Patent Publication Number: US-2021179449-A1

Title: Modified Activated Carbon and Methods of Using Same

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 62/718,764 as filed on Aug. 14, 2018 and titled “MODIFIED ACTIVATED CARBON AND METHODS OF PRODUCING SAME,” the entire disclosure of which is hereby incorporated herein by reference in its entirety for all purposes. 
    
    
     FIELD OF THE TECHNOLOGY 
     One or more aspects relate generally to activated carbon for use in water treatment. 
     BACKGROUND 
     Activated carbon is widely used in gas purification, water purification, metal extraction, and sewage treatment among other applications. Activated carbon is generally a form of carbon that has been physically or chemically processed to increase its porosity and surface area available for adsorption and chemical reactions. Powdered activated carbon (PAC) and granular activated carbon (GAC) are among common forms. 
     SUMMARY 
     In accordance with one or more aspects, a method of treating water containing per- and polyfluoroalkyl substances (PFASs) is disclosed. The method may comprise providing an activated carbon bed comprising activated carbon loaded with a positively-charged surfactant, and introducing the water to the activated carbon bed to promote adsorption of the PFASs. 
     In some aspects, the PFASs may comprise perfluorooctane sulfonic acid (PFOS) or perfluorooctanoic acid (PFOA). The positively-charged surfactant may be a quaternary ammonium-based surfactant. The quaternary ammonium-based surfactant may be cetyltrimethylammonium chloride (CTAC). The activated carbon may be a granular activated carbon (GAC). 
     In some aspects, the method may further comprise introducing a product stream of the activated carbon bed to a downstream unit operation for further treatment. The method may further comprise monitoring a PFAS breakthrough level downstream of the activated carbon bed. The method may further comprise predicting when the PFAS breakthrough level will exceed a predetermined threshold value. The method may further comprise bringing a second activated carbon bed online in response to a predicted PFAS breakthrough time. The method may further comprise regenerating the activated carbon. The method may still further comprise reloading the regenerated activated carbon with the positively-charged surfactant. 
     In accordance with one or more aspects, a water treatment system is disclosed. The system may comprise an activated carbon bed comprising activated carbon treated with a positively-charged surfactant, and a source of water comprising PFASs fluidly connected to an inlet of the activated carbon bed. 
     In some aspects, the PFASs may comprise perfluorooctane sulfonic acid (PFOS) or perfluorooctanoic acid (PFOA). The positively-charged surfactant may be a quaternary ammonium-based surfactant. The quaternary ammonium-based surfactant may be CTAC. The activated carbon may be a granular activated carbon (GAC). The activated carbon may be substantially mesoporous. The activated carbon may be a virgin or reactivated carbon material. The activated carbon may be made from bituminous coal, coconut-shell, or anthracite coal. 
     In some aspects, the system may further comprise a PFAS sensor positioned downstream of the activated carbon bed. The system may further comprise a controller in communication with the PFAS sensor and configured to predict a number of bed volumes remaining until a PFAS breakthrough level will exceed a threshold value. The controller may be configured to generate a service request based on the number of bed volumes remaining. In at least some aspects, performance measured as bed volumes to breakthrough may be at least doubled or at least tripled in comparison to a system including untreated activated carbon. 
     The disclosure contemplates all combinations of any one or more of the foregoing aspects and/or embodiments, as well as combinations with any one or more of the embodiments set forth in the detailed description and any examples. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Certain illustrative features and examples are described below with reference to the accompanying figures in which: 
         FIG. 1  presents a schematic of a water treatment system in accordance with one or more embodiments; and 
         FIG. 2  presents comparative breakthrough data as discussed in the accompanying Example. 
     
    
    
     It will be recognized by the person of ordinary skill in the art, given the benefit of this disclosure, that the figures are purely for illustrative purposes. Other features may be present in the embodiments disclosed herein without departing from the scope of the description. 
