Sorptive polymer composites for enhanced SO2 removal

Abstract

Durable pollution control systems, articles, and methods for removing multiple flue gas pollutants. The pollution control systems include articles comprising a sorbent polymer composite (SPC) comprising a sorbent material and a polymer material, the SPC material being in the form of a sheet, the sheet having a smooth surface. The sorbent polymer composite can have a smooth surface as measured by the surface optical smoothness measurements provided herein.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of Provisional Application No. 63 / 449,645, filed March 3, 2023, which is incorporated herein by reference in its entirety for all purposes.

[0002] Field FIELD OF THE DISCLOSURE This disclosure relates to the field of pollution control systems and methods for removing compounds and particulate matter from gas streams. [Background technology]

[0003] background Coal-fired power plants, municipal waste incinerators, and oil refineries produce large amounts of flu gases, which contain substantial types and quantities of environmental pollutants, such as sulfur oxides (SO2 and SO3), nitrogen oxides (NO, NO2), mercury (Hg) vapor, and particulate matter (PM). In the United States, coal combustion alone produces approximately 27 million tons of SO2 and 45 tons of Hg each year.

[0004] Therefore, there is a need for improved control systems and methods for removing sulfur oxides, mercury vapor, and particulate matter from industrial flue gases, such as those from coal-fired power plants. x There is a need to provide an improved, durable system capable of simultaneously removing multiple flue gas pollutants, such as Hg vapor and PM2.5, at low cost. It is desirable that the system be simple, not generate secondary pollutants, and have the ability to produce a useful end product. In particular, it would be ideal to develop a system or device that does not contain halogens or reservoirs, is durable, and is economical to manufacture, combined with a sorbent polymer composite substrate. Summary of the Invention

[0005] Abstract This summary provides a high-level overview of various aspects and introduces some of the concepts that are further described in the Detailed Description section below. The subject matter should be understood by reference to appropriate portions of the entire specification, any or all drawings, and each claim.

[0006] In some embodiments, a sorbent polymer composite material (SPC material) or sorbent polymer composite (SPC) is provided comprising a sorbent material and a polymer material, wherein the SPC material is in the form of a sheet, and the sheet has a smooth surface. As explained in more detail herein, "smooth" in this context should be understood as a measure of optical surface uniformity. The level of smoothness can be ascertained, for example, by measuring color change, or alternatively, by surface topography. Various methods that can be employed are further explained below.

[0007] In some embodiments, the SPC material can be incorporated into a pollution control system capable of simultaneously removing multiple flue gas pollutants, including but not limited to SO 2 . x , Hg vapor, and PM2.5 (particulate matter with a diameter of 2.5 micrometers or less). Some embodiments include a simple pollution control system that may not create secondary pollutants.

[0008] In some embodiments, the SPC material sheet can have a smooth surface of 12.0 or less as measured by the surface optical smoothness measurement provided herein. In some embodiments, this measurement can be less than 15. In other embodiments, this value can be less than 14.7, or less than 14.5, or less than 14.0, or less than 13.5, or less than 13.0, or less than 12.5, or less than 12.0, or less than 11.9, or less than 11.8, or less than 11.7, or less than 11.6, or less than 11.5.

[0009] In any of the foregoing Sorptive Polymer Composite (SPC) embodiments, the polymeric material comprises at least one of polyfluoroethylene propylene (PFEP), polyperfluoroacrylate (PPFA), polyvinylidene fluoride (PVDF), terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCFE), poly(ethylene-co-tetrafluoroethylene) (ETFE), ultra-high molecular weight polyethylene (UHMWPE), polyethylene, polyparaxylylene (PPX), polylactic acid (PLLA), polyethylene (PE), expanded (expanded, expanded, stretched, or foamed) polyethylene (ePE), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), or any combination thereof.

[0010] In any of the foregoing sorbent polymer composite (SPC) embodiments, the polymeric material comprises PVDF.

[0011] In any of the foregoing sorbent polymer composite (SPC) embodiments, the PVDF is a PVDF homopolymer.

[0012] In any of the foregoing sorbent polymer composite (SPC) embodiments, the PVDF is a PVDF copolymer.

[0013] In any of the foregoing sorbent polymer composite (SPC) embodiments, the PVDF copolymer is a copolymer of PVDF and hexafluoropropylene (HFP).

[0014] In any of the foregoing sorbent polymer composite (SPC) embodiments, the polymeric material comprises a polymer having a surface energy in the range of 15 dynes / cm to 31 dynes / cm.

[0015] In any of the foregoing sorbent polymer composite (SPC) embodiments, the polymeric material comprises a fluoropolymer.

[0016] In any of the foregoing sorbent polymer composite (SPC) embodiments, the polymeric material comprises PTFE.

[0017] In any of the foregoing sorbent polymer composite (SPC) embodiments, the polymeric material comprises ePTFE.

[0018] In any of the foregoing sorbent polymer composite (SPC) embodiments, the polymer material comprises fibrils and nodes, and the polymer material becomes porous upon stretching, thereby forming voids between the fibrils and nodes.

[0019] In any of the foregoing sorbent polymer composite (SPC) embodiments, the sorbent material is 400 ml 2 / g.

[0020] In any of the foregoing sorbent polymer composite (SPC) embodiments, the sorbent of the sorbent polymer composite is 400 ml 2 / g~2000m 2 / g.

[0021] In any of the foregoing sorbent polymer composite (SPC) embodiments, the sorbent material is selected from activated carbon, zeolite, or any combination thereof.

[0022] In any of the foregoing sorbent polymer composite (SPC) embodiments, the sorbent material is activated carbon.

[0023] In any of the foregoing sorbent polymer composite (SPC) embodiments, the sorbent material comprises activated carbon in an amount of 70% to 90% based on the total weight of the SPC material.

[0024] In some embodiments of the aforementioned sorbent polymer composite, the sorbent polymer composite (SPC) comprises 20% to 24% PTFE, 2% to 6% PVDF, and the balance carbon.

[0025] In any of the foregoing sorbent polymer composite (SPC) embodiments, the sheet can be 0.2 to 2 mm thick.

[0026] In any of the foregoing sorbent polymer composite (SPC) embodiments, the sheet has a thickness of 0.5 to 1.5 mm.

[0027] In any of the foregoing sorbent polymer composite (SPC) embodiments, the material does not contain halogens, sulfur, or reservoirs.

[0028] Some embodiments of the present disclosure relate to articles having a layered structure that can include the SPC of any of the preceding embodiments.

[0029] In any of the foregoing embodiments, the article comprises or further comprises at least one permeation control material.

[0030] In any of the foregoing embodiments, the article comprises a plurality of pleated sheets and a plurality of flat sheets in an alternating configuration.

[0031] In any of the preceding embodiments, the article comprises a flue-gassing device. In some embodiments, the article is a flue-gassing device. In some embodiments, the article is part of a flue-gassing device. In some embodiments, the device is configured to extract at least one SO from a flue-gassing stream. x A device for removing compounds.

