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Abstract

A process for immobilizing reactive Whetlerite carbon particles and forming a self-supporting structure of high compressive strength therefrom is described in which the self-supporting structure substantially eliminates the formation of carbon fines while retaining the adsorption characteristics of the carbon particles. The process for immobilizing the adsorbent carbon particles in the self-supporting structure comprises the steps of: (a) mixing in an environment having a relative humidity of less than about 35 percent, Whetlerite carbon particles, a major portion of which has particle sizes in the range of from about 200 to about 2,000 microns, with a powdered polymeric binding material, preferably a thermoplastic material having a solid-liquid transition stage, in an amount of about 5 to about 20 percent by weight, based on the weight of the total mixture, a major portion of the particles of the polymeric binding material having particle sizes in the range of about 8 to about 30 microns, to form a mixture of the carbon particles partially coated with the polymeric binding material; (b) placing the mixture in a container of a desired shape; and (c) applying a pressure of up to about 400 psi while the mixture is contacted with an inert gas and is at an elevated temperature, this temperature being near the solid-liquid transition stage (when the polymeric binding material is a thermoplastic material), thereby forming the structure and immobilizing the particles.

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First Claim