Solid Adsorbent Fiber Manufacturing via Dip-Coating
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Solution Overview
Problem
Current beaded adsorbent systems have low packing density, are brittle and prone to dusting, limiting throughput due to friction and impact intolerance, and suffer from diffusion limitations that slow kinetics, while structured adsorbent beds face challenges in high adsorbent particle loading during commercial production.
Innovation Solution
A method of manufacturing supported solid adsorbent fibers by dip-coating a solid fiber support with a polymeric dope containing adsorbent particles and a binder, followed by spraying a coagulant to solidify the binder, which includes optional steps like degassing, solvent extraction, and applying functional or protective layers, to enhance adsorbent loading and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the mass or average diameter of beads is increased to increase throughput, then the attrition velocity increases and throughput improves, but the kinetics slow down due to diffusion limitations
Solution Approach 1:
The invention segments the adsorbent bed into a structured configuration where adsorbent particles are arranged in a fixed, organized pattern rather than as loose beads. This segmentation allows for optimized flow paths and reduced diffusion distances while maintaining high throughput capacity.
Solution Approach 2:
The invention transitions from a one-dimensional bead flow system to a multi-dimensional structured bed where adsorbent particles are positioned in specific spatial arrangements. This dimensional change enables simultaneous optimization of throughput (via parallel flow paths) and kinetics (via reduced diffusion distances to multiple adsorption sites).
2Quantity of substance
If conventional beaded adsorbents are used to achieve high packing density, then the bed structure is simple, but the beads are brittle and prone to dusting due to friction and impacts
Solution Approach 1:
The invention uses composite materials where adsorbent particles are embedded in or combined with a more mechanically robust matrix or support structure. This composite approach maintains high packing density while the supporting structure provides mechanical strength and resistance to friction-induced dusting.
Solution Approach 2:
The structured bed configuration provides a predetermined mechanical framework that cushions and distributes mechanical stresses before they can cause particle fracture. The fixed structure absorbs impact forces that would otherwise cause brittle bead breakage and dusting during operation.
3Reliability
If gas velocity is limited to 80-90% of fluidization velocity to avoid dusting, then dusting is prevented, but the flow rates and throughput are limited
Solution Approach 1:
The invention creates a dynamically stable structured bed that maintains its configuration at higher gas velocities than conventional fluidized beds. The fixed structural framework allows the system to operate dynamically at elevated velocities without the particles becoming fluidized and causing dusting, thereby decoupling the dusting prevention constraint from the velocity limit.
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
The method increases adsorbent particle loading without discontinuities, improves mechanical strength, and enhances kinetic performance by reducing the characteristic dimension of the adsorbent structure, thereby increasing throughput and efficiency in gas separation processes.
Implementation Method 1
spraying the dip-coated solid fiber support with a coagulant liquid such that the dissolved polymeric binder coated on the solid fiber support as part of the polymeric dope is solidified
Data Source
AI summary
A solid adsorbent fiber includes a solid support fiber that is enveloped by a solidified polymeric binder and also adsorbent particles.