[0032] The present disclosure also provides a method of treating a fluegas stream, comprising providing a fluegas stream and contacting the fluegas stream with a fluegas treatment device comprising a sorbent polymer composite (SPC) according to any of the previous embodiments, wherein the fluegas stream has a temperature of at least 50° C. and a relative humidity of at least 50%, and the fluegas stream contains at least one SO 2 at a concentration of at least 20 ppm. x The present invention relates to a method, comprising the steps of:

[0033] In any of the preceding embodiments, the method comprises using 20% ​​to 99.9% SO x It has removal efficiency.

[0034] In any of the preceding embodiments, the method further comprises: x The process involves converting the compound to sulfuric acid on an SPC material and recovering the converted sulfuric acid.

[0035] In any of the foregoing embodiments of the method, the at least one SO x The compounds include sulfur dioxide (SO2), sulfur trioxide (SO3), or any combination thereof. [Brief explanation of the drawings]

[0036] drawing Some embodiments of the present disclosure are described herein, by way of example only, with reference to the accompanying drawings. Referring now in detail to the drawings, it is emphasized that the illustrated embodiments are exemplary and are intended to illustratively illustrate embodiments of the present disclosure. In this regard, it will become apparent to those skilled in the art from a reading of the description in conjunction with the drawings how embodiments of the present disclosure may be practiced.

[0037] [Figure 1] FIG. 1 is an exemplary schematic diagram of a flue gas processing unit.

[0038] [Figure 2] FIG. 2 illustrates in cross-section a non-limiting embodiment of a sorbent polymer composite (SPC) described herein.

[0039] [Figure 3] FIG. 3 shows an additional non-limiting embodiment of a sorbent polymer composite (SPC) described herein.

[0040] [Figure 4A]FIG. 4A shows a comparative example of a sorbent polymer composite (SPC) exhibiting a non-uniform appearance.

[0041] [Figure 4B] FIG. 4B shows a sorbent polymer composite (SPC) exhibiting a uniform appearance according to some non-limiting embodiments of the present disclosure.

[0042] [Figure 5A] FIG. 5A shows a comparative example of a sorbent polymer composite (SPC) exhibiting a non-uniform appearance.

[0043] [Figure 5B] FIG. 5B shows a sorbent polymer composite (SPC) exhibiting a uniform appearance, according to some non-limiting embodiments of the present disclosure.

[0044] [Figure 6] FIG. 6 illustrates a sorbent polymer composite (SPC) exhibiting a uniform appearance, according to some non-limiting embodiments of the present disclosure.

[0045] [Figure 7] FIG. 7 illustrates a non-limiting embodiment of a pollution control system having any of the articles described herein. DETAILED DESCRIPTION OF THE INVENTION

[0046] Detailed Description Among the benefits and improvements disclosed, other objects and advantages of the present disclosure will become apparent from the following description taken in conjunction with the accompanying drawings. While detailed embodiments of the present disclosure are disclosed herein, it should be understood that the disclosed embodiments are merely exemplary of the present disclosure, which may be embodied in various forms. Moreover, the examples given of various embodiments of the present disclosure are intended to be illustrative and not limiting.

[0047] Throughout this specification and claims, the following terms have the meanings expressly associated therewith unless the context clearly dictates otherwise. As used herein, the phrases "in one embodiment," "in an embodiment," and "in some embodiments" do not necessarily refer to the same embodiment, but may. Additionally, as used herein, the phrases "in another embodiment" and "in some other embodiments" do not necessarily refer to different embodiments, but may. It is intended that all embodiments of the present disclosure be combinable without departing from the scope or spirit of the disclosure.

[0048] As used herein, the term "between" does not necessarily mean that something is located immediately adjacent to another element. In general, the term refers to a configuration in which something is sandwiched between two or more other things. At the same time, the term "between" can also describe something being immediately adjacent to two opposing things. Thus, in any one or more of the embodiments disclosed herein, a particular structural component located between two other structural elements can be as follows: A particular structural component is placed directly between both of two other structural elements such that it directly contacts both of the other two structural elements. A particular structural component is positioned directly adjacent to only one of the other two structural elements so that it directly contacts only one of the other two structural elements. A particular structural element is positioned indirectly adjacent to only one of the other two structural elements such that the particular structural element is not in direct contact with only one of the other two structural elements, but there is another element juxtaposed with the particular structural element and one of the other two structural elements. A particular structural component may be indirectly located between two other structural elements such that it is not in direct contact with both of the other structural elements, and other features may be located between them; or Any combination thereof.

[0049] As used herein, the term "based on" is not exclusive and allows for based on additional unrecited factors unless the context clearly dictates otherwise. Additionally, throughout this specification, the meanings of "a," "an," and "the" include plural references. The meaning of "in" includes "in" and "on."

[0050] All prior patents and publications referenced herein are incorporated by reference in their entirety.

[0051] Sorptive polymer composites (SPCs) have proven particularly effective in removing undesirable components from flue gas streams, including, but not limited to, at least one SO x compounds and mercury vapor.

[0052] Although the use of at least one halogen source may increase the removal efficiency of the SPC, the SPC disclosed herein does not include a halogen source.

[0053] As used herein, the term "sorbent" refers to a substance that has the property of collecting molecules of other substances by at least one of absorption, adsorption, or a combination thereof. The sorbent material of the sorbent polymer composite material can include at least one of activated carbon, coal-derived carbon, lignite-derived carbon, wood-derived carbon, coconut-derived carbon, silica gel, zeolite, or any combination thereof.

[0054] As used herein, the term "composite" refers to a material that includes two or more constituent materials that have different physical or chemical properties, and whose combination results in a material with properties that differ from those of the individual components.

[0055] As used herein, a "sorbent polymer composite" (SPC) or "sorbent polymer composite" is a composite comprising a sorbent and a polymer. In embodiments, a sorbent polymer composite can include sorbent particles embedded in the microstructure of the polymer.

[0056] As used herein, the term "polymer" refers to one or more homopolymers, copolymers, or terpolymers. As used herein, "embedded" means that a first material is distributed throughout a second material.

[0057] As used herein, the term "permeation control material" refers to a material configured to release one or more substances from a reservoir at a slower rate than would be released if the substance were not present in the permeation control layer.

[0058] As used herein, the term "flue gas stream" refers to a gas mixture that includes at least one by-product of a combustion process (e.g., without limitation, a coal combustion process). In some embodiments, the flue gas stream may consist solely of by-products of the combustion process. In some embodiments, the flue gas stream may include at least one gas at a concentration that is elevated relative to the concentration resulting from the combustion process. For example, in one non-limiting example, the flue gas stream may be subjected to a "scrubbing" process, in which water vapor may be added to the flue gas stream. Thus, in some such embodiments, the flue gas stream may include a concentration of water vapor that is elevated relative to the initial water vapor concentration resulting from combustion. Similarly, in some embodiments, the flue gas stream may include at least one gas at a concentration that is reduced relative to the initial concentration of the at least one gas exiting the combustion process. This may occur, for example, by removing at least a portion of the at least one gas after combustion. In some embodiments, the flue gas stream may take the form of a gas mixture that is a combination of by-products of multiple combustion processes.

