Monolith with catalytic or sorbent beads
A monolith for catalytic or sorbent purposes. The monolith includes a substrate sheet having attached thereto a plurality of catalytic or sorbent beads. Each bead has a diameter of at least fifty microns. The substrate sheet at least partially defines one or more channels through the monolith. Fluid flowing through the channels will contact the beads for catalytic or sorbent purposes.
1. A method of making a monolith for catalytic or sorbent purposes, comprising the steps of:
(a) providing a substrate sheet having a top surface and a bottom surface;
(b) coating both of the surfaces with an adhesive composition, wherein both of the surfaces are coated at the same location along the substrate sheet for at least a portion of the substrate sheet;
(c) contacting both of the coated surfaces with a plurality of catalytic or sorbent beads so that the beads are attached to the substrate sheet, each bead having a diameter of at least 50 microns, each bead having catalytic or sorbent material on an exposed surface of the bead; and
(d) providing a separator sheet to separate the catalytic or sorbent beads on adjacent coated surfaces of the substrate sheet.
2. The method of claim 1 , wherein the adhesive composition being an organic adhesive.
3. The method of claim 1 , further comprising spirally winding the substrate sheet of step (c) and the separator sheet of step (d) to form a monolith, the separator sheet at least partially defining one or more channels through the monolith.
4. The method of claim 3 , further comprising disposing the spiral wound monolith into a tube.
5. The method of claim 1 , further comprising folding the substrate sheet of step (c) and the separator sheet of step (d) back and forth to define a series of adjacent surfaces.
6. The method of claim 1 , further comprising providing a plurality of substrate sheets in step (a) and a plurality of separator sheets in step (d), further arranging the plurality of substrate sheets of step (c) one adjacent the next in a stack, and further arranging the separator sheets between the adjacent substrate sheets, the separator sheets at least partially defining one or more channels through the monolith.
7. The method of claim 1 , wherein the beads being catalytic beads effective to catalyze one or more reactions selected from the group consisting of reforming of methanol, conversion of CO to CO 2 , water-gas shift, oxidation of methanol to formaldehyde, converting ozone to oxygen, oxidation of a hydrocarbon, and reduction of NO x.
8. The method of claim 1 , wherein the beads being sorbent beads effective to (a) sorb CO 2 or SO x or NO x from a gas, (b) sorb CO 2 or sulfur compounds or heavy hydrocarbons from natural gas, (c) separate CO 2 or hydrogen or another gas from syngas, or (d) separate H 2 O from a gas.
9. The method of claim 1 , wherein the beads can perform their catalytic or sorbent function effectively at a process temperature between 4° C. and 300° C.
10. The method of claim 1 , wherein the separator sheet is corrugated.
11. A monolith for catalytic or sorbent purposes, the monolith comprising:
a substrate sheet having a top surface and a bottom surface, the top surface and the bottom surface being coated with an adhesive such that both of the surfaces are coated at the same location along the substrate sheet for at least a portion of the substrate,
a separator sheet,
wherein both of the coated surfaces of the substrate sheet have adhesively attached thereto a plurality of catalytic or sorbent beads at the same location along the substrate sheet for at least a portion of the substrate sheet, each bead having a diameter of at least 50 microns, each bead having catalytic or sorbent material on an exposed surface of the bead, and
wherein the substrate sheet and the separator sheet at least partially define one or more channels through the monolith, the one or more channels being effective to permit a fluid to contact the beads when the fluid flows through the channel, and wherein the separator sheet separates the catalytic or sorbent beads on adjacent coated surfaces of the substrate sheet.
12. The monolith of claim 11 , wherein each bead has a diameter of 50 microns to 10 mm.
13. The monolith of claim 11 , wherein the beads are attached to the substrate sheet by an organic adhesive.
14. The monolith of claim 11 , wherein the beads are catalytic beads effective to catalyze one or more reactions selected from the group consisting of reforming of methanol, conversion of CO to CO 2 , water-gas shift, oxidation of methanol to formaldehyde, converting ozone to oxygen, oxidation of a hydrocarbon, and reduction of NO x.
15. The monolith of claim 11 , wherein the beads are sorbent beads effective to (a) sorb CO 2 or SO x or NO x from a gas, (b) sorb CO 2 or sulfur compounds or heavy hydrocarbons from natural gas, (c) separate CO 2 or hydrogen or another gas from syngas, or (d) separate H 2 O from a gas.
16. The monolith of claim 11 , wherein the beads can perform their catalytic or sorbent function effectively at a process temperature between 4° C. and 300° C.
17. The monolith of claim 11 , wherein the substrate sheet and the separator sheet are spirally wound.
18. The monolith of claim 11 , comprising a plurality of said substrate sheets, each substrate sheet being substantially planar, the substrate sheets being arranged one adjacent the next in a stack, and
a plurality of said separator sheets, wherein each separator sheet is arranged between adjacent substrate sheets.
19. The monolith of claim 11 , further comprising a tube, the monolith being disposed within the tube.
20. The monolith of claim 11 , wherein the separator sheet is corrugated.
21. The monolith of claim 11 , wherein the substrate sheet and the separator sheet are metal.
22. The monolith of claim 11 , further comprising a band for holding the monolith together.
23. The monolith of claim 11 , wherein the separator sheet is not coated with catalyst or sorbent material.
24. A monolith for catalytic or sorbent purposes, the monolith comprising:
a substrate sheet having a top surface and a bottom surface, the top surface and the bottom surface being coated with an adhesive such that both of the surfaces are coated at the same location along the substrate sheet for at least a portion of the substrate,
a separator sheet, wherein the separator sheet is corrugated,
wherein both of the coated surfaces have adhesively attached thereto a plurality of catalytic or sorbent beads at the same location along the substrate sheet for at least a portion of the substrate sheet, each bead having a diameter of at least 50 microns, each bead having catalytic or sorbent material on an exposed surface of the bead, and
wherein the substrate sheet and the separator sheet at least partially define one or more channels through the monolith, the one or more channels being effective to permit a fluid to contact the beads when the fluid flows through the channel, and wherein the separator sheet separates the catalytic or sorbent beads on adjacent coated surfaces of the substrate sheet.