Extruded structural bodies for carbon capture

Abstract

In one aspect, monolithic structural bodies formed of extruded carbon dioxide (CO2) sorbent materials are described herein. Additionally, extrusion batch compositions and associated methods of forming such monolithic bodies are also described herein. In some embodiments, an extrusion batch composition for a monolithic adsorber comprises a polymeric phase at least partially solubilized in an organic solvent, and a particulate CO2 sorbent, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf.

Description

[0001] EXTRUDED STRUCTURAL BODIES FOR CARBON CAPTURE

[0002] RELATED APPLICATION DATA

[0003] The present application claims priority pursuant to Article 8 of the Patent Cooperation Treaty to United States Provisional Patent Application Serial Number 63 / 601,046 filed November 20, 2023, which is incorporated herein by reference in its entirety.

[0004] FIELD

[0005] The present invention relates to monolithic structural bodies for gas treatment applications and, in particular, to structural bodies formed of extruded carbon dioxide sorbent materials.

[0006] BACKGROUND

[0007] Global warming and associated climate change induced by human activities presents an existential threat to numerous ecosystems and the way of human life as it is currently understood. The mining and burning of fossil fuels are chief contributors global warming via the massive release of heat trapping gases, including methane and carbon dioxide. Carbon dioxide accounts for the bulk of greenhouse gas emissions, as the concentration of carbon dioxide has eclipsed the 400 ppm mark in recent years. Current carbon dioxide levels exceed any concentration in the last 800,000 years.

[0008] In view of this alarming trend in atmospheric carbon dioxide concentration, countries and industry have initiated various mitigation strategies to reduce carbon dioxide emissions, as well as methane emissions. Electrification of vehicles and transportation systems has drawn considerable attention. Moreover, the transition to green / renewable sources of energy, including wind and solar, has received significant private and public investment. While promising, these mitigation strategies fail to address carbon dioxide that is currently in the atmosphere and the ongoing need for fossil fuel consumption as a source of energy as the global economy transitions to a carbon neutral state. Accordingly, current carbon dioxide levels are left to slow, natural degradation processes. Carbon capture from fossil fuel combustion and from the air is essential to achieve a carbon neutral state. SUMMARY

[0009] In one aspect, monolithic structural bodies formed of extruded carbon dioxide (CO2) sorbent materials are described herein. Additionally, extrusion batch compositions and associated methods of forming such monolithic bodies are also described herein. In some embodiments, an extrusion batch composition for a monolithic adsorber comprises a polymeric phase at least partially solubilized in an organic solvent, and a particulate CO2 sorbent, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf.

[0010] In another aspect, an extrusion batch composition for a monolithic adsorber comprises a particulate polymeric phase and a particulate CO2 sorbent disposed in or dispersed in an aqueous or aqueous-based continuous phase, and a viscosity modifier at least partially solubilized in the aqueous or aqueous-based continuous phase, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf. In some embodiments, the particulate CO2 sorbent of extrusion batch compositions described herein comprise aminated particles. Moreover, extrusion batch compositions described herein can further comprise one or more pore forming agents and / or reinforcing agents, including fiber reinforcing agents.

[0011] Extruded monolithic structural gas treatment bodies are also provided herein. In some embodiments, an extruded monolithic structural gas treatment body comprises a plurality of inner partition walls formed of an extruded batch composition wherein a particulate CO2 sorbent is associated with a polymeric binder phase, the inner partition walls defining flow channels through the monolithic structural gas treatment body. The extruded monolithic structural gas treatment body exhibits hierarchical pore structure advantageous for CO2 capture. The extruded monolithic structural gas treatment body can have a macroporosity of 0.05-2 cm3 / g in pores of diameter ranging from 0.1 pm to 50 pm and / or a mesoporosity of 0.01-0.5 cm3 / g in pores of diameter ranging from 1-100 nm. Additionally, extruded monolithic structural gas treatment bodies described herein can exhibit a CO2 adsorption capacity of at least 0.5 mmol / g or at least 1 mmol / g of the particulate CO2 sorbent in the monolithic structural gas treatment body.

[0012] In another aspect, methods of making monolithic structural bodies for CO2 adsorption are described herein. A method, in some embodiments, comprises providing an extrusion batch including a polymeric binder, and a particulate CO2 sorbent, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf. The extrusion batch is extruded into the monolithic structural body comprising a plurality of inner partition walls formed from the extrusion batch wherein the particulate CO2 sorbent is associated with the polymeric binder, and the inner partition walls define flow channels through the monolithic structural body. The resultant extruded monolithic structural body can have any composition and / or properties described herein.

[0013] In another aspect, methods of capturing CO2 from a gas stream are provided. A method, in some embodiments, comprises providing an extruded monolithic structural gas treatment body including a plurality of inner partition walls formed of an extruded batch composition, the extruded batch composition including a particulate CO2 sorbent is associated with a polymeric binder phase, the inner partition walls defining flow channels through the monolithic structural gas treatment body. The gas stream comprising CO2 is flowed through the flow channels and captured with the CO2 sorbent. The captured CO2 can be subsequently desorbed from the monolithic structural gas treatment body for downstream processing, including storage or sequestration. The extruded monolithic structural body can have any composition and / or properties described herein.

[0014] These and other embodiments are further described in the following detailed description.

[0015] BRIEF DESCRIPTION OF THE DRAWINGS

[0016] FIG. 1 illustrates a honeycomb-like monolithic structural gas treatment body according to some embodiments herein.

[0017] FIG. 2 illustrates flow channels defined by the inner partition walls in a honeycomb-like monolithic structural gas treatment body according to some embodiments herein.

[0018] FIG. 3 ill ustrates a method of determining the average thickness of the outer peripheral wall and inner partition walls of a monolithic structural gas treatment body.

[0019] FIG. 4 is a scanning electron microscopy (SEM) image of a flow channel of monolithic structural gas treatment body described herein according to some embodiments.

[0020] FIG. 5 is a picture of a monolithic structural gas treatment body described herein according to some embodiments.

[0021] FIG. 6 is a picture of a monolithic structural gas treatment body described herein according to some embodiments. DETAILED DESCRIPTION

[0022] Embodiments described herein can be understood more readily by reference to the following detailed description and examples and their previous and following descriptions. Elements, apparatus and methods described herein, however, are not limited to the specific embodiments presented in the detailed description and examples. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations will be readily apparent to those of skill in the art without departing from the spirit and scope of the invention.