[0059] As used herein, "SO" x The term "sulfur compound" refers to any oxide of sulfur. In some non-limiting embodiments, "SO x "Sulfur compounds" may specifically refer to gaseous oxides of sulfur, which are known environmental pollutants. x Non-limiting examples of compounds include sulfur dioxide (SO2) and sulfur trioxide (SO3). x Additional non-limiting examples of compounds include sulfur monoxide (SO), disulfur monoxide (SO), and disulfur dioxide (SO).

[0060] As used herein, a "carbon particle" is any particle that contains carbon.

[0061] As used herein, "porous carbon particles" refers to carbon particles that have pores and does not include carbon particles that do not have pores, i.e., porous carbon particles exclude "non-porous" carbon particles.

[0062] As used herein, the term "permeation control particle" refers to at least one permeation control material in the form of a particle.

[0063] Some embodiments of the present disclosure relate to articles comprising a sorbent polymer composite (SPC).

[0064] FIG. 1 shows a schematic diagram of a flue gas treatment device in which flue gas 10 from a combustor is reduced in temperature by a heat exchanger and introduced into an electrostatic precipitator or baghouse 11. After passing through the electrostatic precipitator or baghouse 11 to remove particulate matter, the treated flue gas is further reduced in temperature by unit 12. In one embodiment, unit 12 is a water spray to further increase gas humidity. In another embodiment, unit 12 can be in the form of a limestone scrubber to remove SO2. The treated flue gas is then introduced into a sorbent house 13 containing a sorbent polymer composite 100. In another embodiment (not shown), the sorbent house can be conveniently located above the limestone scrubber. Referring again to FIG. 1, SO2 and SO3 are converted to sulfuric acid on the surface of the sorbent polymer composite 100. In some embodiments, mercury vapor in the treated flue gas 10 is absorbed into the sorbent polymer composite substrate 100. The discharged sulfuric acid, along with the trapped particulates, drips into the acid reservoir 14. Finally, the treated flue gas is discharged from the sorbent house 13 and discharged through the stack 15.

[0065] In some embodiments, the flue gas stream has a temperature of at least 20° C. and a relative humidity of at least 50%. In some embodiments, the flue gas stream contains at least one SO 2 at a concentration of at least 20 ppm. x Contains compounds.

[0066] In some embodiments, the flue gas stream has a temperature of at least 50° C. and a relative humidity of at least 60%. In some embodiments, the flue gas stream contains at least one SO 2 at a concentration of at least 20 ppm. x Contains compounds.

[0067] In some embodiments, the flue gas stream has a temperature greater than 20°C, greater than 30°C, greater than 40°C, greater than 50°C, greater than 60°C, greater than 70°C, greater than 75°C, greater than 80°C, greater than 85°C, or greater than 90°C.

[0068] In some embodiments, the flue gas stream has a temperature of less than 20°C, less than 30°C, less than 40°C, less than 50°C, less than 60°C, less than 70°C, less than 75°C, less than 80°C, less than 85°C, or less than 90°C.

[0069] In some embodiments, the flue gas stream has a temperature of 20°C to 80°C, 30°C to 80°C, 40°C to 80°C, 50°C to 80°C, 60°C to 80°C, or 70°C to 80°C.

[0070] In some embodiments, the flue gas stream has a temperature between 20°C and 70°C, between 20°C and 60°C, between 20°C and 50°C, between 20°C and 40°C, or between 20°C and 30°C.

[0071] In some embodiments, the flue gas stream has a temperature between 30°C and 70°C. In some embodiments, the flue gas stream has a temperature between 40°C and 60°C.

[0072] In some embodiments, the flue gas stream has a temperature of 50°C to 70°C, 60°C to 70°C, 55°C to 70°C, or 55°C to 60°C.

[0073] In some embodiments, the flue gas stream has a temperature of 65°C to 70°C, 70°C to 75°C, 75°C to 80°C, 80°C to 85°C, or 85°C to 90°C.

[0074] In some embodiments, the flue gas stream has a temperature of 65°C to 90°C, 70°C to 90°C, 75°C to 90°C, 80°C to 90°C, or 85°C to 90°C.

[0075] In some embodiments, the flue gas stream has a temperature of 65°C to 75°C, 65°C to 80°C, 65°C to 85°C, or 65°C to 90°C.

[0076] In some embodiments, the flugus stream has a relative humidity of at least 50%. In some embodiments, the flugus stream has a relative humidity of at least 55%, at least 60%, at least 70%, or at least 80%. In some embodiments, the flugus stream has a relative humidity of at least 80%.

[0077] In some embodiments, the fluoxetine stream has a relative humidity of 50% to 100%. In some embodiments, the fluoxetine stream has a relative humidity of 60% to 100%, 70% to 100%, 80% to 100%, or 90% to 100%.

[0078] In some embodiments, the flue gas stream contains at least one SO at a concentration of at least 1 ppm, at least 5 ppm, at least 10 ppm, at least 20 ppm, at least 25 ppm, at least 30 ppm, at least 35 ppm, at least 40 ppm, at least 45 ppm, at least 50 ppm, at least 100 ppm, at least 500 ppm, or at least 1000 ppm. x Contains compounds.

[0079] In some embodiments, the flue gas stream contains at least one SO at a concentration of 1 ppm to 3000 ppm, 5 ppm to 3000 ppm, 10 ppm to 3000 ppm, 50 ppm to 3000 ppm, or 100 ppm to 3000 ppm. x Contains compounds.

[0080] In some embodiments, the flue gas stream contains at least one SO at a concentration of 20 ppm to 2500 ppm, 25 ppm to 2500 ppm, 30 ppm to 2000 ppm, 35 ppm to 2000 ppm, 40 ppm to 2000 ppm, 45 ppm to 2000 ppm, 50 ppm to 2000 ppm, 50 ppm to 1900 ppm, 50 ppm to 1800 ppm, 50 ppm to 1700 ppm, 50 ppm to 1600 ppm, or 50 ppm to 1500 ppm. x Contains compounds.

[0081] In some embodiments, the fluegas stream is flowed over at least one surface of the sorbent polymer composite for a period of at least 100 days, hi some embodiments, the fluegas stream is flowed over at least one surface of the article for a period of at least 200 days, at least 300 days, at least 400 days, at least 500 days, at least 600 days, at least 700 days, at least 800 days, at least 900 days, at least 1,000 days, at least 2,000 days, at least 3,000 days, at least 4,000 days, or at least 5,000 days.

[0082] In some embodiments, the fluoxetine stream is passed over at least one surface of the sorbent polymer composite for a period of 100 days to 10,000 days, hi some embodiments, the fluoxetine stream is passed over at least one surface of the article for a period of 500 days to 10,000 days, a period of 1,000 days to 10,000 days, or a period of 5,000 days to 10,000 days.

[0083] In some embodiments, the flugas stream is flowed over at least one surface of the sorbent polymer composite for a period of 100 days to 5,000 days, a period of 100 days to 1,000 days, or a period of 100 days to 500 days.

[0084] In some embodiments, the flugas stream is flowed over at least one surface of the sorbent polymer composite for a period of 500 days to 10,000 days, or for a period of 1,000 days to 5,000 days.

