Abstract: A structure made predominately of an NZP-type phase having the general formula RxZ4P6−ySiyO24, where 0≦x≦8, 0≦y≦6, R is Li, Na, K, Rb, Cs, Mg, Ca, Sr, Ba, Y, and/or lanthanides, and Z is Zr, Ti, Nb, Ta, Y, and/or lanthanidess, and optionally a sintering additive. The structure has an open porosity of at least 20% by volume, median pore diameter in micrometers of at least a value defined by the quantity [10−0.10(% open porosity)], both as measured by mercury porosimetry, and four-point modulus of rupture as measured on a solid rod of circular cross section, of at least 300 psi. Method of making the structure involves forming a mixture of NZP-forming raw material powders that are metal oxide sources capable of reacting to form an NZP-type reaction product, and/or pre-reacted powder having the above general formula.

Abstract: Powder mixtures and a method of forming and shaping the mixtures. The method involves compounding the components of powder materials, binder, solvent for the binder, surfactant, and non-solvent with respect to at least the binder, the solvent, and the powder materials. The non-solvent is lower in viscosity than the binder combined with the solvent. The solvent is present in an amount that is less than the amount that would be present otherwise. The components are mixed and plasticized, and shaped to form a green body. The choice of components results in improved wet green strength in the green body. The method is especially useful for extrusion processing of aqueous binder systems such as water and cellulose ethers and hydrophobic non-solvents, to form structures such as honeycombs. In the body, the ratio, upon subsequent firing, of the isostatic strength to the A-axis strength is at least about 20% higher than in bodies made without the mixture composition of the invention.

Abstract: A device for use in processing of a liquid and/or gas stream. The device is made up of a monolithic structure having active powder for treating streams. The structure has an inlet end and an outlet end and a multiplicity of cells extending from inlet end to outlet end. The cells are separated from one another by porous walls, a portion of the total number of cells being plugged in a pattern such that a stream enters the device through the unplugged cells at the inlet end and passes through at least two porous walls and the active powder in-between, and thereafter passes out of the device through unplugged cells at the outlet end. The device finds use in a number of applications including ion exchange, adsorption, biological and chemical reactions, and catalytic applications.

Abstract: A crystalline glass-ceramic article composed of a cordierite phase of cordierite crystals or aggregates of near-parallel crystallites, having a formula of either Mg2Al4Si5O18 or AxByMg2Al4+x+2ySi5−x−2yO18. With the first formula, the average size of the cordierite crystals or aggregates is less than 70 micrometers, and the mean coefficient of thermal expansion from 22° C. to 800° C. (CTE) is less than 9×10−7/° C. With the second formula, A is either sodium or potassium, B is either strontium or barium, the sum of x and y is not less than 0.01, and when either x or y equal zero, the CTE is not more than 14×10−7/° C. The article is especially suitable as a filter or catalyst substrate.

Abstract: A method of forming an article involves forming a mixture of components powder materials, organic binder, solvent for the binder, non-solvent with respect to at least the binder, the solvent, and the powder materials, wherein the non-solvent is lower in viscosity than the binder combined with the solvent, mixing and plasticizing, and shaping to form a green structure. The green structure is dried and fired to impart strength and form the product article. The firing is done by heating to a first temperature of less than 200° C. at a heating rate of no greater than 1° C. per minute, heating from the first temperature to a second temperature of 200° C. to 300° C. at a heating rate of 2° C. per minute to 20° C. per minute, heating from the second temperature to a third temperature of above 300° C. to about 500° C. at a heating rate of no greater than 1° C. per minute, and heating from the third temperature to a fourth temperature of greater than about 500° C.

Abstract: A method of making activated carbon of various pore size distributions involves an providing oxidized pitch, carbonizing the pitch when the softening point of the pitch is less than about 250° C., and activating the pitch to produce activated carbon. A catalyst metal can be included with the pitch to produce mesoporosity in the activated carbon.