[0023] I. Organic Solvent-Based Extrusion Batch Compositions

[0024] Extrusion batch compositions are described herein for the production of monolithic structural gas treatment bodies (adsorbers) formed of extruded particulate CO2 sorbent. In some embodiments, an extrusion batch for a monolithic adsorber comprises a polymeric phase at least partially solubilized in an organic solvent, and a particulate CO2 sorbent, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf. The particulate CO2 sorbent, in some embodiments, has a particle size of 1-100 pm. In some embodiments, the particulate CO2 sorbent has a DIO particle size of 0.5-3 pm, and a D90 particle size of 15-30 pm. The particulate CO2 sorbent can be milled to achieve the foregoing particle sizes. Depending on specific compositional identity of the particulate CO2 sorbent, the milling process can begin with drying the particulate CO2 sorbent to a residual moisture of 0-20 percent. The dried particulate CO2 sorbent is then dry ball milled for 18-24 hours, followed by sieving with a 50 mesh screen.

[0025] Moreover, the particulate CO2 sorbent can be present in an amount of 15-70 weight percent, 15-50 weight percent, or 20-40 weight percent of the extrusion batch. The particulate CO2 sorbent, in some embodiments, comprises a particulate support and one or more chemical functionalities operable for the adsorption of CO2 associated with the support. The support, in some embodiments, can be porous or solid. The support, for example, can comprise solid polymeric beads / particles or porous polymeric beads / particles. When porous, the support can exhibit macroporosity and / or mesoporosity. The particulate CO2 sorbent, for example, can comprise aminated particles. The aminated particles can comprise primary amines, secondary amines, or combinations thereof. Amine functionalities can be associated with polymeric chains including, linear, branched, grafted, dendritic, and / or hyper-branched chains. In some embodiments, the polymeric chains comprise epoxyalkane-functionalized amine, including epoxyalkane functionalized polyethylenimine. Such polymeric chains can be coated onto the particulate support or chemically bound to the particulate support. Organic compounds comprising amine functionalities for CO2 adsorption can also include small (non-polymeric) molecules, such as tetra(ethylenepentamine) (TEPA). In some embodiments, for example, the particulate CO2 sorbent is commercially available from Lanxess AG of Cologne, Germany under the LEWATIT® trade designation. The particulate sorbent, in some embodiments, is organic. In being organic, the particulate sorbent excludes metal containing species, including metal organic frameworks, alkali metals, and metal oxide species such as silica and / or alumina.

[0026] In some embodiments, the particulate CO2 sorbent exhibits high surface area. The particulate CO2 sorbent, for example, can exhibit surface area of at least 250 m2 / g, at least 500 m2 / g, or at least 1,000 m2 / g, in some embodiments.

[0027] In addition to the particulate CO2 sorbent, the extrusion batch composition comprises a polymeric binder at least partially solubilized in an organic solvent. The polymeric binder, in some embodiments, comprises one or more thermoplastics. Suitable polymeric binder can be selected according to several considerations, including identities of the particulate CO2 sorbent and organic solvent. Polymer of the polymeric binder can be homopolymer or copolymer. Suitable copolymers include alternating copolymers, block copolymers, statistical copolymers or random copolymers. In some embodiments, polymer of the polymeric binder comprises heterocyclic monomeric units or acetal monomeric units. Acetal monomeric units can be cyclic or non-cyclic. In some embodiments, acetal monomeric units are employed in combination with other monomeric units, such as alcohols and / or acetates. Polymer of the polymeric binder, for example, can be polyvinyl butyral (PVB) or derivatives thereof. Butyryl content, acetate content, and / or hydroxyl content of the PVD can be varied according to several considerations, including chemical identity of the particulate CO2 sorbent, desired viscosity and / or plasticity of the extrusion batch, and chemical identity of other batch components described herein. In some embodiments, the PVB can comprise up to 80% polyvinyl butyral with the balance polyvinyl acetate and polyvinyl alcohol. Moreover, in some embodiments, the PVB comprises an acetate content of 1-10 percent and / or a polyvinyl alcohol content of 15-30 percent.

[0028] The polymeric binder can be present in the batch composition in any desired amount. Considerations governing the amount of polymeric binder in the extrusion batch composition can include the identity and desired loading of the particulate CO2 sorbent, achieving the desired plasticity of the batch composition, and the desired mechanical and / or CO2 adsorbent properties of the extruded monolithic body. In some embodiments, the polymeric binder is present in an amount of 1-30 weight percent or 2-20 weight percent of the extrusion batch composition.

[0029] Specific identity of the organic solvent in the extrusion batch composition can be dependent on the identities of the polymeric binder and the particulate CO2 sorbent. The organic solvent at least partially solubilizes the polymeric binder. Moreover, the particulate CO2 sorbent should be stable in the organic solvent and be resistant to aggregation. In some embodiments, the organic solvent is a polar aprotic solvent. The organic solvent, in some embodiments, comprises acetone, alcohol, acetate, dimethyl sulfoxide, ketone, alkylene chloride, alkyl ester, glycol ether, or mixtures thereof. The organic solvent can provide or constitute the balance of the extrusion batch composition. The extrusion batch composition can be prepared, in some embodiments, by at least partially solubilizing the polymeric binder in the organic solvent, followed by addition of the particulate CO2 sorbent. Mechanical agitation, such as mixing, can be employed to further prepare the extrusion batch composition.

[0030] The extrusion batch composition, in some embodiments, further comprises one or more pore forming agents. Pore forming agents can be insoluble in the organic solvent and soluble in water or aqueous-based solvents. Subsequent to forming the extruded monolith, the pore forming agent can be washed out or dissolved with water or aqueous-based solvent, thereby forming the desired pore structure in the extruded monolith. Any suitable pore forming agent can be employed. Pore forming agent identities, sizes, and amounts can be selected according to several considerations, including desired pore structure in the extruded monolith and solubility characteristics in water or aqueous-based solvent. In some embodiments, pore forming agents comprises salts, sugars, or mixtures thereof. Pore forming agents of differing sizes can be used to provide a hierarchical pore structure, in some embodiments. In some embodiments, pore forming agent is present in an amount of 5-50 weight percent or 10-30 weight percent of the extrusion batch composition.

[0031] Additionally, in some embodiments, the extrusion batch composition can comprise an extrusion aid component. The extrusion aid component can comprise one or more species facilitating or aiding the extrusion process. In some embodiments, the extrusion aid component comprises one or more polyalkylene-glycols, fatty acids, or mixtures thereof. The extrusion aid component can be present in an amount of 1-30 weight percent or 10-25 weight percent of the extrusion batch composition. In some embodiments, the extrusion aid component is soluble in water or aqueous-based solvent and can be washed from the extruded monolith. Washing the extrusion aid component can assist in developing pore structure of the extruded monolith, in some embodiments.