[0085] FIG. 2 illustrates, in cross-section, a non-limiting embodiment of a sorbent polymer composite (SPC) 200 described herein. In this non-limiting embodiment, the sorbent polymer composite (SPC) 200 includes a sorbent material 202 (such as activated carbon) partially or completely coating a polymer material 204. In embodiments, the sorbent polymer composite can include sorbent particles embedded in the microstructure of the polymer. In some embodiments, the particles can be activated carbon particles. In some embodiments, the polymer microstructure can include fibrils. In some embodiments, the polymer can be expanded PTFE. A sorbent polymer composite is defined as a sorbent material embedded within a matrix of a polymer material. Non-limiting configurations of the sorbent polymer composites described herein are described in U.S. Pat. No. 9,827,551 to Hardwick et al. and U.S. Pat. No. 7,442,352 to Lu et al., each of which is incorporated herein by reference in its entirety.

[0086] In some embodiments, the sorbent polymer composite (SPC) 200 can include one or more homopolymers, copolymers, or terpolymers. In some embodiments, the polymer can include at least one fluoromonomer, with or without additional non-fluorinated monomers.

[0087] In some embodiments, the polymer material 204 of the sorbent polymer composite (SPC) 200 can include at least one of polyfluoroethylene propylene (PFEP), polyperfluoroacrylate (PPFA), polyvinylidene fluoride (PVDF), terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCFE), poly(ethylene-co-tetrafluoroethylene) (ETFE), ultra-high molecular weight polyethylene (UHMWPE), polyethylene, polyparaxylylene (PPX), polylactic acid (PLLA), polyethylene (PE), expanded (expanded, expanded, stretched, or foamed) polyethylene (ePE), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), or any combination thereof.

[0088] In some embodiments, the polymer material 204 of the sorbent polymer composite (SPC) 200 can include polyvinylidene fluoride (PVDF). In some embodiments, the PVDF can be a PVDF homopolymer. In some embodiments, the PVDF can be a PVDF copolymer. In some embodiments, the PVDF copolymer is a copolymer of PVDF and hexafluoropropylene (HFP). Non-limiting commercially available examples of PVDF homopolymers or copolymers that may be suitable for some embodiments of the present disclosure include, but are not limited to, KYNAR FLEX® PVDF copolymer and KYNAR SUPERFLEX® PVDF copolymer, each commercially available from Arkema.

[0089] In some embodiments, the polymeric material 204 of the sorbent polymer composite (SPC) 200 can include fluoromonomers such as polytetrafluoroethylene (PTFE), fluoroethylenepropylene (FEP), perfluoroacrylates, perfluoroalkoxyalkanes (PFAs), polyvinylidene fluoride (PVDF), terpolymers of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (CFE), or other copolymers or terpolymers of fluoromonomers and other non-fluorinated monomers. In certain embodiments, particularly suitable substrates can include expanded fluoropolymers such as ePTFE.

[0090] In some embodiments, the polymer is expanded polytetrafluoroethylene (ePTFE). In some embodiments, the structure of the polymer becomes porous upon expansion, and voids may form between the fibrils and nodes of the polymer.

[0091] In some embodiments, the sorbent polymer composite (SPC) 200 has a thickness in the range of 0.2 mm to 2 mm, 0.4 mm to 2 mm, 0.5 mm to 2 mm, 0.5 mm to 1.75 mm, or 0.5 mm to 1.5 mm. In some embodiments, the sorbent polymer composite (SPC) has a thickness in the range of 0.2 mm to 1.75 mm, 0.3 mm to 1.6 mm, 0.4 mm to 1.6 mm, or 0.5 mm to 1.55 mm, or 0.5 mm to 1.5 mm. In some embodiments, the sorbent polymer composite (SPC) has a thickness in the range of 0.4 mm to 1.6 mm, or 0.5 mm to 1.6 mm. In some embodiments, the thickness of the sorbent polymer composite (SPC) can be measured using cross-sectional scanning electron microscopy.

[0092] In some embodiments, the polymer of the sorbent polymer composite (SPC) 200 has a surface energy of less than 31 dynes / cm, less than 30 dynes / cm, less than 25 dynes / cm, less than 20 dynes / cm, or less than 15 dynes / cm.

[0093] In some embodiments, the polymer of the sorbent polymer composite (SPC) 200 has a surface energy in the range of 15 dynes / cm to 31 dynes / cm, 20 dynes / cm to 31 dynes / cm, 25 dynes / cm to 31 dynes / cm, 30 dynes / cm to 31 dynes / cm, 15 dynes / cm to 30 dynes / cm, 15 dynes / cm to 25 dynes / cm, or 15 dynes / cm to 20 dynes / cm.

[0094] In some embodiments, the polymer of the sorbent polymer composite (SPC) 200 has a surface energy in the range of 20 dynes / cm to 25 dynes / cm.

[0095] 2, the sorptive polymer composite 200 includes a sorptive material 202. In some embodiments, the sorptive material 202 of the SPC 200 includes activated carbon, zeolite, or a combination thereof. In some embodiments, the sorptive material 202 of the SPC 200 is activated carbon, where the activated carbon is derived from coal, lignite, wood, coconut shells, other carbonaceous materials, or any combination thereof. In some embodiments, the sorptive polymer composite 200 can further include an additional layer having a polymeric material 204.

[0096] In some embodiments, the sorbent material 202 of the SPC 200 is 400 m 2 / g, more than 600m 2 / g, over 800m 2 / g, more than 1000m 2 / g, more than 1200m 2 / g, 1400m 2 / g, more than 1600m 2 / g, over 1800m 2 / g or more than 2000m 2 / g.

[0097] In some embodiments, the sorbent material 202 of the SPC 200 has a surface area of ​​400 m 2 / g~2000m 2 / g, 500m 2 / g~2000m 2 / g, 600m 2 / g~2000m 2 / g, 700m 2 / g~2000m 2 / g, 800m 2 / g~2000m 2 / g, 900m 2 / g~2000m 2 / g or 1000m 2 / g~2000m 2 / g range.

[0098] In some embodiments, the sorbent material 202 of the SPC 200 has a surface area of ​​400 m 2 / g~1800m 2 / g, 400m 2 / g~1700m 2 / g, 400m 2 / g~1600m 2 / g, 400m 2 / g~1500m 2 / g, 500m 2 / g~1500m 2 / g, 600m 2 / g~1500m 2 / g, or 700m 2 / g~1500m 2 / g range.

[0099] In some embodiments, the sorbent material 202 of the SPC 200 has a surface area of ​​600 m 2 / g~1800m 2 / g, 700m 2 / g~1600m 2 / g, or 800m 2 / g~1400m 2 / g range.

[0100] In some embodiments, the sorptive material 202 of the SPC 200 comprises activated carbon in an amount of about 50% to about 99%, or about 60% to about 95%, or about 60% to about 90%, or about 60% to about 85%, or about 60% to about 84%, or about 60% to about 83%, or about 60% to about 82%, or about 65% to about 81%, or about 70% to about 80%, based on the total weight of the SPC material.

