1 to a carbonization process, wherein the carbonized monolithic substrate or the carbonized activated monolithic substrate is electrically conductive.

15. 10. A method for forming a monolithic substrate according to claim 1, the method comprising: extruding the extrudable paste; and subjecting the extruded extrudable paste to a drying and / or curing process; A method wherein the drying and / or curing treatment comprises a heat treatment at a temperature in the range of 50°C to 400°C for a treatment time of 1 minute to 2 hours.

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