[0032] Extrusion batch compositions described herein can optionally include one or more reinforcement agents. Reinforcement agents can include reinforcing fibers, including glass (SiCh) fibers, carbide fibers, ceramic fibers, polymeric fibers, and mixtures thereof. In some embodiments, reinforcing fibers have a diameter of 0.1 pm to 30 pm and / or length up to 10 mm. Reinforcement agent can be present in an amount of 0.5-10 weight percent of the extrusion batch composition, in some embodiments.

[0033] As described herein, the extrusion batch composition has a plasticity of 0.06 to 1.3 kgf. To measure plasticity of an extrusion batch composition described herein, a representative sample of the extrusion batch composition is removed from the mixer and pressed into a steel cup. A piston is inserted into the top of the cup and pressed with a hydraulic press to a pressure of 300 psi + / -10 psi for 3 minutes. When compaction is complete, the piston is removed and the pressed sample of the extrusion batch is aligned under the test unit. The compression test unit (MTS Criterion C42) is setup with a needle that is 47mm in length with a round tip that is 2.01mm +.01 -0.03. The needle is pressed into the extrusion batch at a fixed rate and forced through the material at a fixed rate of 0.635 mm / s. The resultant force (kgf) is recorded and the test software determines the stable pressure required for the needle to pass through the sample. Once complete, the needle is extracted, cleaned and the cup is rotated to a position at least 4 mm away from the original insertion point and the test is repeated. This process occurs for a total of 5 tests - a successful test is accepted if the relative standard deviation of the tests is less than 0.5 kgf

[0034] II. Aqueous-Based Extrusion Batch Compositions

[0035] In another aspect, aqueous-based extrusion batch compositions are described herein for the production of monolithic structural gas treatment bodies (adsorbers) formed of extruded particulate CO2 sorbent. In some embodiments, an extrusion batch composition for a monolithic adsorber comprises a particulate polymeric phase and a particulate CO2 sorbent disposed or dispersed in an aqueous or aqueous-based continuous phase, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf. In some embodiments, the batch composition further comprises a viscosity modifier at least partially solubilized in the aqueous or aqueous-based continuous phase.

[0036] The particulate CO2 sorbent of the aqueous-based extrusion batch composition can have any chemical composition and / or properties described in Section I above. For example, the particulate CO2 sorbent can exhibit a DIO particle size of 0.5-3 pm, and a D90 particle size of 15-30 pm. The particulate CO2 sorbent can also be present in the aqueous-based extrusion batch in an amount of 15-70 weight percent, 15-50 weight percent or 20-40 weight percent of the extrusion batch.

[0037] In addition to the particulate CO2 sorbent, the extrusion batch comprises a particulate polymeric phase disposed in or dispersed in the aqueous or aqueous-based continuous phase. In some embodiments, the particulate polymeric phase comprises an olefin-acetate copolymer, styrene-acrylate copolymer, or acrylic polymer. For example, the particulate polymeric phase can comprise polyethylene-vinyl acetate (PEVA) or derivatives thereof, in some embodiments. Copolymers of particles dispersed in the aqueous phase can have any desired constructions consistent with the technical objectives described herein. The styrene and acrylic contents of styrene-acrylate copolymer can be varied. Additionally, the polyethylene and polyvinyl acetate contents of PEVA can be varied. In some embodiments, for example, the particulate polymeric phase comprises PEVA having an acetate content of 1 to 40 percent or 10 to 30 percent. Alternatively, the PEVA can have an acetate content of greater than 50 percent, such as 50-90 percent.

[0038] The particulate polymeric phase comprises a polyalkyl-siloxane, in some embodiments. For example, the particulate polymeric phase can comprise polydimethyl-siloxane. In some embodiments, the particulate polymeric phase can comprise one or more elastomeric species. The particulate polymer phase, for example, can include polybutadiene or styrene-butadiene (SBR).

[0039] The particulate polymeric phase can comprise a single species of polymer or at least two differing particulate polymeric species. The two differing polymeric species can be thermoplastics. In some embodiments, the particulate polymeric phase comprises a first particulate polymeric species of olefin-acetate copolymer or aryl-acrylate copolymer and a second particulate polymeric species comprising heterocyclic monomeric units. The heterocycle monomeric units can include acetal monomeric units. In some embodiments, the first or second polymeric phase can comprise an elastomeric species. For example, the first polymeric phase can be a thermoplastic recited herein, and the second polymeric phase can comprise and elastomer recited herein. The first and second polymeric species can be present in any desired ratio. In some embodiments, the ratio of the first particulate polymeric species to the second particulate polymeric species ranges from 2:1 to 1 :2.

[0040] The particulate polymeric phase can be present in an amount of 5-20 weight percent of the extrusion batch composition. In some embodiments, the particulate polymeric phase of the aqueous-based extrusion batch composition has a DIO particle size selected from Table 1 and / or a D90 particle size selected from Table 2.

[0041] Table 1 - DIO particle size (pm)

[0042] Depending specific identity, the particulate polymeric phase of the aqueous-based extrusion batch composition can be provided as a powder or as an aqueous dispersion or emulsion. In some embodiments, styrene-acrylate copolymer and / or styrene butadiene copolymer of the particulate polymeric phase are initially provided as emulsions for incorporation into batch compositions described herein. In such embodiments, the emulsions can have any solids content consistent with the technical objectives described herein. The polymeric particle emulsions, in some embodiments, have a solids content of 30-70 percent or 40-60 percent.

[0043] The viscosity modifier of the extrusion batch composition, in some embodiments, comprises one or more polyalkylene oxides. Additionally, the viscosity modifier can be present in an amount of 1-10 weight percent of the extrusion batch composition. The extrusion batch composition may further comprise one or more extrusions aids and / or one or more reinforcement agents described in Section I above.

[0044] In contrast to the extrusion batch compositions described in Section I above, the aqueous or aqueous-based continuous phase provides or constitutes the balance of the extrusion batch composition.

[0045] III. Extruded Monolithic Structural Gas Treatment Bodies (Adsorbers)

[0046] Extruded monolithic structural gas treatment bodies operable for the capture of CO2 from gas streams are also described herein. An extruded monolithic structural gas treatment body, in some embodiments, comprises a plurality of inner partition walls formed of an extruded batch composition, the extruded batch composition including a particulate CO2 sorbent associated with a polymeric binder phase, the inner partition walls defining flow channels through the monolithic structural gas treatment body. The extruded monolithic structural gas treatment body can also comprise an outer peripheral wall formed of the extruded batch composition.