[0101] FIG. 3 illustrates an additional non-limiting embodiment of a sorbent polymer composite (SPC) 300 described herein. In this configuration, a sorbent material 302 (e.g., activated carbon) partially or completely coats a polymeric material 304 (e.g., the node structure of ePTFE) to form the sorbent polymer composite 300. In some embodiments, the sorbent polymer composite can include a sorbent material incorporated into the microstructure of the polymeric material. In other embodiments, the sorbent polymer composite can include a sorbent material embedded within the matrix of the polymeric material. In some embodiments, the polymeric material 304 can include fibrils. In some embodiments, the polymeric material 304 can be expanded PTFE.

[0102] Sorptive polymer composites include a polymeric material and a sorbent material. In some embodiments, the sorbent material is embedded in the polymeric material. By embedding the sorbent material in the polymeric material, the sorbent material not only retains its physical and chemical properties but also gains benefits such as cleanability, chemical inertness, and water repellency. Furthermore, incorporating the sorbent material into the polymeric material facilitates handling. In some embodiments, the polymeric material is PTFE or a combination of PTFE and polyvinylidene fluoride (PVDF). In some embodiments, the polymeric material is PTFE, PVDF, or a combination thereof, and the sorbent material is activated carbon. The structure of PTFE is advantageous in that upon stretching, the polymeric material becomes porous, forming micropores between the polymer fibrils and nodes, depending on the stretching conditions used. When activated carbon or other high surface area sorbent materials are mixed with PTFE, the resulting mixture can be stretched to form a porous structure. In this case, the polymer nodes at least partially comprise activated carbon, as shown in FIG. 3. FIG. 3 shows a sorptive material 302 (eg, activated carbon particles) and a polymeric material 304 (eg, PTFE fibrils).

[0103] In some embodiments, the sorbent polymer composite can comprise or consist of 15% to 50% polymeric material and the remainder a sorbent material. In some embodiments, the sorbent polymer composite can comprise or consist of 15% to 40% polymeric material and the remainder a sorbent material, or 20% to 30% polymeric material and the remainder a sorbent material, or 20% to 30% polymeric material and the remainder a sorbent material, or 20% to 30% polymeric material and the remainder a activated carbon. In some embodiments, the sorbent polymer composite (SPC) can comprise 20% to 24% PTFE, 2% to 6% PVDF, and the remainder a activated carbon. In another embodiment, the sorbent polymer composite (SPC) can comprise 20% to 24% PTFE, 2% to 6% PVDF, and the remainder a activated carbon. Notably, such SPC does not contain any type or other components such as halogen sources, reservoirs, or sulfur.

[0104] Optionally, up to 20 wt. % graphite can be added to the sorptive polymer composite, where wt. % is based on the total weight of the sorptive polymer composite. In other embodiments, the amount of graphite can range from 0.1 to 20 wt. %, or 1 to 15 wt. %, or 2 to 15 wt. %, or 5 to 15 wt. %, or 8 to 12 wt. %, based on the total weight of the sorptive polymer composite.

[0105] The sorbent polymer composite can be in the form of a sheet. In some embodiments, at least one sheet comprises a first surface and a second surface opposite the first surface. In some embodiments, the first surface is configured to absorb at least one gas component, such as SO. x The at least one sheet is configured such that when a gas stream (such as, but not limited to, a flue gas stream) having the formula: flows over (and near) the first surface of the at least one sheet, the at least one gas component reacts within the sorbent polymer composite of the at least one sheet to produce at least one liquid product. In some embodiments, the at least one gas component flows over (and near) both the first surface and the second surface of the at least one sheet.

[0106] In some embodiments, the at least one gas component is mercury vapor, at least one SO x at least one of the compounds, hydrogen sulfide, and a combination thereof; x Regarding the compound, SO x Removal is achieved by oxidation to produce H2SO4 (sulfuric acid). x This can be a complex process requiring the transport of SO, O, and HO. x To overcome the effects of sulfuric acid accumulation due to oxidation, the sorbent polymer composite can function as a "reverse sponge" to expel sulfuric acid. The phenomenon of acid solution expulsion, called "reverse sponge," is described, for example, in U.S. Patent No. 7,442,352 by Lu et al.

[0107] Certain comparative devices formed from sorbent polymer composites can face significant challenges due to liquid accumulation. Performance can decline over time as the liquid forms a permeable network within the sorbent polymer composite. Eventually, this network can become continuous with the surface of the sorbent polymer composite, and further liquid generation can cause the liquid to drain to the surface of the sorbent polymer composite. Due to lower contaminant solubility and diffusivity, liquid-wetted portions of the sorbent polymer composite can perform worse than areas that remain dry. Thus, in some embodiments, the sorbent material of the sorbent polymer composite removes the greatest amount of target contaminants possible.

[0108] In some embodiments, before a liquid product is produced, the interior of at least one sheet takes the form of dry particles exposed to the reactants. A film of liquid (e.g., sulfuric acid + water) may begin to grow around each particle. In some embodiments, this liquid, which may contain acid, may preferentially avoid contact with the polymer portion of the sorbent polymer composite due to the relative surface energy difference between the polymeric material and the sorbent material of the sorbent polymer composite.

[0109] In some embodiments, at least one sheet comprises a plurality of perforations. As used herein, the term "perforations" refers to holes created by boring at least one sheet, piercing at least one sheet, punching at least one sheet, or any other mechanism that deforms, displaces, or removes a portion of at least one sheet. In some embodiments, the plurality of perforations can limit fluid pressure within the sorbent polymer composite, thereby altering the development of the internal permeable network. In some embodiments, the plurality of perforations can have characteristics described, for example, in U.S. Patent Application Publication No. 20220258099 to Stark et al.

[0110] 4A and 5A are photographs of a comparative sorbent polymer composite, which has a non-uniform appearance exhibiting some visual defects, such as "mottle" (a mottled color appearance) in the form of an irregular pattern of relatively light and dark areas. For example, when making comparative sheets, mottle is caused by small-scale variations at the interface between the polymeric material and the sorbent material. The present disclosure relates to SPCs that have a relatively uniform surface appearance (also referred to as a smooth surface appearance) compared to the surface appearance of comparative SPCs.

[0111] Surface optical smoothness can be measured using the image analysis techniques described herein. Surprisingly, SPCs with a relatively uniform surface appearance (or a smooth surface appearance) exhibit higher SO than the same SPCs exhibiting a relatively non-uniform surface appearance. x The smooth surface appearance of the SPC according to the present disclosure can be characterized by optical measurements using ImageJ, an open-source image analysis software available from the National Institutes of Health. In some embodiments, a surface optical smoothness value of less than 15.0 indicates high SO x In some embodiments, this measurement can be 14.7 or less, or less than 14.5, or less than 14.0, or less than 13.5, or less than 13.0, or less than 12.5, or less than 12.0, or less than 11.9, or less than 11.8, or less than 11.7, or less than 11.6, or less than 11.5.

[0112] In another embodiment, the smoothness or visual uniformity of the SPC surface can be measured using a BYK Cloud Runner Mottle Meter available from BYK-Chemie GmbH, Wesel, Germany.

