Activated Carbon with Homogeneous Metal Loading
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Solution Overview
Problem
Existing methods for producing spherical activated carbon with catalytic activity are costly and inefficient, requiring post-production impregnation with metal catalysts, which is inconvenient and leads to non-homogeneous distribution and reduced adsorption capacity.
Innovation Solution
Intertropolymerization of metals into carbonaceous organic polymers during their formation, followed by carbonization and activation, allowing for homogeneous metal loading throughout the activated carbon structure, reducing production time and metal requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If post-production impregnation with metal catalysts is used, then catalytic activity is achieved, but metal distribution is non-homogeneous and adsorption capacity is reduced
Solution Approach 1:
The patent applies preliminary action by incorporating metal catalysts into the polymer matrix during the polymerization process, before carbonization and activation. This ensures homogeneous metal distribution throughout the activated carbon structure, eliminating the non-homogeneous distribution problem associated with post-production impregnation methods.
Solution Approach 2:
The patent merges the catalyst incorporation step with the polymer synthesis step. By combining metal salt addition with polymerization in a single process sequence, the metal catalysts become uniformly distributed within the polymer matrix before carbonization, avoiding the need for separate impregnation steps and preventing adsorption capacity loss.
2Reliability
If post-production impregnation is used, then catalytic activity is achieved, but production time is extended and metal usage increases
Solution Approach 1:
The patent performs catalyst incorporation during polymerization, completing the catalytic function preparation before carbonization and activation. This eliminates the need for separate impregnation and drying steps, significantly reducing production time while maintaining catalytic activity.
Solution Approach 2:
The patent combines multiple process steps (catalyst addition, polymerization, and catalyst incorporation) into a single integrated process. This merging of operations reduces the number of discrete steps, decreases production time, and lowers metal usage by achieving uniform distribution during synthesis rather than requiring excess metal for post-impregnation.
3Reliability
If conventional impregnation methods are used, then catalytic function is added, but adsorption capacity is reduced due to pore blockage
Solution Approach 1:
The patent incorporates metal catalysts during polymerization, distributing them throughout the polymer matrix before carbonization. This preliminary incorporation ensures that metals are uniformly dispersed at the molecular level, preventing pore blockage and preserving adsorption capacity while still providing catalytic function.
Solution Approach 2:
The patent achieves local quality by distributing metal catalysts uniformly throughout the polymer matrix at the molecular level during polymerization. This localized, homogeneous distribution ensures catalytic activity throughout the material while preventing localized pore blockage, maintaining both catalytic function and adsorption capacity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach results in activated carbon with enhanced catalytic activity and improved protection against both chemical and biological poisons, with reduced energy consumption and metal usage, achieving superior performance compared to conventionally impregnated activated carbon.
Implementation Method 1
carbonaceous organic polymers into which, in the course of their formation (i.e. their production or synthesis, respectively), at least one metal, preferably in the form of a metal atom and/or of a metal ion, has been interpolymerized
Implementation Method 2
carbonization and subsequent activation of carbonaceous organic polymers
Implementation Method 3
carbonization and subsequent activation of carbonaceous organic polymers
Implementation Method 4
activated carbon has fairly unspecific adsorptive properties and therefore is the most widely used adsorbent
Data Source
AI summary
The invention refers to a process for producing activated carbon having catalytic activity by carbonization and subsequent activation of carbonaceous organic polymers, wherein carbonaceous organic polymers into which, in the course of their formation, at least one metal atom and/or metal ion has been interpolymerized are subjected to a carbonization and subsequent activation, forming an activated carbon loaded with the metal atom and/or metal ion. This obviates subsequent loading with the metal by costly and inconvenient impregnation after the activated carbon has been produced. By endowing the starting materials with the metal, moreover, a more homogeneous loading is achieved, and that homogeneous throughout all kinds of pores (i.e. macropores, mesopores and micropores), so that catalytic activity is enhanced, and in addition, activation is accelerated.