[0047] The extruded monolithic structural gas treatment body can exhibit a hierarchical pore structure. In some embodiments, the extruded monolithic body has a macroporosity of 0.05-2 cm3 / g in pores of diameter ranging from 0.1 pm to 50 pm and / or a mesoporosity of 0.01-0.5 cm3 / g in pores of diameter ranging from 1-100 nm. This hierarchical pore structure can be dispersed throughout the outer peripheral wall and inner partition walls of the monolithic structural gas treatment body. Macroporosity can be measured by mercury (Hg) porosimetry, and mesoporosity can be measured by nitrogen (N2) physisorption.

[0048] The inner partition walls are arranged inside the dimensions defined by the outer peripheral wall, and plurality of flow channels are defined by the inner partition walls, the flow channels extending longitudinally through the monolithic structural gas treatment body. FIG. 1 illustrates a honeycomb-like monolithic structural gas treatment body according to some embodiments herein. The extruded honeycomb-like structural gas treatment body in the embodiment of FIG. 1 comprises an outer peripheral wall 10 and a plurality of inner partition walls 11. The inner partition walls 11 define a plurality of flow channels 12 extending longitudinally through the honeycomb-like monolithic structural gas treatment body. FIG. 2 illustrates flow channels 12 defined by the inner partition walls 11 in a honeycomb-like monolithic structural body according to some embodiments herein. The inner partition walls 11 and their junctures with the outer peripheral wall serve as boundaries for adjacent flow channels 12. When a portion of the outer peripheral wall 10 serves as a boundary for a flow channel 12, that portion may be referred to as an outer peripheral wall segment 13. As illustrated in FIGS. 1 and 2, the flow channels 12 establish a flow channel density or cell density over the inlet and outlet faces of the monolithic structural gas treatment body. An extruded monolithic structural gas treatment body described herein can have any desired cell density or flow channel density. As described above, the monolithic structural gas treatment body has a cell density of at least 50 cpsi. In some embodiments, the monolithic structural gas treatment body has a cell density of 75 cpsi to 900 cpsi. For example, the monolithic structural gas treatment body can have a cell density of 100 cpsi to 500 cpsi, 140 cpsi to 450 cpsi, or 170 cpsi to 500 cpsi. Additionally, length of the flow channels or cells, in some embodiments, is at least 100 mm or at least 110 mm. In some embodiments, length of the flow channels of cells of the monolithic structural has treatment body is at least 120 mm or at least 125 mm. The flow channels or cells can have any desired cross-sectional geometry, including various polygonal geometries such as triangular, square, or hexagonal.

[0049] The average inner partition wall thickness of an extruded monolithic structural gas treatment body described herein is 0.1 mm to 1.5 mm. In some embodiments, the average inner partition wall thickness can be 0.3 mm to 0.7 mm, or 0.4 mm to 0.6 mm. The thickness of the outer peripheral wall and inner partition walls are determined with a caliper or micrometer with a resolution of 0.01 mm. FIG. 3 illustrates a method of determining the average thickness of the outer peripheral wall 10 and inner partition walls 11. The thickness of the outer peripheral wall 10 is measured in twelve (12) different locations on the monolithic structural gas treatment body. The twelve measuring locations comprise three points on each side of the square outer peripheral wall as demonstrated in FIG. 3. The average thickness of the outer peripheral wall 10 is calculated by averaging the values obtained from the twelve (12) measurements. Similarly, the average thickness of the inner partition walls 11 is determined by initially measuring the thickness of the inner partition walls 11 at twelve (12) different locations throughout the monolithic body. The inner partition walls 11 are measured in the horizontal and vertical directions as displayed in FIG. 3. The average thickness of the inner partition walls 11 is calculated by averaging the values obtained in the twelve measurements.

[0050] Thin inner partition walls can assist in achieving high cpsi without sacrificing open frontal area of the monolithic structural gas treatment body and / or inducing undesirable pressure drop sustained by gas flow through the monolithic structural body. The open frontal area (OF A) of an extruded monolithic structural gas treatment body is that portion of the body cross-section available for gas flow on a cross-sectional surface normal to the direction of gas flow. An increased open frontal area can result in more efficient fluid flow characteristics within the monolithic body, which can decrease the pressure drop sustained by fluids passing through the monolithic structural gas treatment body. An extruded monolithic structural gas treatment body described herein, in some embodiments, has an OFA of at least 40 percent or at least 50 percent. In some embodiments, a monolithic structural gas treatment body has an OFA of at least 60 percent or at least 70 percent. OFA of an extruded monolithic structural gas treatment body can range from 40-90 percent, 65-90 percent, 65-85 percent, 70-90 percent, 70-80 percent, 75-85 percent, or 80-90 percent, in some embodiments.

[0051] An extruded monolithic structural gas treatment body described herein, in some embodiments, also has a hydraulic diameter of at least 60 mm or at least 100 mm. The hydraulic diameter of the structural gas treatment body is defined as being equal to the cross-sectional area perpendicular to the direction of flow through the body multiplied by four and divided by the value of the outer perimeter of the outer peripheral wall. When the monolithic structural gas treatment body displays a circular cross-sectional geometry, the hydraulic diameter is equal to the diameter of the circular cross-sectional area. In the case of a square cross-sectional geometry, the hydraulic diameter is equal to the length or width of a side. Accordingly, the hydraulic diameter characterizes the size of the monolithic structural gas treatment body with larger values of hydraulic diameter corresponding to larger monolithic structural gas treatment bodies. In some embodiments, the monolithic structural gas treatment body has a hydraulic diameter of at least 100 mm, at least 120 mm, or at least 130 mm. The hydraulic diameter of the monolithic structural gas treatment body can range from 100 mm to 150 mm, from 120 mm to 150 mm, or from 130 mm to 150 mm. In some embodiments, hydraulic diameter of the monolithic structural gas treatment body can be greater than 150 mm. Hydraulic diameter of the monolithic structure gas treatment body can have an upper limit of 300 mm, in some embodiments. Monolithic structural gas treatment bodies described herein, in some embodiments, can swell when exposed to water. In some embodiments, for example, the hydraulic diameter of the monolithic structural gas treatment body increases by 1-7 percent or 7-30 percent upon exposure to water. Increases in hydraulic diameter upon water exposure are determined according to the following protocol. A monolithic structural gas treatment body described herein is initially dried under vacuum at 65°C for two hours. The dried monolithic structural gas treatment body is subsequently immersed in water having a temperature of 80°C for two hours. Upon completion of the two hours, the monolithic structural gas treatment body is removed from the water, and the hydraulic diameter is measured upon removal from the water.