[0113] As used herein, the term "surface optical smoothness" refers to a variable related to the color uniformity of a sheet. The lower the surface optical smoothness value, the better the SO of the SPC.x As shown, the images of the SPC surfaces in Figures 4B, 5B, and 6 have a uniform surface appearance compared to the images of the comparative SPC surfaces shown in Figures 4A and 5A, and therefore the SPCs in Figures 4B, 5B, and 6 have a higher SO x This indicates that the ion exchange reaction has a high removal efficiency.

[0114] The sorbent polymer composite materials disclosed herein can be produced using the method described in U.S. Patent Application Publication No. 2005 / 0057888 by Mitchell et al., the disclosure of which is incorporated herein in its entirety. The combination of polymeric material and sorbent material can be mixed under high shear conditions, followed by a residence period of at least one hour at ambient temperature. During the residence period, the initial mixture of polymeric material and sorbent material is subjected to little or no shear. The residence period can range from one hour to up to one year. Typically, the residence period is 12 to 36 hours. After the residence period with little or no shear, the mixture can be subjected to a second high shear step. Optionally, up to 20% graphite can be added prior to the second high shear step. After the second shear step, the agglomerated material can be rolled or calendered between two or more rolls to form a sheet of desired width and thickness to form the sorbent material-polymer composite.

[0115] In other embodiments, after the residence period, up to about 20% graphite can be added to the mixture to form a graphite-containing mixture. The graphite-containing mixture can be subjected to a relatively low shear mixing process, such as a manual mixing step, for a period of from 1 minute to several hours, e.g., up to 6 hours. After the low shear step, the agglomerated mixture can be rolled or calendered between two or more rolls to form a sheet of desired width and thickness to form the sorbent polymer composite.

[0116] In some embodiments, the present disclosure relates to a method of making a sorbent polymer composite, comprising the steps of: a) forming a precursor mixture by mixing a polymeric material and a sorbent material; b) shearing the precursor mixture under high shear; c) subjecting the material from step b) to a residence period of little or no shear under ambient conditions for at least 1 hour; d) shearing the mixture from step c) under high shear conditions to form an agglomerated mixture; and e) calendering the agglomerated mixture to form an article.

[0117] In yet another embodiment, the present disclosure relates to a method of making a sorbent polymer composite, comprising the steps of: a) forming a precursor mixture by mixing a polymeric material and a sorbent material; b) shearing the precursor mixture under high shear; c) subjecting the material from step b) to a low or no shear residence period of at least 1 hour under ambient conditions; d) adding graphite to the mixture from step c); shearing the mixture from step d) under low shear conditions to form an agglomerated mixture; and e) calendering the agglomerated mixture to form an article.

[0118] Some embodiments of the present disclosure relate to articles having layered structures that can include SPC. Some embodiments of the present disclosure relate to methods of obtaining articles that include a sorbent polymer composite (SPC). The SPC is typically formed as a sheet. The sheet can be a flat sheet, or in other embodiments, a flat sheet can be corrugated or pleated to form a pleated sheet.

[0119] In some embodiments, the article comprises, or further comprises, at least one permeation control material. In some embodiments, the permeation control material comprises a polyethylene wax. In some embodiments, the permeation control material comprises a polypropylene wax.

[0120] In some embodiments, an article comprises the SPC described herein in the form of a sheet or multiple sheets. In some embodiments, an article comprises any of the SPC materials described herein in the form of a pleated sheet or multiple pleated sheets. In yet other embodiments, an article can comprise multiple pleated sheets alternating with multiple flat sheets. In some embodiments, an article comprises multiple sheets forming multiple channels. In some embodiments, the multiple sheets are configured such that at least one liquid product can drain through each channel of the multiple channels. In some embodiments, the multiple channels comprise multiple adjacent channels, and each adjacent channel of the multiple adjacent channels is connected.

[0121] In some embodiments, the pleated sheets can be shaped with undulations (e.g., U-shaped and / or V-shaped pleats) to maintain spacing between the flat sheets and thereby define channel configurations. In some embodiments, at least a portion of one of the plurality of pleated sheets and the plurality of flat sheets includes a beveled top sheet to drain liquid-containing droplets formed thereon.

[0122] In some embodiments, the articles described herein can be assembled by layering alternating pleated and flat sheets within a corresponding plurality of support frames, each of which can have at least two opposing ends at least partially open for passage of gas flow therethrough. In some embodiments, a plurality of support frames in a rectangular prism configuration and / or an oblique prism configuration can be utilized.

[0123] In that regard, a frame of right prism configuration can be utilized to supportably house alternating layers of pleated and flat sheets, whereby the layers of flat sheets and the layers of pleats in the pleated sheets are oriented substantially perpendicular to the parallel planes defined by the opposed open ends of the frame, and the pleats in the pleated sheets are oriented substantially parallel to a central axis of the frame extending through the opposed open ends. Alternatively and / or additionally, a frame of oblique prism configuration can be utilized to supportably house alternating layers of pleated and flat sheets, whereby the flat sheets and the pleated sheets are oriented at an angle (i.e., non-perpendicular) to the parallel planes defined by the opposed open ends of the frame, and the pleats in the pleated sheets are oriented substantially parallel to a central axis of the frame extending through the opposed open ends.

[0124] Some embodiments of the present disclosure relate to a system including any of the exemplary articles and / or article embodiments disclosed herein. In some embodiments, the system includes a passageway configured to allow a gas flow therethrough. In some embodiments, the article is housed within the passageway. In some embodiments, at least a portion of the article is positioned to contact the flue gas flow.

[0125] FIG. 7 illustrates a non-limiting embodiment of a device or pollution control system 1100 having at least one of the articles described herein. Some non-limiting applications of the pollution control system 1100 can be to control air pollutant emissions to comply with various air pollutant emission standards. The pollution control system 1100 can be configured to capture elemental mercury and oxidized gas-phase mercury from industrial flues. The pollution control system 1100 can include individual stackable modules 1102 that can be installed downstream of the particle collection system. In some embodiments, the modules 1102 can be configured with one or more embodiments of the articles 1104 (shown in enlarged partial view in FIG. 11 ) described herein.

[0126] In some embodiments, the system can include a plurality of articles formed in a plurality of channels. In such embodiments, a gas stream can flow between the channels such that the gas stream directly contacts at least a portion of the SPC. In some embodiments, the plurality of channels in the device can facilitate the flow of reactants, such as gaseous components, over one or more surfaces of the system and the discharge of at least one liquid product.

[0127] Non-limiting exemplary configurations of systems that can include examples as described herein can be found in U.S. Pat. No. 9,381,459 to Stark et al., which is incorporated herein by reference in its entirety for all purposes.

[0128] In another embodiment, the present disclosure relates to a method of treating a gas stream comprising providing a flu-gas stream, contacting the flu-gas stream with a device or pollution control system 1100 described herein, wherein the flu-gas stream has a temperature of at least 50° C. and a relative humidity of at least 50%, and wherein the flu-gas stream contains at least one SO 2 at a concentration of at least 20 ppm. x The method comprises the steps of: x can be removed.

