The effect of co-impregnated acids on the performance of Zn-based broad spectrum respirator carbons.

Impregnated activated carbons (IACs) that are used in multi-gas respirator applications usually contain copper and/or zinc impregnants. Co-impregnating with properly selected acids can improve the distribution of the metallic impregnant on the carbon and improve the gas adsorption capacity of the IAC. In this work a comparative study of some common acids co-impregnated with a zinc nitrate (Zn(NO(3))(2)) precursor is performed. The IACs were heated in an inert atmosphere at temperatures which promoted the thermal decomposition of Zn(NO(3))(2) to zinc oxide (ZnO). The gas adsorption properties of the IACs were tested using ammonia (NH(3)), sulphur dioxide (SO(2)) and hydrogen cyanide (HCN) challenge gases. Powder X-ray diffraction (XRD) was used to identify the impregnant species present after heating and to study impregnant distribution. Gravimetric analysis was used to determine the impregnant loading, and help to identify the impregnant species after heating. The interactions between the co-impregnated acid and Zn(NO(3))(2) precursor during heating are discussed. The relationship between impregnant species and gas adsorption capacity is discussed.

The effect of heating temperature and nitric acid treatments on the performance of Cu- and Zn-based broad spectrum respirator carbons.

Impregnated activated carbons (IACs) that are used in broad spectrum gas mask applications have historically contained copper and/or zinc impregnants. The addition of an oxidizing agent, such as nitric acid (HNO(3)) can be useful in distributing the metallic impregnants uniformly on the activated carbon substrate. In this work, we study IACs prepared from copper nitrate (Cu(NO(3))(2)) and zinc nitrate (Zn(NO(3))(2)) precursors as a function of HNO(3) content present in the impregnating solution and as a function of heating temperature. The gas adsorption capacity of the IACs was determined by dynamic flow testing using sulfur dioxide (SO(2)), ammonia (NH(3)), hydrogen cyanide (HCN) and cyclohexane (C(6)H(12)) challenge gases under dry and humid conditions. The thermal decomposition and distribution of the impregnant on the activated carbon substrate is studied using X-ray diffraction (XRD), scanning electron microscopy (SEM) and thermal analysis techniques. Relationships between gas adsorption capacity, impregnant distribution and the species of surface impregnants are discussed.

A combinatorial approach to screening carbon based materials for respiratory protection.

A combinatorial materials science approach for the discovery of an impregnated activated carbon that can adsorb a wide variety of toxic gases (i.e. a multi-gas carbon) has been developed. This approach presently allows for the parallel preparation and investigation of 64-100 IAC samples at once increasing the rate of discovery of viable multi-gas carbons. Multi-gas carbons were prepared using a solutions handling robot and screened gravimetrically for their effectiveness as gas adsorbents. The method was validated using known gas adsorbent materials such as ZnCl(2), K(2)CO(3) and CuO-impregnated carbons. The calculated adsorption capacities and stoichiometric ratios of reactions for these known gas adsorbent materials, when evaluated using the combinatorial approach, was comparable to the values obtained using traditional methods of analysis. A library of samples prepared by combining various amounts of CuO and ZnO impregnants showed the expected decreasing trend in the calculated stoichiometric ratio of reaction with respect to increasing amount of impregnants added. The method is now ready to use to explore new systems of impregnated activated carbons.

The investigation of copper-based impregnated activated carbons prepared from water-soluble materials for broad spectrum respirator applications.

The preparation of impregnated activated carbons (IACs) from aqueous, copper-containing solutions for broad spectrum gas filtration applications is studied here. Several samples were studied to determine the effect that impregnant loading, impregnant distribution and impregnant recipe had on the overall performance. Dynamic flow testing was used to determine the gas filtration capacity of the IAC samples versus a variety of challenge gases. X-ray diffraction (XRD), scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX) were used to characterize the impregnant distribution on the carbon as a function of impregnant loading. Oven tests were performed to determine the thermal stability of the IAC samples exposed to elevated temperatures. The role impregnant distribution plays in gas filtration capacity and the overall performance of the IAC samples is discussed. The IAC samples prepared in this work were found to have gas filtration capacities as good as or better than broad spectrum respirator carbon samples prepared from the patent literature. IACs impregnated with an aqueous 2.4 M Cu(NO(3))(2)/0.04 M H(3)PO(4).12MoO(3)/4M HNO(3) solution that were heated to 200 degrees C under argon were found to have the best overall performance of the samples studied in this work.

Investigation of copper oxide impregnants prepared from various precursors for respirator carbons.

Copper oxide impregnated activated carbon was prepared by three methods and studied as a respirator carbon. Using techniques such as dynamic flow testing, X-ray diffraction (XRD), thermal analysis, scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX), copper oxide impregnants, derived from different sources such as basic copper carbonate (Cu(2)CO(3)(OH)(2)), copper nitrate (Cu(NO(3))(2)) and copper chloride (CuCl(2)) reacted with sodium hydroxide (NaOH), have been studied. Dynamic flow tests performed using sulfur dioxide (SO(2)), ammonia (NH(3)) and hydrogen cyanide (HCN) challenge gases allow the determination of the stoichiometric ratio of reaction (SRR) between challenge gas and impregnant. Thermal gravimetric analysis experiments showed that an inert heating environment was required when thermally decomposing the Cu(NO(3))(2) impregnant to CuO to avoid damaging the activated carbon substrate. SEM has been used to investigate dispersal and particle size of the impregnant on the activated carbon. XRD permits the identification of crystalline and amorphous phases as well as the grain size of the impregnant. XRD analysis of samples before and after exposure to SO(2) has allowed the active impregnant in SO(2) adsorption to be identified. The relationship between SRR, impregnant loading and grain size is discussed. Methods to improve impregnant distribution are presented and their impact discussed.

Understanding the role of each ingredient in a basic copper carbonate based impregnation recipe for respirator carbons.

Basic copper carbonate (Cu(2)CO(3)(OH)(2)) is often used as an impregnant in activated carbons for respiratory filters. The mechanisms that allow adsorption of toxic gases by an activated carbon loaded with a Cu(2)CO(3)(OH)(2)-based impregnation recipe are studied here. Several samples were studied to determine the effect of ingredients added during impregnation, impregnant loading and drying temperature on performance. The filtering capacity of the samples is quantified by the stoichiometric ratio of reaction (SRR) between the impregnant and the challenge gas. X-ray diffraction (XRD), thermal gravimetric analysis (TGA), scanning electron microscopy (SEM) and energy dispersive X-ray analysis (EDX) were used to characterize the impregnant both on and off the carbon as a function of loading and heat-treatment temperature. The influence of the phase and dispersion of the impregnant on the SRR is the focus of this report.