[0052] An extruded monolithic structural gas treatment body described herein can exhibit a dry crush strength of at least 0.4 kg / cm2. In some embodiments, the dry crush strength of an extruded monolithic structural gas treatment body is in the range of 0.4 to 15 kg / cm2. Moreover, an extruded monolithic structural has treatment body can exhibit a hot boil crush strength of at least 0.1 kg / cm2. In some embodiments, the hot boil crush strength of an extruded monolithic structural gas treatment body is in the range of 0.1 to 5 kg / cm2. Dry crush strength and hot boil crush strength values are determined according to the following protocol. Extruded monolithic structural adsorber is trimmed into a cube approximately 25x25x25mm in dimensions - ridges are removed via sandpaper after trimming. Samples are weighed and height, width and length measurements are collected with a caliper. Testing is conducted using a crush test machine (MTS Criterion C42) setup with a 1000N load cell. Each sample is placed in the center of the crush platens with a %” piece of silicone closed cell foam on the top and bottom covering the area of the surface. Samples are crushed with the cell orientation perpendicular to the force at a speed of 0.1 in / min. Once catastrophic failure is observed by the machine by registering 5 N drop in force, the peak load is recorded and converted into a compression force response by dividing the force by the measured area of the sample. For each material, testing is conducted under two different conditions dry and hot post boil. For the dry condition, parts are tested at ambient conditions. For the hot post boil test condition, parts are placed in boiling DI water for 1 hour directly next to the test unit; after one hour the sample is extracted, weighed, and dimensionally measured prior to being placed back into boiling DI water next to the test fixture. After an additional 5 minutes of heating, the part is removed and crushed within 30 seconds of removal. Reported values are the average of four crush samples from the same monolith. An extruded monolithic structural gas treatment body described herein, in some embodiments, has a CO2 adsorption capacity of at least 0.5 mmol / g, at least 1 mmol / g, at least 1.2 mmol / g, or at least 1.5 mmol / g of particulate CO2 sorbent in the monolithic structural gas treatment body. Adsorption capacity of the extruded monolithic structural gas treatment body can be 1 mmol / g of particulate CO2 sorbent to 5 mmol / g of particulate CO2 sorbent, in some embodiments. CO2 adsorption by monolithic structural gas treatment bodies described herein is measured by thermogravimetric analysis (TA Instruments TGA) under the conditions of 35°C, 2% CO2, 20% O2, and the balance N2. The monolithic structural gas treatment body in desorbed of CO2 at 110°C under N2 for 60 minutes prior to the 120 minute CO2 adsorption cycle. Change in mass of the monolithic structural gas treatment body between post desorption and CO2 adsorption equilibrium is employed to calculate the CO2 adsorption.

[0053] Additionally, an extruded monolithic structural gas treatment body described herein, in some embodiments, reaches 70% CO2 adsorption equilibrium capacity on through flow testing (TFT) basis in 70 minutes or less. In some embodiments, the extruded monolithic structural gas treatment body reaches such equilibrium in less than 50 minutes or less than 20 minutes. 70% CO2 adsorption equilibrium capacity on TFT basis can be reached by an extruded monolithic structural gas treatment body described herein in a time period of 10-70 minutes or 15-60 minutes, in some embodiments. Equilibrium testing conditions are as follows:

[0054] • Rate was measured with through flow testing (TFT) to measure the gas concentration after the part to determine the rate of adsorption. Conditions: Adsorption = 35°C, 450ppm CO2, 2% H2O, 20% O2; SV=37000

[0055] • Desorption = 105°C, 100% N2.

[0056] • Under these conditions, adsorption was measured for 360 minutes - equilibrium capacity is defined as the total CO2 adsorbed over that timeframe

[0057] • Equilibrium capacity = (C02in (at t) — C02out (at t)) * At , wherein t is from 0-360 minutes and At is 1 / 6 minutes.

[0058] As described herein, the extruded monolithic structural gas treatment bodies are formed from an extruded batch composition wherein a particulate CO2 sorbent is associated with a polymeric binder phase. In such as construct, the particulate CO2 sorbent is dispersed throughout the inner partition walls and associated with the hierarchical pore structure described herein. In some embodiments, the extruded monolithic structural gas treatment body is formed of an extrusion batch composition described in Section I above. Alternatively, the extruded monolithic structural gas treatment body is formed of an extrusion batch composition described in Section II above. Accordingly, the monolithic structural gas treatment body will contain polymeric binder and particulate CO2 sorbent consistent with the extrusion batches of Section I or Section II. In some embodiments, the polymeric binder phase is present in an amount of 1-40 weight percent or 5-35 weight percent of the gas treatment body. The particulate CO2 sorbent is present in an amount of 60-90 weight percent of the gas treatment body. Additionally, reinforcement agent, when employed, can be present in an amount of 0.5-10 weight percent of the gas treatment body.

[0059] Consistent with employing steam to desorb CO2 captured by monolithic structural gas treatment bodies described herein, the polymeric binder, in some embodiments, is insoluble in boiling water. In being insoluble, the polymeric binder can have less than 0.1% solubility in boiling water. In some embodiments, for example, the polymer binder does not include polyvinyl alcohol (PVA) or cellulose or cellulose-based binders such as carboxymethyl cellulose (CMC) and related materials.

[0060] A monolithic structural gas treatment body described herein, in some embodiments, can exhibit a CO2 sorbent utilization efficiency of at least 60 percent or at least 70 percent. In some embodiments, CO2 sorbent utilization efficiency of the monolithic structural gas treatment body can be 60-100 percent. CO2 sorbent utilization efficiency is the CO2 adsorption capacity of the monolithic structural gas treatment body divided by the CO2 adsorption capacity of the virgin particulate CO2 sorbent, as determined by TGA above.

[0061] IV. Methods of Making Extruded Monolithic Structural Gas Treatment Bodies (Adsorbers)

[0062] In another aspect, methods of making extruded monolithic structural gas treatment bodies are described herein. A method, in some embodiments, comprises providing an extrusion batch including a polymeric binder, and a particulate CO2 sorbent, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf. The extrusion batch is extruded into the monolithic structural body comprising a plurality of inner partition walls formed from the extrusion batch wherein the particulate CO2 sorbent is associated with the polymeric binder, and the inner partition walls defining flow channels through the monolithic structural body. The resultant extruded monolithic structural body can have any composition and / or properties described in Section III herein. Moreover, extrusion batches for the method can be selected from Sections I and II herein.

[0063] The extrusion system may include extruder machines, a filter or screen, and an extrusion die. The filter or screen may be utilized to facilitate passage of the extrusion batch composition through the die while minimizing shear stresses. Particles that can clog the die are removed without removing the CO2 sorbent, binders, pore formers, glass fibers and / or other reinforcement agents that provide advantageous product properties. In some embodiments, for example, a wedge-shaped screen is employed to prevent or mitigate removal of fiber reinforcements from the extrusion batch composition.