[0129] In yet another embodiment, the method comprises: x The method can further include converting the compound to a liquid sulfur-containing compound and collecting the liquid compound. The liquid sulfur-containing compound can include sulfuric acid. In another embodiment, the method can include adding water vapor to the gas stream upstream of the sorbent polymer composite substrate.

[0130] In some embodiments, the method comprises about 20% to about 99%, or about 30% to about 99%, or about 40% to about 99%, or about 50% to about 99%, or about 50% to about 97%, or about 50% to about 95%, or about 50% to about 93%, or about 50% to about 90% SO xSmooth SPC has been found to have several advantages. For example, one advantage is that it reduces SO 2 removal efficiency compared to less smooth SPC. x Furthermore, liquid sulfur-containing compounds formed on the SPC can be more efficiently removed from the sheet.

[0131] To demonstrate the improved properties of embodiments of articles implemented in the embodied systems and methods described herein, various example and comparative examples of articles were tested, and the results are described in detail below.

[0132] Test Method Surface optical smoothness measurement

[0133] Optical smoothness was measured according to the following procedure. A sample of the sorbent polymer composite, approximately 25.4 centimeters on each side, was removed from each roll. A square wooden frame, 24.1 centimeters on each side, was placed on top of each sample to ensure the sample lay flat on the table. A diffuse light source was used to illuminate the sample, minimizing or completely eliminating reflections. Images of the samples were captured using the camera on a Google Pixel 6 cell phone (available from Google, Mountain View, California). The distance from the sample to the camera was approximately 61 centimeters. The flatness of the camera was confirmed using an on-board gyroscope.

[0134] A 1000 pixel x 1000 pixel portion of the image (105 pixels per inch) was then analyzed using the GCSA SurfChar1Q plugin for FIJI / ImageJ (available from the NIH) (available at https: / / www.gcsa.net / IJ / SurfCharJ.html) with the following settings: images were converted to 32-bit grayscale and set to "Level Surface."

[0135] The output of this analysis is a dimensionless number representing the optical roughness Ra. Higher values ​​of Ra indicate more surface irregularities. As can be seen from the example, samples with values ​​below 12 have high SO x Indicates removal efficiency. Samples with values ​​above 12 have low SO x The removal efficiency is shown.

[0136] SO2 removal efficiency test equipment

[0137] The SO2 removal efficiency is determined by the following process. SO2 vapor removal was performed using an apparatus including: (1) an air supply regulated by a mass flow controller; (2) a SO2 supply source supplied at 1% concentration balanced by a nitrogen gas cylinder; (3) a triangular sample cell with a side length of 30.5 cm and equipped with a bypass, placed in an oven maintained at 60°C; and (4) a Teledyne T100H UV fluorescence SO2 analyzer. This test was performed to determine the relative SO2 vapor removal efficiency. x This test is designed to provide an indication of the SO removal efficiency. x Removal data is often lower than can be achieved by the articles, devices or pollution control systems described herein.

[0138] Test specimens for each example were cut from each composite sheet. The specimens were 30.5 centimeters (cm) long and 3 cm wide. The specimens were folded lengthwise along the centerline and placed within a 30.5 cm triangular sample cell. The triangular sample cell contained a mixing means to provide a more turbulent gas flow. This mixing means could be achieved by 1) cutting one or more semicircular, square, or triangular flaps into the tape, or 2) adding one or more vaned plastic pieces to the test cell.

[0139] Removal efficiency is reported as the difference between the inlet level (which bypasses the sample) and the outlet level (which passes through the sample). Percent efficiency is defined as: % efficiency = 100 x [concentration (inlet) - concentration (outlet)] / [concentration (inlet)].

[0140] Operating condition #1

[0141] An SO2-containing gas mixture containing 100 ppm SO2, 21% O2 at 100% relative humidity (balance N2) is flowed through the triangular sample cell at 12 liters / min at 60°C for the specified time. SO2 removal efficiency is calculated at regular intervals and reported as an average value over the entire run time. Turbulent gas flow was achieved by cutting one or more flaps into the test specimen.

[0142] Operating Condition #2 A SO2-containing gas mixture containing 400 ppm SO2, 4.7% O2 at 100% relative humidity (balance N2) is flowed through the triangular sample cell at 6 liters / min at 60°C for the specified time. SO2 removal efficiency is calculated at regular intervals and reported as an average value over the entire run time. Turbulent gas flow was achieved by adding a plastic strip with one or more vanes or fins to the test cell. [Example]

[0143] Example - Sorptive Polymer Composite (SPC) Aggregates

[0144] Activated carbon PAC20 BF is available from Norit Cabot Corporation, Marshall, Tex. Two different lot numbers were used in these examples: supplier lot 4664689 and supplier lot 4922959.

[0145] INOFLON® GN7003, a PFOA-free polytetrafluoroethylene (PTFE) powder, is available from Gujarat Fluorochemicals Limited, Gujarat, India.

[0146] Polyvinylidene fluoride KYNAR® Flex 2751-00 is available from Arkema, Inc., King of Prussia, Pennsylvania.

[0147] Synthetic graphite with an average particle size of 14 to 18 microns is available from Asbury Carbons, Inc., Asbury, New Jersey.

[0148] Expanded polytetrafluoroethylene (ePTFE) membrane with a nominal thickness of 0.01 mm and an areal density of 2.5 g / m² is available from WL Gore and Associates Inc., USA.

[0149] Comparative example A

[0150] A blend of 74% by weight (wt%) PTFE, 22% by weight PAC20 BF activated carbon (Lot No. 4922959), and 4% by weight PVDF was dry-mixed to prepare a composite. This dry blend was fibrillated under high shear using the method described in U.S. Patent Application Publication No. 2005 / 0057888 by Mitchell et al. After the shearing process, the material was stored at zero shear for 24 hours at an ambient temperature of approximately 22°C (±5°C). Several kilograms of this material were removed, and the remaining 500 grams of this material was calendered with an ePTFE membrane to form composite sheets 1 to 1.1 millimeters (mm) thick and 318 to 345 mm wide. A photograph of the resulting sheet is shown in Figure 4A.

[0151] Example 1

[0152] A 500 gram (g) sample of Control Example A was subjected to a second high shear step as described in US Patent Application Publication No. 2005 / 0057888 to Mitchell.

[0153] After the second shearing step, the agglomerated material was removed from the device and calendered with a PTFE membrane to form a composite sheet measuring 1 to 1.1 millimeters (mm) thick and 318 to 345 mm wide. A photograph of the formed sheet is shown in Figure 4B.

[0154] Comparative example B

[0155] A blend of 74% by weight (wt%) PTFE, 22% by weight of activated carbon (PAC20 BF activated carbon, lot number 4664689), and 4% by weight of PVDF was dry-mixed to form a mixture. This dry mixture was fibrillated under high shear using a milling device described in U.S. Patent Application Publication No. 2005 / 0057888 to Mitchell et al. After the shearing process, the material was stored under zero shear conditions for 24 hours at an ambient temperature of approximately 22°C (±5°C). Several kilograms of this material were removed, and the remaining 500 grams of this material was calendered with a PTFE membrane to form a composite sheet measuring 1 to 1.1 millimeters (mm) thick and 318 to 345 mm wide. A photograph of the resulting sheet is shown in Figure 5A.

