Innovative Filters Using Nanomaterials for Removal of Gaseous Pollutants and Particulates from Contaminated Air StreamsEPA Contract Number: EPD16003
Title: Innovative Filters Using Nanomaterials for Removal of Gaseous Pollutants and Particulates from Contaminated Air Streams
Investigators: McKenna, John D
Small Business: ETSVP-JV, LLC
EPA Contact: Richards, April
Project Period: February 1, 2016 through January 31, 2018
Project Amount: $299,985
RFA: Small Business Innovation Research (SBIR) - Phase II (2015) Recipients Lists
Research Category: Small Business Innovation Research (SBIR) , Nanotechnology , SBIR - Air Pollution Monitoring and Control
A uniquely qualified team consisting of ETSVP-JV, LLC a small business joint venture, and subcontractor RTI International, are commercializing an innovative reactive nanofiber filtration media for controlling PM2.5 and volatile organic compounds (VOCs). Materials developed for the Department of Defense to protect troops from chemical and biological agents are the foundation for next generation filter media for control of Hazardous Air Pollutants (HAPs). For this Phase II project effort our team proposes to conduct pilot-scale demonstration and full-scale demonstration of novel dual stage reactive nanofiber filtration media that significantly enhances combined PM and HAP baghouse control capabilities over current state-of-the-art.
The reactive nanofiber filtration media is a composite comprised of: polyphenylene sulfide (PPS) felt, a nanoscale reactive coating, and a nanofiber membrane on a nonwoven support. The nanofiber membrane has a fiber size distribution controlled to below 200 nm and a unique three-dimensional structure. This unique nanofiber structure provides enhanced particle collection per air flow resistance compared to conventional and even competing nanofiber filtration media. The reactive nanoscale coating can be applied to the felt or the felt and the nanofibers. Unlike conventional approaches that have to incorporate reactive particles into a fiber matrix, the reactive coating is deposited conformally onto the fibers and uniformly throughout the entire volume of the filter media. The structure is laminated together to form a robust composite aimed at removing both PM and VOCs. In Phase I we demonstrated PM removal to emissions below 0.00004 gr/dscf and a Mullen burst strength of 633 psi. The MIT flex endurance was measured as more than 259,900 flexes in the warp direction and more than 100,700 in the fill direction. Reactive materials deposited onto the felt media reduced a concentrated gas mixture of benzene, hexane, 1,3 butadiene, and acrolein to less than a few ppm’s of each VOC.
For Phase II, our project team proposes to mature the technology to demonstration of commercial-scale production. We will first mature the integrated fiber material at the bench-scale and finalize attachment of the catalyst chemistry. After successful testing at the bench-scale, we will move to developing pilot-scale sized materials. Testing at commercial-scale will complete the Phase II technical portion. Commercial-scale production will involve producing amounts of media that can be used in a large commercial baghouse unit. Once the reactive nanofiber filtration media is produced, the materials will be tested in the field at a large utility provider.