     DETAILED DESCRIPTION 
     In accordance with one or more embodiments, activated carbon may be used to treat water. In some embodiments, activated carbon may be applied for the removal of various negatively-charged contaminant molecules. Notable amongst such molecules are per- and polyfluoroalkyl substances (PFASs), also referred to as perfluorinated chemicals (PFCs), that are present in wastewater. These man-made chemical compounds are very stable and resilient to breakdown in the environment. They may also be highly water soluble because they carry a negative charge when dissolved. They were developed and widely used as a repellant and protective coating. Though they have now largely been phased out, elevated levels are still widespread. For example, water contaminated with PFAS or PFC may be found in industrial communities where they were manufactured or used, as well as near airfields or military bases where firefighting drills were conducted. PFAS or PFC may also be found in remote locations via water or air migration. Many municipal water systems are undergoing aggressive testing and treatment. 
     In some non-limiting embodiments, activated carbon may be applied for the adsorption of PFAS or PFC in water. In some embodiments, cationic PFAS of PFC levels in water may be addressed. In some specific non-limiting embodiments, common PFCs such as perfluorooctanoic acid (PFOA) and/or perfluorooctane sulfonic acid (PFOS) may be removed from water via an activated carbon treatment operation. The U.S. Environmental Protection Agency (EPA) developed revised guidelines in May 2016 of a combined lifetime exposure of 70 parts per trillion (PPT) for PFOS and PFOA. Federal, state, and/or private bodies may also issue relevant regulations. In some embodiments, other approaches for PFC removal, such as the use of ion exchange resin, may be used in conjunction with activated carbon treatment as described herein. 
     While any organic portion of PFCs may be large enough to allow for sufficient adsorption, the presence of a negative charge greatly reduces carbon performance. 
     In accordance with one or more embodiments, activated carbon may be modified in order to facilitate and/or promote the removal of negatively-charged contaminant molecules, such as PFCs from water. The performance of activated carbon in terms of PFC, i.e. PFAS, adsorption may be greatly improved via the techniques disclosed herein. In some embodiments, carbon performance measured as bed volumes to breakthrough may be at least doubled or at least tripled. 
     In accordance with one or more embodiments, the water solubility associated with the negative charge carried by most dissolved PFCs, i.e. PFAS, may be countered via modification of activated carbon used in water treatment operations. Activated carbon may be loaded or conditioned with any positively-charged compound to promote direct interaction with the negative charge associated with PFCs. A measurement of surface charge may therefore confirm that the disclosed material modification was implemented. In some non-limiting embodiments, the modification may provide a functionalized activated carbon material which exhibits a positive surface charge greater than about 0.09 milliequivalents/gram, as measured in accordance with the Surface Charge Titration Protocol at a pH of 7.5. In some embodiments, activated carbon may be coated with a positively-charged surfactant. The presence of cationic surfactant on the activated carbon may therefore confirm that the disclosed material modification was implemented. In some embodiments, the surfactant may be approved for use in connection with consumable products such as drinking water. In some non-limiting embodiments, the activated carbon may be treated with a quaternary ammonium-based surfactant. In some specific non-limiting embodiments, activated carbon may be surface coated with cetyltrimethylammonium chloride (CTAC). 
     In accordance with one or more embodiments, any activated carbon may be used as the starting material for modification as described herein. The activated carbon may be PAC or GAC. In some embodiments, GAC may be preferred for PFOA and PFOS treatment. Various mesh sizes may be implemented. For example, GAC may be activated carbon with particle sizes predominantly greater than 80 mesh. Various carbon types may also be implemented. For example, the carbon may be made from bituminous coal, coconut shell, or anthracite coal. The carbon may be virgin activated carbon. In other embodiments, the carbon may be reactivated carbon. In some embodiments, the starting material may be made from bituminous or sub-bituminous carbon. In other embodiments, coconut-shell based activated carbon may be used. In at least some embodiments, spent activated carbon may be thermally reactivated. While the coating described herein would likely be destroyed during thermal reactivation, it can be reapplied to a reactivated carbon prior to reintroducing an associated carbon bed into service. 