[0064] Once extruded, the monolithic structural gas treatment body can be dried at ambient temperature or heated to at least 100°C for drying. Additionally, the extruded monolithic structural gas treatment body can also be washed to remove salt pore former and water soluble extrusion aids.

[0065] V. Methods of CO2 Capture

[0066] In another aspect, methods of capturing CO2 from a gas stream are provided. A method, in some embodiments, comprises providing an extruded monolithic structural gas treatment body including a plurality of inner partition walls formed of an extruded batch composition wherein a particulate CO2 sorbent is associated with a polymeric binder phase, the inner partition walls defining flow channels through the monolithic structural gas treatment body. The gas stream comprising CO2 is flowed through the flow channels and captured with the CO2 sorbent. The captured CO2 can be subsequently desorbed from the monolithic structural gas treatment body for downstream processing, including storage or sequestration. In some embodiments, the monolithic structural gas treatment body is heated with steam or heated nitrogen (N2) to desorb the captured CO2. In some embodiments, the structural gas treatment body is isolated from the gas stream, subjected to vacuum to evacuate the gas, steam is flowed through the adsorber wherein a portion of the steam is condensed on the adsorber desorbing the CO2 and carrying away the desorbed CO2 for further processing, and the adsorber is subject to vacuum again to evaporate the condensed steam and cool the adsorber, prior to removing isolation to start another adsorption cycle to capture the CO2. The extruded monolithic structural body can have any composition and / or properties described in Section III herein above. Additionally, the gas stream can be ambient air or a flue gas stream from a combustion source. Such combustions sources include electrical power generation facilities and other industrial emission facilities. In some embodiments, flue gas streams are diluted with ambient air and / or otherwise processed or cooled prior to contact with structural gas treatment bodies described herein. These and other embodiments are further illustrated by the following non-limiting examples.

[0067] EXAMPLE 1 - Extrusion Batch Compositions

[0068] A total of seven extrusion batches having composition and properties described herein were prepared according to the Table 3 below. Three of the extrusion batch compositions employed organic solvent (Organic 1-3), while the remaining three extrusion batch compositions were aqueous-based (Aq 1-7).

[0069] Table 3 - Extrusion Batch Compositions (wt.%)

[0070] * 20-25% ethylene content

[0071] **SILRES® MK designation from Wacker Chemie AG f STYRONAL® 656 from BASF ff ACRONAL® 296D from BASF

[0072] * ACRONAL® 4810 from BASF

[0073] J} BUTVAR® B-76 from Eastman Chemical Table 3 - Extrusion Batch Compositions (wt.%) (con’t)

[0074] EXAMPLE 2 - Extruded Monolithic Structural Gas Treatment Bodies (CO 2 Adsorbers) Each of the extrusion batch compositions in Example 1 were extruded into a monolithic structural gas treatment body for the capture of CO2 as set forth in Tables 4 and 5. The extruded monolithic bodies were honeycombs with the cell count and hydraulic diameter listed in Table 4.

[0075] Table 4 - Structural Parameters of Extruded Monolithic Structural Gas Treatment Bodies (Adsorbers)

[0076] Table 5 - Extruded Monolithic Structural Gas Treatment Bodies (Adsorbers)

[0077] FIG. 4 is a scanning electron microscopy (SEM) image of a flow channel of the honeycomb monolith of Sample 1. Additionally, FIG. 5 is a picture of a section of Sample 1 illustrating the flow channels. FIG. 6 is a picture of the honeycomb monolith of Sample 2. As Sample 2 exhibits a lower cell count, the inner partition wall thickness increases. The extruded honeycomb monolithic bodies of Samples 1-8 exhibited CO2 adsorption capabilities with efficient CO2 sorbent utilization as provided in Table 5. As set forth herein, CO2 adsorption capacity was determined by TGA.

[0078] Various embodiments of the invention have been described in fulfillment of the various objectives of the invention. It should be recognized that these embodiments are merely illustrative of the principles of the present invention. Numerous modifications and adaptations thereof will be readily apparent to those skilled in the art without departing from the spirit and scope of the invention.

Claims

CLAIMS1. An extrusion batch composition for a monolithic adsorber comprising: a polymeric binder at least partially solubilized in an organic solvent; and a particulate carbon dioxide (CO2) sorbent, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf.

2. The extrusion batch composition of claim 1, wherein the particulate CO2 sorbent has a particle size of 1-100 pm.

3. The extrusion batch composition of claim 1, wherein the particulate CO2 sorbent has a D10 particle size of 0.5-3 pm.

4. The extrusion batch composition of claim 3, wherein the particulate CO2 sorbent has a D90 particle size of 15-30 pm.

5. The extrusion batch composition of claim 1, wherein the particulate CO2 sorbent is present in an amount of 15-70 weight percent of the extrusion batch.

6. The extrusion batch composition of claim 1, wherein the particulate CO2 sorbent is present in an amount of 20-40 weight percent of the extrusion batch.

7. The extrusion batch composition of claim 1, wherein the polymeric binder is present in an amount of 2-20 weight percent of the extrusion batch.

8. The extrusion batch composition of claim 1, wherein the particulate CO2 sorbent comprises aminated particles.

9. The extrusion batch composition of claim 8, wherein the aminated particles are polymeric.

10. The extrusion batch composition of claim 1 further comprising a pore former component.

11. The extrusion batch composition of claim 10, wherein the pore former component comprises one or more water soluble particulate species.

12. The extrusion batch composition of claim 11, wherein the water soluble particulate species is selected from the group consisting of salts and sugars.

13. The extrusion batch composition of claim 10, wherein the pore former component is present in an amount of 1-50 weight percent of the extrusion batch.

14. The extrusion batch composition of claim 1 further comprising a reinforcing agent.

15. The extrusion batch composition of claim 14, wherein the reinforcing agent comprises glass fibers, ceramic fibers, polymeric fibers, or mixtures thereof.

16. The extrusion batch composition of claim 14, wherein the reinforcing agent is present in the extrusion batch in an amount of 0.5-10 weight percent.

17. The extrusion batch composition of claim 1, wherein the polymeric phase is a thermoplastic.

18. The extrusion batch composition of claim 1, wherein polymer of the polymeric binder comprises heterocyclic monomeric units.

19. The extrusion batch composition of claim 1, wherein polymer of the polymeric phase comprises acetal monomeric units.

20. The extrusion batch composition of claim 19, wherein the acetal monomeric units are cyclic.

21. The extrusion batch composition of claim 1 further comprising an extrusion aid component.

22. The extrusion batch composition of claim 21, wherein the extrusion aid component is present in an amount of 5-30 weight percent of the extrusion batch composition.