Abstract: Mesoporous carbon and method of making involves forming a mixture of a high carbon-yielding carbon precursor that when carbonized yields greater than about 40% carbon on a cured basis, and an additive that can be catalyst metal and/or low carbon-yielding carbon precursor that when carbonized yields no greater than about 40% by weight carbon on a cured basis. When a catalyst metal is used, the amount of catalyst metal after the subsequent carbonization step is no greater than about 1 wt. % based on the carbon. The mixture is cured, and the carbon precursors are carbonized and activated to produce mesoporous activated carbon.

Abstract: Mesoporous carbon and method of making involves forming a mixture of a high carbon-yielding carbon precursor that when carbonized yields greater than about 40% carbon on a cured basis, and an additive that can be catalyst metal and/or low carbon-yielding carbon precursor that when carbonized yields no greater than about 40% by weight carbon on a cured basis. When a catalyst metal is used, the amount of catalyst metal after the subsequent carbonization step is no greater than about 1 wt. % based on the carbon. The mixture is cured, and the carbon precursors are carbonized and activated to produce mesoporous activated carbon.

Abstract: A fired body and method for producing the body that involves compounding the components of powder materials, binder, aqueous solvent for the binder, and non-solvent with respect to at least the solvent, binder, and powder materials. The non-solvent is made up of a high molecular weight organic portion having a molecular weight of greater than 200, and a low molecular weight organic portion having a molecular weight of up to 200. The components are mixed and plasticized to form a plasticized mixture which is then shaped to form a green body. The green body is then dried and fired.

Abstract: A small pore hydrophilic molecular sieve body and method of making same involves forming a plasticized mixture of hydrophilic molecular sieve powder having a pore size of no greater than about 5.0 angstroms, temporary binder, silicone resin binder emulsion, and polar vehicle, shaping the mixture into a green monolithic body, and drying and heat-treating the green monolithic body to impart strength to the green body and form the product molecular sieve monolith. The body is made up of about 80% to 95% by weight molecular sieve with the balance being silica binder.

Abstract: An electrode for deionization of water is made of a continuous activated carbon structure. The activated carbon is derived from a synthetic carbon precursor. The structure has openings, inlet and outlet ends such that water entering the inlet end passes through the openings and exits through the outlet end, a conductive coating on at least part of the outer surface of the structure, and a metal wire in contact with the structure. A deionization system is made up of the electrodes in series so that the outlet end of one electrode is next to the inlet end of the nearest downstream electrode. The metal wire of each electrode is connected to a power source to deliver the opposite charge as the charge delivered to its neighboring electrodes. Each of the electrodes is fixedly attached to and sealed within a housing with an air and moisture-tight seal. Openings in the housing between the electrodes, allow air to be removed before use.

Abstract: A cordierite body is produced by providing cordierite-forming raw materials. The raw materials are intimately blended with effective amount of vehicle and forming aids to impart plastic formability and green strength to the raw materials and form a plastic mixture. A green body is formed which is dried and heated from room temperature up to a maximum temperature of about 1360° C. to 1435° C. at an average heating rate of at least about 315° C. per hour and held at maximum temperature for about 0.05 to 4.4 hours. The total heating time from room temperature to the end of the hold at the maximum temperature is less than about 4.5 hours. The resulting body is predominately cordierite, having a mean coefficient of thermal expansion from about 25° C. to 800° C. of less than about 15×10−7° C.−1 in at least one direction.

Abstract: A fired body and method of making involves compounding powder, binder, aqueous solvent for the binder, surfactant, and non-solvent with respect to at least the binder, the solvent, and the powder, with the addition of an organosilicon compound. The non-solvent is lower in viscosity than the binder combined with the solvent, and the amount of solvent is less than the amount that would be used absent the non-solvent. The components are mixed and plasticized and then shaped into a green body, which is then fired to produce the product body. The organosilicon compound enhances the stiffness in the green body afforded by other non-solvents, and results in increased strength and reduced cracking in the fired body, among other advantages.