     In accordance with various non-limiting embodiments, the starting material to be modified may be an activated carbon as described in U.S. Pat. Nos. 8,932,984 and/or 9,914,110, both to Evoqua Water Technologies LLC, each of which hereby being incorporated herein by reference in its entirety for all purposes. The activated carbon may be Westates® carbon commercially available from Evoqua Water Technologies LLC. In some specific embodiments, the activated carbon may be an AquaCarb® liquid phase carbon commercially available from Evoqua Water Technologies LLC. Selection of an activated carbon material may be based on its physical properties as well as its capability for selectively adsorbing various organic and inorganic materials to meet specific water purification requirements. 
     In accordance with one or more embodiments, a microporous activated carbon, a mesoporous activated carbon, or an activated carbon having any ratio of microporous to mesoporous structure may be modified. In at least some embodiments, a mesoporous activated carbon may be used. For purposes of one or more disclosed embodiments, the term micropore refers to a pore of about 2 to about 20 Angstroms in diameter while the term mesopore refers to a pore of about 20 to about 500 Angstroms in diameter based on definitions commonly known to those skilled in the art and as adopted by the International Union of Pure and Applied Chemistry (IUPAC). Percentages relating to micropore volume and mesopore volume, or percentages in conjunction with the terms microporous and mesoporous, used above and throughout may generally refer to percentage of total pore volume as calculated from gas adsorption isotherms and as commonly recognized by those skilled in the art. 
     In accordance with one or more embodiments, various techniques known to those skilled in the relevant art may be implemented in terms of treating the activated carbon. For example, a set volume of material, i.e. CTAC, at a specified concentration may be recirculated through a carbon bed for a predetermined period of time and at a predetermined contact time to achieve a desired degree of loading. Column size and/or volume may be controlling factors. The activated carbon may also be coated or treated with other approaches. The treated or modified activated carbon may then be applied for water treatment. 
     In accordance with one or more non-limiting embodiments, wastewater may be contacted with modified activated carbon, i.e. in GAC form, in a semi-batch or continuous process. In some non-limiting embodiments, fixed bed, expanded bed, moving bed or fluidized bed adsorption processes may be used in conjunction with the modified activated carbons discussed herein. Various factors may impact contactor design including particle size, column diameter, flow rate of incoming wastewater, residence time, adsorption bed height, pressure drop and breakthrough time. In general, as the wastewater moves through the activated carbon, pollutants may be adsorbed via movement from the wastewater to the carbon bed. The overall adsorption process may be dominated by a mass transfer step from the wastewater bulk to the surface of the carbon particle through the boundary layer surrounding the particle. Internal diffusion through the carbon pores and adsorption onto the surface of the particle may also be involved. 
     In accordance with one or more embodiments, product water treated with a modified activated carbon as described herein may be potable. In at least some embodiments, modified activated carbon as described herein may find utility in the municipal water treatment market and may be used to produce drinking water. The disclosed techniques may be integrated with one or more pre- or post-treatment unit operations. For example, a modified activated carbon may be used in conjunction with another activated carbon treatment operation and/or other water treatment technique such as ion exchange. 