23. An extrusion batch composition for a monolithic adsorber comprising: a particulate polymeric phase and a particulate carbon dioxide (CO2) sorbent disposed in an aqueous or aqueous-based continuous phase, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf.

24. The extrusion batch composition of claim 23 further comprising a viscosity modifier at least partially solubilized in the aqueous or aqueous-based continuous phase,25. The extrusion batch composition of claim 23, wherein the particulate CO2 sorbent has a DIO particle size of 0.5-3 pm.

26. The extrusion batch composition of claim 25, wherein the particulate CO2 sorbent has a D90 particle size of 15-30 pm.

27. The extrusion batch composition of claim 23, wherein the particulate CO2 sorbent is present in an amount of 15-70 weight percent of the extrusion batch.

28. The extrusion batch composition of claim 23, wherein the particulate CO2 sorbent is present in an amount of 20-40 weight percent of the extrusion batch.

29. The extrusion batch composition of claim 23, wherein the particulate CO2 sorbent comprises aminated particles.

30. The extrusion batch composition of claim 29, wherein the aminated particles are polymeric.

31. The extrusion batch composition of claim 23, wherein the particulate polymeric phase has a particle size of 0.05 pm to 100 pm.

32. The extrusion batch composition of claim 23, wherein the particulate polymeric phase has a DIO particle size of 0.01pm to 5 pm.

33. The extrusion batch composition of claim 32, wherein the particulate polymeric phase has a D90 particle size of 0.1 pm to 20 pm or 10-60 pm34. The extrusion batch composition of claim 23, wherein the particulate polymeric phase is present in an amount of 2-20 weight percent of the extrusion batch composition.

35. The extrusion batch composition of claim 23, wherein the particulate polymeric phase comprises an olefin-acetate copolymer, aryl acrylate, or polyalkyl-siloxane.

36. The extrusion batch composition of claim 23, wherein the particulate polymeric phase is formed of polyalkyl-siloxane.

37. The extrusion batch composition of claim 23 further comprising a reinforcing agent including glass fibers, ceramic fibers, polymeric fibers, or mixtures thereof.

38. The extrusion batch composition of claim 23, wherein the viscosity modifier comprises one or more polyalkylene oxides.

39. The extrusion batch composition of claim 23, wherein the viscosity modifier is present in an amount of 1-10 weight percent of the extrusion batch composition.

40. The extrusion batch of claim 23, wherein the particulate polymeric phase comprises at least two differing particulate polymeric species.

41. The extrusion batch of claim 40, wherein the at least two differing particulate polymeric species are thermoplastics.

42. The extrusion batch of claim 41, wherein the particulate polymeric phase comprises a first particulate polymeric species of olefin-acetate copolymer or aryl-acrylate copolymer and a second particulate polymeric species comprising heterocyclic monomeric units.

43. The extrusion batch of claim 42, wherein the heterocyclic monomeric units include acetal monomeric units.

44. The extrusion batch of claim 42, wherein a ratio of the first particulate polymeric species to the second particulate polymeric species ranges from 2:1 to 1 :2.

45. An extruded monolithic structural gas treatment body comprising: a plurality of inner partition walls formed of an extruded batch composition, the batch composition including a particulate carbon dioxide (CO2) sorbent is associated with a polymeric binder phase, the inner partition walls defining flow channels through the monolithic structural gas treatment body.

46. The extruded monolithic structural gas treatment body of claim 45 having a macroporosity of 0.05-2 cm3 / g in pores of diameter ranging from 0.1 pm to 50 pm.

47. The extruded monolithic structural gas treatment body of claim 45 having a hierarchical pore structure including a mesoporosity of 0.01-0.5 cm3 / g in pores of diameter ranging from 1- 100 nm.

48. The extruded monolithic structural gas treatment body of claim 45 having a CO2 adsorption capacity of at least 0.5 mmol / g of the CO2 particulate sorbent in the monolithic structural gas treatment body.

49. The extruded monolithic structural gas treatment body of claim 45 having a CO2 adsorption capacity of at least 1.2 mmol / g of the CO2 particulate sorbent in the monolithic structural gas treatment body.

50. The extruded monolithic structural gas treatment body of claim 45 having a CO2 adsorption capacity of at least 1.5 mmol / g of the CO2 particulate sorbent in the monolithic structural gas treatment body.

51. The extruded monolithic structural gas treatment body of claim 45 having a CO2 adsorption capacity of 1 mmol / g to 5 mmol / g of the CO2 particulate sorbent in the monolithic structural gas treatment body.

52. The extruded monolithic structural gas treatment body of claim 45, wherein the polymeric binder phase is present in an amount of 5-40 weight percent of the gas treatment body.

53. The extruded monolithic structural gas treatment body of claim 45, wherein the particulate CO2 sorbent is present in an amount of 60-95 weight percent of the gas treatment body.

54. The extruded monolithic structural has treatment body of claim 45, wherein the particulate CO2 sorbent is present in an amount of 70-80 weight percent of the gas treatment body.

55. The extruded monolithic structural gas treatment body of claim 45, wherein the polymeric binder comprises polymer including heterocyclic monomeric units.

56. The extruded monolithic structural gas treatment body of claim 55, wherein the heterocyclic monomeric units comprise acetal monomeric units.

57. The extruded monolithic structural gas treatment body of claim 45, wherein the polymeric binder comprises olefm-acetate copolymer.

58. The extruded monolithic structural gas treatment body of claim 55, wherein the polymeric binder phase comprises a mixture of two or more polymeric species.

59. The extruded monolithic structural gas treatment body of claim 58, wherein the polymeric binder phase comprises a first polymeric species of olefin-acetate copolymer or arylacrylate copolymer and a second polymeric species comprising heterocyclic monomeric units.

60. The extruded monolithic structural gas treatment body of claim 59, wherein a ratio of the first polymeric species to the second polymeric species ranges from 2: 1 to 1 :2.

61. The extruded monolithic structural gas treatment body of claim 45, having at least 50 cells per square inch.

62. The extruded monolithic structural gas treatment body having a hydraulic diameter of at least 100 mm.

63. The extruded monolithic structural gas treatment body of claim 45, having an open frontal area of at least 40 percent.

64. The extruded monolithic structural gas treatment body of claim 45, wherein the inner partition walls have average thickness of the inner partition walls of 0.1 mm to 1.5 mm.

65. The extruded monolithic structural gas treatment body of claim 45, wherein the particulate CO2 sorbent comprises aminated particles.

