FILTER MEDIA

Abstract

Aspects of the present disclosure provide composite carbon blocks with improved capacity for the removal of contaminants such as THMs (trihalomethanes) and trace VOCs (volatile organic compounds) found in water. In one aspect, a filtration matrix comprises a polymeric binder and an adsorptive media comprising activated carbon having a bulk density of 0.54 (0.57, or even 0.60) g/cc or greater. The carbon BET surface area can be 1100 (950, or even 550) m2/g or less. The polymeric binder can be ultra high molecular weight polyethylene. Also provided are methods of making filtration matrixes.

Description

Claims

1. A filtration matrix for the removal of contaminants from water comprising a polymeric binder and an adsorptive media, the adsorptive media comprising an activated carbon having a bulk density of 0.54 g/cc or greater.

2. The filtration matrix of claim 1, wherein the bulk density is 0.57 g/cc or greater.

3. The filtration matrix of claim 2, wherein the bulk density is 0.60 g/cc or greater.

4. The filtration matrix of claim 1, wherein the carbon BET surface area is 1100 m2/g or less.

5. The filtration matrix of claim 1, wherein the BET surface area is 950 m2/g or less.

6. The filtration matrix of claim 1, wherein the BET surface area is 550 m2/g or less.

7. The filtration matrix of claim 1, wherein the polymeric binder comprises ultra high molecular weight polyethylene.

8. The filtration matrix of claim 1, comprising a VOC capacity according to NSF-53 of 20 gal/in3 or greater.

9. The filtration matrix of claim 1, comprising a VOC capacity according to NSF-53 of 30 gal/in3 or greater.

10. The filtration matrix of claim 1, comprising a VOC capacity according to NSF-53 of 40 gal/in3 or greater.

11. The filtration matrix of claim 1, wherein the polymeric binder is present in an amount of no greater than 30%.

12. The filtration matrix of claim 11, wherein the polymeric binder is present in an amount of no greater than 15%.

13. The filtration matrix of claim 12, wherein the polymeric binder is present in an amount of no greater than 10%.

14. The filtration matrix of claim 1, wherein the adsorptive media is present in an amount of at least 70% of the total weight of the matrix.

15. The filtration matrix of claim 14, wherein the adsorptive media is present in an amount of at least 85%.

16. The filtration matrix of claim 15, wherein the adsorptive media is present in an amount of at least 87%.

17. A method of making a filtration matrix comprising: mixing an adsorptive media comprising an activated carbon with ultra high molecular weight polyethylene to form a mixture, wherein the activated carbon has a bulk density of 0.54 g/cc or greater and a BET surface area of 1100 m2/g or less;filling a mold with the mixture;heating the mold to a temperature in the range of 160° C. to 200° C.; andcooling the mold.

18. The method of claim 17, wherein the adsorptive media is present in an amount in the range of 50 to 90% by weight and ultra high molecular weight polyethylene in an amount in the range of 10 to 50% by weight

19. The method of claim 17, wherein impulse filling is used to fill the mold.

20. The method of claim 17, wherein vibration filling is used to fill the mold.

21. The method of claim 17, further compressing the mixture until a fixed length of the filtration matrix is obtained.

22. The method of claim 19, wherein the impulse filling is used to fill a plurality of molds, and wherein a plurality of filtration matrixes is formed.

23. The method of claim 22, wherein a standard deviation of the average weight of the plurality of filtration matrixes is no greater than 10% of the average weight.

24. The method of claim 23, wherein the standard deviation is no greater than 5%.