       FIG. 1  presents a schematic of a water treatment system  100  in accordance with one or more embodiments. Process stream  110  containing an elevated level of PFAS/PFC is introduced to GAC unit  120   a  for treatment. GAC unit  120   a  may include modified activated carbon as described herein. Various pre-treatment and/or post-treatment unit operations may also be integrated into system  100 . Product stream  130  may be directed to a further unit operation for additional treatment, sent to a point of use, or otherwise discharged. Sensor  140  may measure a level of PFAS/PFC downstream of GAC unit  120   a . A controller  150  may receive input from sensor  140  in order to monitor PFAS/PFC levels, intermittently or continuously. The controller may monitor for any identifiable presence of PFAS/PFC in product stream  130 . Monitoring may be in real-time or with lag, either onsite or remotely. Beneficially, operation of system  100  can be conducted with confidence in that PFAS/PFC breakthrough levels are being monitored. For example, detecting an identifiable PFAS/PFC level may be indicative that a threshold or target level is approaching as may require maintenance or service. In some embodiments, the controller may predict how many bed volumes remain before a predetermined PFAS/PFC breakthrough level is reached. A detected PFAS/PFC level may be compared to a threshold breakthrough level that may be considered unacceptable, such as may be dictated by a controlling regulatory body. Maintenance decisions may be made based on such comparison. Various operational parameters including input concentration, flow rate, bed size, and empty bed contact time (EBCT) may also be factored into the determination by the controller. GAC unit  120  may be taken offline for preventative maintenance in response to a predicted PFAS/PFC breakthrough. A backup GAC unit  120   b  may be brought online, temporarily or otherwise, in anticipation of unacceptable breakthrough in connection with GAC unit  120   a . Valve  160  may be in communication with controller  150  to strategically direct process stream  110  between GAC units  120   a  and  120   b . Thus, two or more GAC units may be strategically operated in series or in parallel to efficiently treat elevated PFAS/PFC levels while avoiding deleterious breakthrough in accordance with various embodiments. In accordance with one or more embodiments, a controller which is monitoring PFAS/PFC breakthrough levels may be in communication with a service provider, such as to schedule system maintenance, activated carbon bed replacement, and/or activated carbon bed regeneration. In accordance with at least some embodiments, a controller may collect and/or report data pertaining to PFAS/PFC levels associated with a water treatment system. This data may be input to a service network. 
     A monitoring system may be utilized to gather data from the water treatment system and may provide the gathered data to operators local to the water treatment system or to persons, for example, a water treatment system service provider, remote from the water treatment and monitoring system. The monitoring system may analyze data to determine when service is required and/or create a service schedule. For example, the monitoring system may schedule service based on an estimated number of bed volumes remaining until a threshold breakthrough level is achieved. Projected bed volumes remaining may be compared to a setpoint. If the projected bed volumes remaining is less than the set point, then service may be scheduled. Historical data may also be input to the controller for predictive purposes. Anticipated service lag time may also be a factor. 
     The function and advantages of these and other embodiments will be more fully understood from the following example. The example is intended to be illustrative in nature and is not to be considered as limiting the scope of the materials, systems, and methods discussed herein. 
     Example 
     An activated carbon sample was treated with a 0.04% weight solution of CTAC by recirculating a set volume of the material through a carbon bed overnight at a contact time of approximately 0.1 minutes for a small-scale bed with 170×200 carbon grains and a volume of 0.36 mL. Loading was anticipated to be 0.25 grams CTAC per gram of GAC. The column was characterized by an empty bed contact time (EBCT) of 10 minutes. 
     The treated column was then applied for the removal of PFOA at a concentration of roughly 230 ng/L from groundwater. Comparative breakthrough curves are presented in  FIG. 2  which compares the performance of treated (UC1240AW-T) and untreated (UC1240AW) ULTRACARB® 1240AW coal-based granular activated carbon commercially available from Evoqua Water Technologies LLC. Time to initial breakthrough at a level of 1 ng/L increased from about 25,000 bed volumes to about 80,000 bed volumes with treatment of the activated carbon. The rate of breakthrough was also considerably slower, meaning that the advantage of the treated material increased as the bed was operated to a higher level of breakthrough. Similar results were to be expected in connection with other PFAS/PFC. 
     Having now described some illustrative embodiments, it should be apparent to those skilled in the art that the foregoing is merely illustrative and not limiting, having been presented by way of example only. Numerous modifications and other embodiments are within the scope of one of ordinary skill in the art and are contemplated as falling within the scope of the invention.