[0156] Example 2

[0157] A 500 gram (g) sample of Comparative Example B was subjected to a second high shear step as described in US Patent Application Publication No. 2005 / 0057888 by Mitchell et al.

[0158] After the second shearing step, the agglomerated material was removed from the device and calendered with a PTFE membrane to form a composite sheet measuring 1 to 1.1 millimeters (mm) thick and 318 to 345 mm wide. A photograph of the formed sheet is shown in Figure 5B.

[0159] Comparative example C

[0160] The sample of Comparative Example A was removed after the shearing process, stored in a container, and aged in the container for approximately 6 months at ambient conditions of approximately 22° C. (±5° C.) The aged sample was calendered with a PTFE membrane to form a composite sheet having a thickness of 0.96 millimeters (mm) and a width of 318 to 345 mm.

[0161] Example 3

[0162] A 450-gram sample of the 6-month-aged Comparative Example C was mixed with 50 grams of graphite and the mixture was placed in a container. The container was tumbled by hand for approximately one minute to loosely mix the mixture, after which the mixture was lightly stirred by hand and inspected for uniformity. This mixture was then calendered with a PTFE membrane to form composite sheets 0.93 to 0.96 millimeters (mm) thick and 318 to 345 mm wide. A photograph of the sheets is shown in Figure 6.

[0163] Example 4

[0164] A 500 gram sample of Comparative Example C that had been aged for six months was recombined using the method taught in U.S. Patent Application Publication No. 2005 / 0057888 to Mitchell et al. After the second fibrillation step, the mixture was cooled to ambient temperature of about 22°C (±5°C) and stored for 24 hours. This sample was then calendered with a PTFE membrane to form a composite sheet 0.95 millimeters (mm) thick and 318-345 mm wide.

[0165] The SPCs of Figures 4A, 4B, 5A, 5B, and 6 were evaluated for optical smoothness appearance values, and the results are shown in Table 1. [Table 1]

[0166] The sorbent polymer composite material as described herein exhibits a significantly improved SO x For example, Example 1 shows an increase in SO removal efficiency compared to Comparative Example A. x The removal efficiency is improved by 13.5%. Example 2 shows a reduction in SO removal efficiency compared to Comparative Example B. x Example 3 shows a 20% improvement in SO removal efficiency compared to Comparative Example C. x This shows that the removal efficiency is improved by 9.3%.

[0167] It should be understood that changes may be made in details, particularly in the materials of construction used, the shape, size and arrangement of parts, etc., without departing from the scope of the present disclosure. The specification and described embodiments are exemplary, with the true scope and spirit of the present disclosure being indicated by the following claims.

Claims

1. Sorptive materials, polymer materials, A sorbent polymer composite (SPC) material comprising: the SPC material is in the form of a sheet; The sheet is a sorbent polymer composite (SPC) material having a smooth surface.

2. 10. The SPC material of claim 1, wherein the sheet has an optical smoothness value of less than 12.

0.

3. 2. The SPC material of claim 1, wherein the polymer material comprises at least one of polyfluoroethylene propylene (PFEP), polyperfluoroacrylate (PPFA), polyvinylidene fluoride (PVDF), terpolymer of tetrafluoroethylene, hexafluoropropylene, and vinylidene fluoride (THV), polychlorotrifluoroethylene (PCFE), poly(ethylene-co-tetrafluoroethylene) (ETFE), ultra-high molecular weight polyethylene (UHMWPE), polyethylene, polyparaxylylene (PPX), polylactic acid (PLLA), polyethylene (PE), expanded polyethylene (ePE), polytetrafluoroethylene (PTFE), expanded polytetrafluoroethylene (ePTFE), or any combination thereof.

4. The SPC material of claim 3 , wherein the polymeric material comprises PVDF.

5. The SPC material of claim 4, wherein the PVDF is a PVDF homopolymer.

6. The SPC material of claim 4, wherein the PVDF is a PVDF copolymer.

7. The SPC material of claim 6, wherein the PVDF copolymer is a copolymer of PVDF and hexafluoropropylene (HFP).

8. The SPC material of claim 3, wherein the polymeric material comprises a polymer having a surface energy in the range of 15 dynes / cm to 31 dynes / cm.

9. The SPC material of claim 8 , wherein the polymeric material comprises a fluoropolymer.

10. The SPC material of claim 3 , wherein the polymeric material comprises PTFE.

11. The SPC material of claim 3 , wherein the polymeric material comprises ePTFE.

12. The SPC material of any one of claims 1 to 11, wherein the polymer material comprises fibrils and nodes, and the polymer material becomes porous upon stretching, thereby forming voids between the fibrils and the nodes.

13. The sorbent material is 400 m ２ 10. The SPC material of claim 1 having a surface area of ​​greater than 1000 .mu.m / g.

14. The sorbent material is 400 m ２ / g to 2000m ２ 14. The SPC material of claim 13, having a surface area in the range of 1 / g.

15. The SPC material of any one of claims 1 to 14, wherein the sorptive material is selected from activated carbon, zeolite, or any combination thereof.

16. The SPC material of any one of claims 1 to 15, wherein the sorptive material is activated carbon.

17. 17. The SPC material of claim 16, comprising activated carbon in an amount of 70% to 90% based on the total weight of the SPC material.

18. 20% to 24% PTFE, 2% to 6% PVDF, optionally up to 10% graphite, and The remaining activated carbon, The SPC material according to any one of claims 1 to 17, comprising:

19. The SPC material of claim 1, wherein the sheet has a thickness of 0.2 to 2 mm.

20. 20. The SPC material of claim 19, wherein the sheet has a thickness of 0.5 to 1.5 mm.

21. The SPC material of any one of claims 1 to 20, wherein the material is free of halogens, sulfur or reservoirs.

22. An article comprising the SPC material of any one of claims 1 to 21, comprising a plurality of pleated sheets and a plurality of flat sheets in an alternating configuration.

23. A method for extracting at least one SO from a flue gas stream, comprising the SPC material of any one of claims 1 to 21 or the article of claim 22. ｘ A device for removing compounds.

24. providing a flugas flow; and contacting said flue gas stream with a flue gas treatment device comprising the sorbent polymer composite material of any one of claims 1 to 21; Including, the flue gas stream has a temperature of at least 50°C and a relative humidity of at least 50%; The flue gas stream contains at least one SO 4 in a concentration of at least 20 ppm. ｘ A method for treating a flugas stream containing a compound.

25. SO ｘ 25. The method of claim 24, wherein the removal efficiency is between 20% and 99.9%.

26. At least one SO ｘ converting the compound to sulfuric acid on the SPC material; and recovering the converted sulfuric acid; 26. The method of claim 24 or 25, further comprising:

27. The at least one SO ｘ The compound is sulfur dioxide (SO ２ ), sulfur trioxide (SO ２ 27. The method of any one of claims 24 to 26, comprising:

Images