66. The extruded monolithic structural gas treatment body of claim 65, wherein the aminated particles are polymeric.

67. The extruded monolithic structural gas treatment body of claim 45 further comprising a reinforcing agent including glass fibers, ceramic fibers, polymeric fibers, or mixtures thereof.

68. The extruded monolithic structural gas treatment body of claim 45 having a CO2 sorbent utilization efficiency of 60-99 percent.

69. The extruded monolithic structural gas treatment body of claim 45 having a dry crush strength of 0.4-15 kg / cm2and / or a hot boil crush strength of 0.1-5 kg / cm2.

70. A method of making a monolithic structural body for adsorption of carbon dioxide (CO2) comprising: providing an extrusion batch including a polymeric binder, and a particulate CO2 sorbent, wherein the extrusion batch has a plasticity of 0.06 to 1.3 kgf; and extruding the extrusion batch into the monolithic structural body comprising a plurality of inner partition walls formed from the extrusion batch wherein the particulate CO2 sorbent is associated with the polymeric binder, and the inner partition walls defining flow channels through the monolithic structural body.

71. The method of claim 70, wherein the monolithic structural body has a macroporosity of 0.05-2 cm3 / g in pores of diameter ranging from 0.1 pm to 50 pm.

72. The method of claim 70, wherein the monolithic structural body has a hierarchical pore structure including a mesoporosity of 0.01-0.5 cm3 / g in pores of diameter ranging from 1-100 nm.

73. The method of claim 70, wherein the monolithic structural body has a CO2 adsorption capacity of at least 0.5 mmol / g of the CO2 particulate sorbent in the monolithic structural body.

74. The method of claim 70, wherein the monolithic structural body has a CO2 adsorption capacity of 1 mmol / g to 5 mmol / g of the CO2 particulate sorbent in the monolithic structural body.

75. The method of claim 70, wherein the polymeric binder is present in an amount of 5-40 weight percent of the monolithic structural body.

76. The method of claim 70, wherein the particulate CO2 sorbent is present in an amount of 60-95 weight percent of the monolithic structural body.

77. The method of claim 70, wherein the polymeric binder comprises polymer including heterocyclic monomeric units.

78. The method of claim 77, wherein the heterocyclic monomeric units comprise acetal monomeric units.

79. The method of claim 70, wherein the polymeric binder comprises olefin-acetate copolymer.

80. The method of claim 70, wherein the polymeric binder phase comprises a mixture of two or more polymeric species.

81. The method of claim 80, wherein the polymeric binder phase comprises a first polymeric species of olefin-acetate copolymer or aryl-acrylate copolymer and a second polymeric species comprising heterocyclic monomeric units.

82. The method of claim 82, wherein a ratio of the first polymeric species to the second polymeric species ranges from 2:1 to 1 :2.

83. The method of claim 70, wherein the polymeric binder is solubilized in organic solvent.

84. The method of claim 70, wherein the polymeric binder and the particulate CO2 sorbent are disposed or dispersed in an aqueous or aqueous-based continuous phase.

85. The method of claim 70, wherein the particulate CO2 sorbent comprises aminated particles.

86. The method of claim 85, wherein the aminated particles are polymeric.

87. The method of claim 70, wherein the monolithic structural body has a CO2 sorbent utilization efficiency of at least 60 percent.

88. The method of claim 70, wherein the monolithic structural body has a CO2 sorbent utilization efficiency of at least 70 percent.

89. The method of claim 70, wherein the monolithic structural body has a CO2 sorbent utilization efficiency of 60-100 percent.

90. A method of capturing carbon dioxide (CO2) from a gas stream comprising: providing an extruded monolithic structural gas treatment body including a plurality of inner partition walls formed of an extruded batch composition wherein a particulate CO2 sorbent is associated with a polymeric binder phase, the inner partition walls defining flow channels through the monolithic structural gas treatment body; flowing the gas stream through the flow channels; and capturing CO2 from the gas stream with the particulate CO2 sorbent.

91. The method of claim 90, wherein the extruded monolithic structural gas treatment body has a macroporosity of 0.05-2 cm3 / g in pores of diameter ranging from 0.1 pm to 50 pm.

92. The method of claim 90, wherein the extruded monolithic structural gas treatment body has a hierarchical pore structure including a mesoporosity of 0.01-0.5 cm3 / g in pores of diameter ranging from 1-100 nm.

93. The method of claim 90, wherein the extruded monolithic structural gas treatment body has a CO2 adsorption capacity of at least 0.5 mmol / g of the CO2 particulate sorbent in the monolithic structural gas treatment body.

94. The method of claim 90, wherein the extruded monolithic structural gas treatment body has a CO2 adsorption capacity of at least 1.5 mmol / g of the CO2 particulate sorbent in the monolithic structural gas treatment body.

95. The method of claim 90, wherein the polymeric binder phase is present in an amount of 5-40 weight percent of the gas treatment body.

96. The method of claim 90, wherein the particulate CO2 sorbent is present in an amount of 60-95 weight percent of the gas treatment body.

97. The method of claim 90, wherein the polymeric binder phase comprises polymer including heterocyclic monomeric units.

98. The method of claim 97, wherein the heterocyclic monomeric units comprise acetal monomeric units.

99. The method of claim 90, wherein the polymeric binder phase comprises olefm-acetate copolymer.

100. The method of claim 90, wherein the polymeric binder phase comprises a mixture of two or more polymeric species.

101. The method of claim 90, wherein the polymeric binder phase comprises a first polymeric species of olefm-acetate copolymer or aryl-aciylate copolymer and a second polymeric species comprising heterocyclic monomeric units.

102. The method of claim 101, wherein a ratio of the first polymeric species to the second polymeric species ranges from 2:1 to 1:2.

103. The method of claim 90, wherein the extruded monolithic structural gas treatment body has at least 50 cells per square inch.

104. The method of claim 90, wherein the extruded monolithic structural gas treatment body has a hydraulic diameter of at least 100 mm.

105. The method of claim 90, wherein the extruded monolithic structural gas treatment body has an open frontal area of at least 65 percent.

106. The method of claim 90, wherein the inner partition walls of the extruded monolithic structural gas treatment body have average thickness of the inner partition walls of 0.1 mm to 1.5 mm.

107. The method of claim 90, wherein the particulate CO2 sorbent comprises aminated particles.

108. The method of claim 90, wherein the extruded monolithic structural gas treatment body has a CO2 sorbent utilization efficiency of 60-95 percent.

109. The method of claim 90, wherein the gas stream is ambient air.

110. The method of claim 90, wherein the gas stream is a flue gas stream.

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