Nanoarray based monolithic contaminant filter for efficient submicron PM and NH3 removal

C56-26e-273790The proposed SBIR phase I project aims to develop a new class of low cost nanoarray based monolithic contaminant filter for Clean Hydrogen Production and Separation from Coal Waste, Biomass, MSW and Plastics produced syngas. It is anticipated that the contaminant filter can capture > 95 % of the heavy metal particulate matter (PM) with submicron size and remove > 95 % of NH3 in the syngas stream. These contaminant filters will be composed of metal oxides nanoarray forest on wall-flow based monolithic substrates manufactured using a continuous microwave-assisted hydrothermal method. This new class of nanoarray based wall-flow monolithic filters is of significantly increased micro/meso-porosities and surface roughness, resulting in highly elevated capture capacity and efficiency of the heavy metal PM with a submicron size range. NH3 in the syngas stream will be in-situ captured by using a metal halide adsorber at the same time. With the use of nanoarray structures with well-defined porosities and high surface area, robust and low-cost contaminant filters will be formulated with high PM and NH3 removal throughput, high temperature and chemical resistance, and ease of regeneration. During Phase I, the proposing small business will (1) grow nanoarray on ceramic-based wall-flow monolith substrate and modify the nanoarray using wet impregnation methods to formulate a bifunctional contaminant filter; (2) characterize the physical and chemical properties of the contaminant filters using BET, SEM, XRD etc. methods; (3) evaluate and validate the PM and NH3 removal efficiencies of nanoarray based monolithic filters. Varied parameters will be tested to study and identify the corresponding effects on the PM and NH3 removal efficiencies; (4) optimize and demonstrate the initial prototype filter for PM and NH3 removal at the targeted efficiencies of 95 % or above. It is anticipated that multiple iterations will be required to optimize the nanoarray composition and structure characteristics to achieve the desired porosities and surface roughness for efficient PM and NH3 removal. The synthesis and testing work will be mainly carried out at the proposing small business, while characterization capabilities of the partner research institution will be leveraged to evaluate the structure, porosity, surface area, and acidity properties of the nanoarray based monoliths before and after PM and NH3 removal. The proposed nanoarray technology-based contaminant filter is achieved using a simple modification method leveraging existing commercial ceramic filter substrate with minimum change. The technology can be applied to varied surfaces of customized design, metal, inorganic or organic substances. If developed successfully, this project shall result in a low-cost and highly efficient filtration technology that can be used in various applications, such as face mask, PM filter, plastic filter, and Air filter, etc.