Abstract: A monolithic structure having active material that includes at least inorganic ion exchange material, for purifying a liquid stream of contaminants such as heavy metals, chlorine, volatile organics, pesticides, herbicides, and/or parasites, etc. The structure has an inlet end and an outlet end and a multiplicity of cells extending from inlet to outlet end. The cells are separated from one another by porous walls that are alternatively plugged at each end such that a liquid stream that enters the structure, enters through the unplugged cells at the inlet end and passes through porous walls to be purified by the active material, and thereafter passes out of the structure through unplugged cells at the outlet end. One method of making the structure involves applying active material as a coating on an alternately plugged substrate. The average particle size of the active material after calcination is greater than the average cell wall pore size of the substrate.

Abstract: A method for forming an article involves forming a mixture of components of powder materials, organic binder, solvent for the binder, non-solvent with respect to at least the binder, the solvent, and the powder materials, wherein the non-solvent is lower in viscosity than the binder combined with the solvent, and an agent for retarding the oxidation of the organic components. The components are mixed and plasticized, and shaped into a green structure which is then fired to impart strength and form the product article. The product article has fewer cracks than it would have absent the oxidation-retarding agent.

Abstract: An activated carbon body and method of making the body which involves providing an inorganic substrate, thermosetting resin, and an adsorption enhancing additive which can be sulfur and/or oil which is non-miscible with and non-reactive with the carbon precursor, contacting the inorganic substrate with the carbon precursor and the adsorption enhancing additive to coat the substrate therewith, curing and carbonizing the carbon precursor, and activating the carbon to produce a coating of activated carbon on the substrate and form the activated carbon body. Another method involves forming a mixture of thermosetting resin, adsorption enhancing additive, which can be sulfur, phosphoric acid, and/or the oil, temporary organic binder, optional forming aid, and fillers, shaping the mixture into a body, followed by curing, carbonizing, and activating to produce a shaped body of activated carbon. When sulfur is utilized, a sulfur-carbon bond forms that is characterized by a peak at 165.

Abstract: A method of producing a continuous carbon structure involves providing an inorganic support and a synthetic carbon precursor, contacting the inorganic support with the carbon precursor, curing and carbonizing the carbon precursor. Prior to the carbonizing step, a potassium compound is introduced into the carbon precursor. The potassium compound is greater than about 3% by weight of the total weight of the carbon precursor and potassium compound.The potassium compound is then removed from the carbonized carbon structure. A carbon structure is produced having a surface area of at least about 100 m.sup.2 /g.

Abstract: An activated carbon catalyst having sulfur dispersed homogeneously thereon, the sulfur being chemically bonded to the activated carbon. A method of making the catalyst involves forming an intimate mixture of a synthetic carbon precursor and a sulfur-containing material, curing the carbon precursor, carbonizing the carbon precursor, activating the carbonized carbon precursor to produce an activated carbon catalyst having sulfur chemically bonded to the activated carbon and uniformly dispersed thereon.

Abstract: An activated carbon-crystalline titanium and/or tin silicate composite for purifying waste streams and method of making. The method involves providing a combination of a synthetic carbon precursor, and titanium and/or tin silicate, followed by curing, carbonizing, and activating the carbon precursor. The composite is used to purify fluid streams such as water, of pollutants such as VOC's, heavy metals such as lead, and chlorine.

Abstract: A method for forming and shaping powder mixtures involves compounding, homogenizing, and plasticizing components to form a mixture. The components are powder materials, binder, solvent for the binder, surfactant, and non-solvent with respect to at least the binder, the solvent, and the powder materials. The non-solvent is lower in viscosity than the binder combined with the solvent. The components are chosen to result in improved wet green strength in the subsequently formed green body. The compounding is done by the steps of dry-mixing the powder material, surfactant and binder to form a uniform blend, adding the solvent to the resulting dry blend, and thereafter adding the non-solvent to the blend. The mixture is shaped by passing it through a low to moderate shear extruder, and then through a die to form a green body. The compounding and shaping steps are carried out at a temperature of no greater than ambient temperature. The method is especially suitable for RAM extrusion.